Chevrolet - Civic Si - Workshop Manual - 2004 - 2004

Factory Workshop Manual Make Honda Model Civic Si Engine and year L4-2.0L (2004) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 12 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 13 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 19 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 20 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 26 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 27 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 28 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 29 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 35 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 36 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 37 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Alarm Module: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 38 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Relay and Control Unit Location - Dashboard 64. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 41 72. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 42 67. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 43 Alarm Module: Diagrams 159. Immobilizer Control Unit-Receiver 183. Security Control Unit Connector (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 47 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 48 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 49 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 50 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 51 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 52 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 57 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 58 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 59 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 60 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 61 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 62 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body and Frame/Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 66 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 67 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 71 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 72 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 73 142. Moonroof Close And Open Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 74 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 75 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations 97. Middle of Roof Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 79 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 80 143. Moonroof Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 81 Sunroof / Moonroof Module: Testing and Inspection Moonroof Control Unit Input Test 1. Remove the headliner. 2. Disconnect the 5P connector (A) from the control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the moonroof control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 82 5. Disconnect the moonroof control unit 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, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations 27. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 88 Electronic Brake Control Module: Connector Locations System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 89 190. ABS Modulator-Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 90 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel, and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem, and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the HDS. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the HDS. See the HDS help menu for specific operating instructions. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 91 Electronic Brake Control Module: Testing and Inspection System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 92 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31P connector (B), then disconnect the connector. 3. Disconnect the six brake lines from the ABS modulator-control unit (C). 4. Remove the two 8 mm nuts. 5. Remove the ABS modulator-control unit. Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the HDS, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the HDS. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 97 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 98 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 99 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations 66. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 104 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 105 177. Cruise Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 110 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 111 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 112 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 116 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 117 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 118 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 119 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 123 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 124 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 125 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Testing and Inspection Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 133 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 134 178. DRL Control Unit (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 135 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. It should go off when you turn on the headlight switch and release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard under cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 136 4. Make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, go to step 5 5. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, the control unit must be faulty Replace it '04-05 models 6. Make these input tests at the connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 137 - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 7. 7. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 141 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 142 141. Low Beam Cut ('02-'03 Canada) And DRL Relay (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 143 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 144 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations 74. Left Kick Panel (USA) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 148 137. Fog Light Relays 1 & 2 (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Testing and Inspection Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 155 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 156 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 157 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 161 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 162 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 163 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 174 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 175 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Interior Lighting Module: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 185 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 186 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 187 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 188 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 198 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 199 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 200 Interior Lighting Module: Electrical Diagrams Entry Lights Control System - Circuit Diagram Wiring Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Diagram 115-0 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Diagram 115-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 203 Interior Lighting Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. 5. With the connectors still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 204 6. Reconnect the connectors to the under-dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake then make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty-Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations Low Beam Check Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 208 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 209 Low Beam Check Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 210 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 214 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 215 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Five-terminal type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 216 Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 220 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 221 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 222 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 226 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 232 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 233 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 234 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 235 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 236 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 237 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 238 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 239 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 240 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 241 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 242 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 243 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 244 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 245 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 246 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 247 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 248 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 251 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 252 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 259 DTC P0A94 thru P0157 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 260 DTC P0158 thru P0400 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 261 DTC P0401 thru P0562 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 262 DTC P0563 thru P0748 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 263 DTC P0750 thru P0977 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 264 DTC P0979 thru P1193 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 265 DTC P1253 thru P1459 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 266 DTC P1486 thru P1585 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 267 DTC P1586 thru P1678 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 268 DTC P1679 thru P1860 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 269 DTC P1861 thru P2238 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 270 DTC P2240 thru U0073 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 271 DTC U0100 thru U1288 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 274 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 275 54. Behind Glove Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views 194. ECM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 278 ECM Inputs And Outputs At Connector A (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 279 ECM Inputs And Outputs At Connector A (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 280 ECM Inputs And Outputs At Connectors B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 281 ECM Inputs And Outputs At Connectors E (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 282 ECM Inputs And Outputs At Connectors E (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 285 ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 286 ECM Inputs And Outputs At Connector B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 287 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 288 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 289 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation Engine Control Module: Service and Repair Removal/Installation How to Remove the ECM for Testing 1. Remove the passenger's dashboard lower cover, the passenger's kick panel, and the glove box. 2. Disconnect the connectors (A) and remove the ECM mounting bolts (B). 3. Remove the ECM (C). 4. Install the ECM in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 292 Engine Control Module: Service and Repair Updating the ECM/PCM ECM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM in a troubleshooting procedure. Update the ECM only if the ECM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM can be damaged. How to Update the ECM NOTE: - To ensure the latest program is installed, do an ECM update whenever the ECM is substituted or replaced. - Before you update the ECM, make sure the vehicle's battery is fully charged. - To prevent ECM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM update procedure as described on the HIM label and in the ECM update system. If the software in the ECM is the latest version, replace the ECM. How to Substitute the ECM 1. Remove the ECM from the vehicle. 2. Install a known-good ECM in the vehicle. 3. Rewrite the immobilizer code with the ECM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM and rewrite the immobilizer code with the ECM replacement procedure in the HDS again. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 293 Engine Control Module: Service and Repair Idle Learn Procedure ECM Idle Learn Procedure The idle learn procedure must be done so the ECM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions; - Disconnect the battery. - Replace the ECM or disconnect its connector. - Reset the ECM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.,) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 297 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 298 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 299 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 300 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 301 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 305 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 306 134. A/F Sensor Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 307 Oxygen Sensor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 308 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 313 Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 314 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 315 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 316 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 317 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 321 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 322 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 323 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 324 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 325 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations 88. In Passenger's Seat (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 331 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 332 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 333 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 334 59. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 335 Air Bag Control Module: Diagrams 197. OPDS Unit (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 336 198. SRS Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the console carpet on the passenger's side, then remove the Torx bolt (A) from the SRS unit. 7. Pull down the console carpet on the driver's side, then disconnect the connectors. Remove the Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push them into position until they click. NOTE: When tightening the Torx bolts to the specified torque, be careful to turn them in so that their heads rest squarely on the brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 339 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 340 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedures before performing repairs or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the passenger's side airbag harness 2P connector. 3. Remove the front passenger's seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit 8P connector D and sensor connector (B) from the OPDS unit (C). 5. Remove the two screws (E) and the OPDS unit. Installation 1. Place the new OPDS unit (A) on the seat-back frame. Tighten the two screws (B), and connect the OPDS unit 8P connector D and sensor connector (C) to the OPDS unit. Reinstall the cover (E). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 341 Air Bag Control Module: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Unit When a seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: A new (uninitialized) OPDS unit installed with a faulty OPDS sensor can cause DTC 15-1. 1. Erase the DTC memory (see "Erasing the DTC Memory"). 2. Make sure the front passenger's seat is dry. Set the seat-back in a normal position, and make sure there is nothing on the seat. 3. Make sure the ignition switch is OFF and the MES connector is not shorted. 4. Connect the HDS to the DLC (A). 5. Turn the ignition switch ON (II). 6. From the HDS Main Menu, select SRS, then Misc. Test, then adjustments. In the Adjustment Menu, select OPDS INIT. Follow the screen prompts to initialize the OPDS. 7. Turn the ignition switch OFF. 8. Disconnect the HDS from the DLC. NOTE: If the OPDS system fails to initialize after several attempts, replace the OPDS sensor and retry. If the OPDS system continues to fail to initialize, replace the OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 350 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 351 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 352 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 353 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 354 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 355 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 356 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 357 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 358 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 359 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 360 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 366 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 367 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 368 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 369 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 370 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 371 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 372 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 373 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 374 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 375 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 376 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 381 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 382 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 383 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 389 49. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 390 Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 391 195. EPS Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 392 Steering Control Module: Service and Repair EPS Control Unit Removal/Installation 1. Remove the passenger's dashboard lower cover. 2. Turn up the floor carpet, and remove the EPS control unit. 3. Disconnect the EPS control unit connectors. 4. Install the EPS control unit in the reverse order of removal. 5. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 397 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 398 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 399 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection Power Window Control Module: Testing and Inspection Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5 A) and/or the No. 23 (20 A) fuses in the under-dash fuse/relay box. - Disconnecting the driver's door wire harness. 1. Turn the ignition switch ON (II). 2. Move the driver's window all the way down holding the driver's switch in the AUTO DOWN position; when the window reaches the bottom, hold the driver's window switch in the AUTO DOWN position for 2 seconds. 3. Move the driver's window all the way up holding the driver's switch in the AUTO UP position; when the window reaches the top, hold the driver's window switch in the UP position for 2 seconds. 4. If the window does network in AUTO, repeat steps 1 through 3. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 406 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 407 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 408 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Testing and Inspection Windshield Washer Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations 106. Rear of Cargo Area Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 416 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 417 184. Rear Window Wiper Intermittent Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test Wiper Control Module: Testing and Inspection Control Unit Input Test Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 420 Wiper Control Module: Testing and Inspection Rear Window Wiper Intermittent Control Unit Input Test Rear Window Wiper Intermittent Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 20P connector (A) from the rear window wiper intermittent control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the 20P connector to the rear window intermittent control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 421 5. Disconnect the 20P connector from the rear window wipe intermittent control unit, make these input tests at the connector. - If any test indicates a problem, find and correct the cause,then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Heated Mirror Switch > Component Information > Locations Power Mirrors - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Heated Mirror Switch > Component Information > Locations > Page 427 Heated Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations 86. Driver's Door (Passenger's Similar) 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 431 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 432 Power Door Lock Switch: Diagrams 98. Door Lock Knob Switch, Driver's 99. Door Lock Switch, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No. 2 and No. 3 terminals. - There should be continuity when the door lock knob switch 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. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test > Page 435 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when the door lock switch is in the LOCKED position and no continuity in the neutral position. - There should be continuity between the No. 2 and No. 3 terminals when in the door lock switch is in the UNLOCKED position and no continuity in the neutral position. 4. If the continuity is not as specified, replace the door lock switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 439 171. Power Mirror Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 440 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 447 123. Moonroof Limit Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 448 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 449 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. Fully closed position adjustment 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the position switch (open/close). - Check that the switch plate contacts the switch bracket (G). Auto-stop position adjustment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 450 5. With the moon roof wrench, operate the glass (A) to the auto-stop position. 6. With an open-end wrench, loosen the auto-stop switch mounting bolts (C). 7. Adjust the auto-stop switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the switch (auto-stop). - Check that the switch plate contacts the switch bracket (G). 8. Check the operation of the glass by operating the moonroof switch: From the tilt-up position to the fully closed position, from the fully open position to the auto-stop position, from the auto-stop position to the fully closed position. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Switch: Component Locations 95. Front of Roof 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 455 97. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 456 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 457 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 458 Sunroof / Moonroof Switch: Diagrams 50. Moonroof Auto-stop Switch 144. Moonroof Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement > Page 461 Sunroof / Moonroof Switch: Testing and Inspection Auto-Stop Switch Test Auto-stop Switch Test 1. Remove the headliner. 2. Disconnect the 2P connector from the moonroof auto-stop switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. - The auto-stop position is about 145 mm (5.75 in.) from fully closed. 4. If the continuity is not as specified, repair or replace the auto-stop switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 462 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 467 Interior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 468 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 469 111. Middle of Hatch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 470 41. Hatch Latch Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 471 Trunk / Liftgate Switch: Testing and Inspection Hatch Latch Switch Test 1. Open the hatch. 2. Remove the hatch lower trim panel. 3. Disconnect the 2P connector (A) from the hatch latch (B), 4. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the hatch open. - There should be no continuity with the hatch closed. 5. If the continuity is not as specified, replace the hatch latch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 477 22. Left Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 478 24. Brake Fluid Level Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 479 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 483 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 484 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 485 199. Brake Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 486 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 487 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15 A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15 A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM (E22) and the No.7 HORN, STOP (15 A) fuse. Replace the No.7 HORN, STOP (15 A) fuse. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 488 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet and the insulator cutout (B). Measure the pedal height (C) from the middle of the left side of the pedal pad (D). Standard pedal height (with carpet removed): 184 mm (7 1/4 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the brake pedal by hand. 2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 489 Brake Pedal Position Switch Clearance 1. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 - 0.118 inch) by locking the switch. Make sure the brake lights go off when the pedal is released. 2. Check the brake pedal free play. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 493 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 494 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 495 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations 35. Lower Left Side of Engine Comp. (Right Sim.) 37. Under Left Rear of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 499 102. Right Side of Cargo Area Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 500 Wheel Speed Sensor: Diagrams 86. Wheel Speed Sensor, Left Front 87. Wheel Speed Sensor, Left Rear 88. Wheel Speed Sensor, Right Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 501 89. Wheel Speed Sensor, Right Rear Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 502 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contactless type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the inlet valve closes and if necessary, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, and the outlet valve closes, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 503 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 504 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 510 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 511 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Radiator Fan Switch Switching Temperature Turns ON ............................................................................................................................................. .................................. 196 - 203°F (91 - 95°C) Turns OFF ............................................................................................................................ Subtract 5 - 15°F (3 - 8°C) from actual ON temperature Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 515 3. Under Side of Radiator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 516 57. Radiator Fan Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 517 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch. 1. Remove the radiator fan switch from the radiator. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water, and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between terminal No. 1 and terminal No. 2 according to the table. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 518 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection Coolant Temperature Gauge Circuit Troubleshooting Before testing, check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the malfunction indicator lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshoot the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnostic function. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM. Check for an open in the WHT/GRN wire (gauge connector terminal B13). If no open is found, go to step 5. NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnostic function. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM and recheck. Did the symptom/indication go away? YES - Replace the ECM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 529 Clutch Switch: Diagrams 28. Clutch Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 530 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 79. Inside Steering Wheel 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 534 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 535 Cruise Control Switch: Diagrams 122. Cruise Control Set/Resume/Cancel Switch 136. Cruise Control Main Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch Cruise Control Switch: Testing and Inspection Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch > Page 538 Cruise Control Switch: Testing and Inspection Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch Cruise Control Switch: Service and Repair Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch > Page 541 Cruise Control Switch: Service and Repair Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations 15. Lower Right Rear of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 546 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 547 8. Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 548 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 549 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 2. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 554 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 555 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it work properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations 70. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 562 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 563 36. Evaporator Temperature Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 564 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour warm water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown, in the graph; the resistance should be within the specifications. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 565 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Remove the driver's dashboard lower cover and the under cover. 2. Remove the under-dash fuse/relay box. 3. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Remove the self-tapping screw, and carefully pull out the evaporator temperature. 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 569 21. Left Front of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 570 18. A/C Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 571 Refrigerant Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch Circuit Troubleshooting NOTE: - Do not use this troubleshooting procedure if any of the following items are operative; A/C condenser fan, radiator fan, A/C compressor, or if the heater is inoperative. Refer to the symptom troubleshooting index. - Before performing symptom troubleshooting, check for powertrain DTCs. 1. Turn the ignition switch ON (II). 2. Turn the blower switch on, and check for blower motor operation. Does the blower motor run on all speeds? YES - Go to step 3. NO - Troubleshoot the blower motor circuit. 3. Turn the ignition switch OFF. 4. Disconnect heater control panel connector A (14P). 5. Turn the ignition switch ON (II). 6. Measure the voltage between the No. 4 terminal of heater control panel connector A (14P) and body ground. Is there battery voltage? YES - Go to step 7. NO - Go to step 12. 7. Start the engine. 8. Connect the No. 4 terminal of heater control panel connector A (14P) to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 9. NO - Refer to the multiplex control system. 9. Turn the ignition switch OFF. 10. Disconnect heater control panel connector B (22P). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 572 11. Measure the resistance between the No. 2 terminal of the heater control panel connector A (14P) and the No. 7 terminal of the heater control panel connector B (22P). Is there resistance less than 24 kOhms? YES - Check for loose wires or poor connections at heater control panel connector A (14P) and B (22P) and at the A/C pressure switch 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Test the evaporator temperature sensor. 12. Using the Backprobe Set, connect the No. 9 terminal of under-dash fuse/relay box connector F (12P)to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 13. NO - Refer to the multiplex control system. NOTE: Check for multiplex codes in mode 1. Follow the troubleshooting for any codes found. If no codes are found, substitute known-good multiplex control unit and a ECM one at a time. 13. Disconnect the A/C pressure switch 2P connector and under-dash fuse/relay box connector F (12P). 14. Check for continuity between the No. 2 terminal of the A/C pressure switch 2P connector and the No. 9 terminal of under-dash fuse relay box connector F (12P). Is there continuity? Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 573 YES - Go to step 15. NO - Repair open in the wire between the under-dash fuse/relay box and the A/C pressure switch. 15. Check for continuity between the No. 1 and No. 2 terminals of the A/C pressure switch. Is there continuity? YES - Repair open in the wire between the heater control panel and the A/C pressure switch. NO - Go to step 16. 16. Check for proper A/C system pressure. Is the pressure within specifications? YES - Replace the A/C pressure switch. NO - Repair the A/C pressure problem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 578 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 579 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 580 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 584 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 585 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07AAA-S0XA100 NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel (A) from the floor. 6. Disconnect the fuel pump 5P connector (B). 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is as specified, go to step 8. - If the voltage is not as specified, check for: an open in the YEL/BLK or BLK wire. - poor ground (G 551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 586 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer does not indicate "F", replace the gauge. - If the pointer indicates "F", inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 587 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the above readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 588 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07AAA-S0XA100 See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions 1. Relieve the fuel pressure.See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 589 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install the fuel tank unit in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations 72. In Steering Column Cover Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 593 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 594 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 595 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch, the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the multiplex control unit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed from the ignition switch. 4. If the continuity is not as specified, replace the ignition switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 599 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 600 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 601 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations 11. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 606 20. Back-up Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 607 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 2P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the back-up light switch. Apply liquid gasket (P/N 08718-0001), and install it on the transmission housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 611 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 612 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No. 3 and No. 4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 616 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 617 181. Combination Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 618 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 619 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 623 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 624 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 625 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 629 138. Fog Light Switch (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 633 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 634 163. Hazard Warning Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 635 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 636 Hazard Warning Switch: Service and Repair Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations 79. Inside Steering Wheel Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 640 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 641 4. Horn Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 642 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector No. 2 terminal to body ground. - If the horns sound, go to step 4. - If the horns do not sound, check these items: Horn relay - No. 7 (15 A) fuse in the under-hood fuse/relay box - Horns. - An open in the wire 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horns sound, go to step 6. - If the horns do not sound, replace the cable reel. 6. Reconnect the horn switch positive 1P connector. 7. Using a jumper wire, connect the steering wheel to body ground. 8. Close the contacts between the horn plate and the contact plate. - If the horns sound, replace the steering column. - If the horns do not sound, replace the horn and contact plate. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO 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 injection discharge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 658 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 659 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 660 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 661 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 664 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 665 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 666 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 670 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 671 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 675 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 676 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 677 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 680 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 681 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 690 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 691 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 692 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 693 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 699 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 700 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 701 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 702 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 703 Electric Load Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 704 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 705 100. ELD Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 706 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that's proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 711 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 712 38. Under Left Rear Of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 713 101. FTP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 714 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 718 9. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 719 44. IAT Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 723 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 724 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 725 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 726 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 730 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 731 106. MAP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 732 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 737 36. Rear Underside of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 738 Oxygen Sensor: Diagrams 114. A/F Sensor 128. Secondary HO2S Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) Sensor The A/F Sensor operates over a wide air/fuel range. The A/F Sensor is installed upstream of the TWC, and sends signals to the ECM which varies the duration of fuel injection accordingly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor > Page 741 Oxygen Sensor: Description and Operation Secondary Oxygen Sensor Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the three way catalytic converter (TWC) and sends signals to the ECM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement Oxygen Sensor: Service and Repair A/F Sensor Replacement A/F Sensor Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the A/F sensor 4P connector (A), then remove the A/F sensor (B). 2. Install the A/F sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement > Page 744 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 751 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 752 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 753 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 762 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 763 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 769 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 770 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations Variable Valve Timing Pressure Switch: Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 774 13. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 775 83. VTEC Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 780 Vehicle Speed Sensor: Locations 12. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 781 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 782 113. VSS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 783 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 784 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required Test harness 07LAJ-PT3020A Before testing, inspect the No. 4 (10 A) and No. 10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an Ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Connect the test harness to the VSS. 7. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 8. NO - Repair open in the BLK/YEL or BLK/ORN wire between the VSS and the under-dash fuse/relay box, repair ground or open in BLK wire between VSS and G101. 8. Disconnect the WHT test harness clip (B). 9. Disconnect the test harness from the VSS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 785 10. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 11. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, the gauge assembly or the ECM. 11. Turn the ignition switch OFF. 12. Connect the other test harness connector (A) to the VSS (B). 13. Raise the front of the vehicle, and make sure it is securely supported. 14. Put the vehicle in neutral with the ignition switch ON (II). 15. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Go to step 16. NO - Replace the VSS. 16. Disconnect the 22P connector "B" from the gauge assembly. 17. Connect the positive probe of a voltmeter to the BLU/WHT wire and the negative probe to ground. 18. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Replace the speedometer assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 786 NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 787 Vehicle Speed Sensor: Service and Repair VSS Replacement 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 removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 792 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 793 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 794 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 799 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 800 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 801 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 802 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 805 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 806 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 807 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 811 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 812 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 813 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 816 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 817 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 823 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 824 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 825 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 826 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 827 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 828 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 829 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 830 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 831 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 832 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 836 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 837 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 838 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 839 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 31. Left Front of Vehicle (Bumper Removed) 34. Right Front of Vehicle (Bumper Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 844 87. Left Side of Floor (Right Similar) (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 845 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 846 Impact Sensor: Diagrams 45. Impact Sensor, Left Front 46. Impact Sensor, Right Front 63. Side Impact Sensor, Driver's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 847 64. Side Impact Sensor, Passenger's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement Impact Sensor: Service and Repair Side Impact Sensor Replacement Side Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the appropriate side airbag 2P connector. 3. Remove the seat assembly. 4. Remove the front door sill trim. 5. Disconnect the 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 (B). Installation 1. Install the new side impact sensor with a new Torx bolt (A), then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. 4. Install all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement > Page 850 Impact Sensor: Service and Repair Front Impact Sensor Replacement Front Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's airbag 4P connector, the front passenger's airbag 4P connector, both seat belt tensioner 2P connectors, and both seat belt buckle 4P connectors. 3. Remove the front inner fender. 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 (C). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 89. Under Side of Passenger's Seat 90. Under Side of Driver's Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 854 Seat Belt Buckle Switch: Diagrams 107. Seat Belt Switch, Driver's 108. Seat Belt Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 863 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 864 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 865 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 866 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 867 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 868 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 869 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 870 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 871 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 872 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 873 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 879 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 880 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 881 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 882 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 883 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 884 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 885 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 886 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 887 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 888 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 889 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 890 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 895 Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 896 27. Clutch Interlock Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 897 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install the clutch interlock switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 898 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C). 2. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. To measure the pedal height to the floor, remove the driver's footrest, and measure to where it mounts to the floor. Clutch Pedal Stroke: 130 - 140 mm (5.12 - 5.51 inch) Clutch Pedal Free Play: 10 - 16 mm (0.39 - 0.63 inch) Clutch Pedal Height to floor: 193 mm (7.60 inch) to carpet: 155 mm (6.10 inch) Disengagement Height to floor: 115 mm (4.53 inch) to carpet: 77 mm (3.08 inch) 3. Tighten the clutch pushrod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C). 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten the clutch pedal position switch locknut (A). 7. Loosen locknut (J) and the clutch interlock switch (K). 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 10 - 16 mm (0.39 - 0.63 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 904 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 905 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 906 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 907 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 908 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 909 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 910 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 911 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 912 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 913 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 922 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 923 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 928 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 929 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 940 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 941 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 947 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 948 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 962 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 963 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 969 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 970 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 979 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 980 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Safety Switch > Component Information > Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Safety Switch > Component Information > Locations > Page 987 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 991 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 992 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 993 Power Window Switch: Diagrams 146. Power Window Switch, Passenger's 179. Power Window Master Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test 1. Remove the power window master switch. 2. Disconnect the 14P connector from the switch (A). 3. Check for continuity between the terminals in each switch position according 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. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 996 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the Power window master switch (A). 2. Disconnect the 14P connector (B) from the master switch. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. With the connector still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 997 5. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch '04-05 models 6. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 998 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test 1. Remove the switch panel. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the passenger's power window switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 999 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Window Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the connector, and using a back probe, make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. 5. Disconnect the 5P connector, and make these input tests. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 1000 6. If all the tests prove OK, the switch must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Replacement 1. Remove the door grip. 2. Remove the power window master switch (A) from the door panel. 3. Disconnect the 14P connector (B) from the switch. 4. Remove the three screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 1003 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Passenger's Window Switch Replacement 1. Remove the door grip. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the switch, 4. Remove the two screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1008 85. Washer Fluid Level Switch (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1009 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1010 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1014 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1015 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1016 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1020 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1021 180. Wiper/Washer Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1022 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1023 Wiper Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1033 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1034 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1035 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1036 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1037 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1038 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1039 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1040 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1041 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1047 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1048 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1049 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1050 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1051 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1052 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1053 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1054 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1055 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN041115 > Nov > 04 > Alignment - Specifications For Sport Suspension Kit Alignment: All Technical Service Bulletins Alignment - Specifications For Sport Suspension Kit SOURCE: Honda Service News November 2004 TITLE: Sport Suspension Kit Alignment Specifications APPLIES TO: 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension SERVICE TIP: Doing an alignment on a 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension Kit? Keep in mind the alignment specs aren't entirely the same as the standard specs in the S/M. Refer to this chart for the proper specs on these vehicles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds > Page 1064 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN041115 > Nov > 04 > Alignment - Specifications For Sport Suspension Kit Alignment: All Technical Service Bulletins Alignment - Specifications For Sport Suspension Kit SOURCE: Honda Service News November 2004 TITLE: Sport Suspension Kit Alignment Specifications APPLIES TO: 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension SERVICE TIP: Doing an alignment on a 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension Kit? Keep in mind the alignment specs aren't entirely the same as the standard specs in the S/M. Refer to this chart for the proper specs on these vehicles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds > Page 1074 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1075 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1076 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1077 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1078 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1079 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1080 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1081 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1082 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1083 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1084 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # SN030915 Date: 030901 Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1085 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1086 TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1087 During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1088 NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1089 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1090 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1091 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1092 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1093 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1094 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment > Page 1097 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment > Page 1098 Alignment: Specifications Sport Suspension NOTE: This article has been updated as per TSB SN0411155. With Sport Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1099 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust the toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust the camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: '02-03 Front/rear: 195/60R15 88V Tire size: '04-05 Front/rear: 205/55R16 89V Tire pressure: '02-03 models Front: 230 kPa (2.3 kgf/cm2, 33 psi) Rear: 210 kPa (2.1 kgf/cm2, 30 psi) Tire pressure: '04-05 models Front/Rear: 210 kPa (2.1 kgf/cm2, 30 psi) 4. Check the runout of the wheels and tires. 5. Check the suspension ball joints. (Hold a wheel with your hands, and move it up and down and right and left to check for wobbling). 6. Bounce the vehicle up and down several times to stabilize the suspension. Front Caster Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: '02-03 models 1°40' ± 1° Front caster angle: '04-05 models 1°35' ± 1° Front Camber Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, adjust the camber. Front camber angle: '02-03 models - 0°30' ± 45' Front camber angle: '04-05 models - 0°10' ± 45' Front Camber Adjustment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1100 The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 2. Loosen the damper pinch nuts and bolts (A), and adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. 3. Tighten the bolts to the specified torque. 4. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 5. Check the camber angle. If it is within the specification, check the front toe. If it is not within the specification, go to step 6. 6. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 7. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle. NOTE: The camber angle can be adjusted up to ± 15' (center of tolerance) by replacing one damper pinch bolt with the adjusting bolt. The camber angle can be adjusted up to ± 30' by replacing both upper and lower damper pinch bolts with the adjusting bolts. 8. Tighten the bolts to the specified torque. 9. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 10. Check the camber angle. If it is within the specification, check the front toe, and adjust it if necessary. If it is not within the specification, readjust, and recheck. If the camber angle cannot be adjusted to the specification, check for bent or damaged suspension components. Rear Camber Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, check for bent or damaged suspension components. Rear camber angle: '02-03 models - 0°55' ± 45' Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1101 Rear camber angle: '04-05 models - 0°50' ± 45' NOTICE; Do not loosen the special bolts on the trailing arm. Front Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Center the steering wheel spokes. 2. Check the toe. If it is not within the specification, go to step 3. Front toe-in: 0 ± 3 mm (0 ± 0.12 inch) 3. Loosen the locknut (A) while holding the tie-rod end (B). 4. Turn the tie-rod (C) until the toe is correct. 5. After adjusting, tighten the locknut while holding the tie-rod end. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in (inspection): '02-03 models 1 ± 3 mm (0.04 ± 0.12 inch) Rear toe-in (inspection): '04-05 models 2 ± 3 mm (0.08 ± 0.12 inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the lower arm to adjust the alignment. 4. Replace the self-locking nut with a new one, and lightly tighten. NOTE: Always use a new self-locking nut whenever it has been loosened. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1102 5. Turn the adjusting bolt until the toe is correct. Rear toe-in (adjustment): 2 [2/1] mm (0.08 [0.08/0.04] inch) 6. Tighten the self-locking nut to the specified torque while holding the adjusting bolt. Turning Angle Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Turn the steering wheel fully to the right and left while applying the brake, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. Turning angle: '02-03 Inward: 34°00' ± 2° Outward: 28°00' (reference) Turning angle: '04-05 Inward: 34°40' ± 2° Outward: 28°10' (reference) 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure....................................................................................................................................... ..........320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 54 psi). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1107 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1108 Fuel Pressure: Testing and Inspection Fuel Pressure Test See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment set 07AAJ-S6MA150 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, go to step 5. - If the pump does not run, do the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 52 psi). - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Engine idle Idle speed without load M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam) M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1112 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the idle air control (IAC) valve connected. - Before checking the idle speed, check these items: The malfunction indicator lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - Pull the parking brake lever up. Start the engine, and make sure the headlights are off. 1. Disconnect the evaporative emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer (A) to the test tachometer connector (B), or connect the HDS or a scan tool to the data link connector (DLC) (C) located under the driver's side of the dashboard. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner off. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm 5. Let the engine idle for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures 6. Reconnect the EVAP canister purge valve 2P connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 1117 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Disconnect the PCV hose (A). 2. Open the air cleaner housing cover (B). 3. Remove the air cleaner (C) from the air cleaner housing (D). 4. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1122 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1133 Ignition System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1134 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1135 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. - Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling - Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of indium tip plugs (A); replace the spark plug if the gap is out of specification. 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs as listed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1136 4. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head, finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Engine Assembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1140 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the intake manifold cover. 4. Disconnect all four injector connectors. 5. Start the engine, and let it run until it stalls. 6. Remove the four ignition coils. 7. Remove the four spark plugs. 8. Attach the compression gauge to the spark plug hole. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check these items, then remeasure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ..................... 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust ................................................................ ...................................................................................................... 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1144 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket. 3. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust: 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1145 4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag. 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 6. Tighten the locknut, and recheck the clearance. Repeat the adjustment if necessary. 7. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 8. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1146 9. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 10. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 11. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 12. Check and, if necessary, adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Caution: Incorrect removal or installation of the timing chain can result in damage to internal engine components. For complete Timing Chain Removal and Installation information, please refer to Timing Chain; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications HVAC Compressor: Drive Belt Tension .............................................................................................................................................. Auto Tensioner (Needs No Adjustment) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1153 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1154 Drive Belt: Testing and Inspection Drive Belt Inspection Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If it is out of the standard range, replace the drive belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1155 Drive Belt: Service and Repair Drive Belt Replacement 1. Move the auto-tensioner (A) to relieve tension from the drive belt (B), and remove the drive belt. 2. Install the new belt in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1156 Drive Belt: Tools and Equipment Honda Serpintine Belt Wrench AST tool# HON1419 -Lightweight and slim design -Equipped with 14mm and 19mm, 12 point securing attachments Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1157 -Works on most Honda applications Contact AST for pricing Assenmacher Specialty Tools 1 800 525 2943 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 1163 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Disconnect the PCV hose (A). 2. Open the air cleaner housing cover (B). 3. Remove the air cleaner (C) from the air cleaner housing (D). 4. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1167 Cabin Air Filter: Service and Repair Dust and Pollen Filter Replacement The dust and pollen filters should be replaced every 30,000 miles (48,000 km) or 24 months whichever comes first Replace the filters more often if the air flow is less than usual, or if the vehicle is driven in areas that have high concentrations of soot from industry or diesel powered vehicles. 1. Open the glove box. Remove both glove box stops, then let the glove box hang down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1172 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair Engine Oil Filter Replacement Special Tool Required Oil filter wrench 07HAA-PJ70100 Engine Oil Filter (3/4-turn type) 1. Remove the oil filter with the special tool. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 3/4 turn clockwise. Tightening torque: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Page 1176 5. If 4 numbers or marks (1 to 4 or V to VVVV) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom. ^ Tighten the filter by turning it clockwise 3 numbers or marks from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. Oil Filter Feed Pipe Replacement 1. Remove the oil filter. 2. Remove the oil filter feed pipe. 3. Install the two 20 x 1.5 mm nuts (A) 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 49 Nm (5.0 kgf-cm, 36 ft. lbs.), then remove the nuts from the oil filter feed pipe. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid ...................................................................................................................................... Genuine Honda DOT 3 Brake Fluid (P/N 08798-9008) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1185 Brake Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid type ................................................................................................................................................ Always use only Honda DOT 3 brake fluid Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Refill Capacity ............................................................................................................ ..................................................... 5.0 L (5.3 US qt.) Reserve Tank Capacity ....................................................................................................................... ................................................. 0.53 L (0.56 US qt.) Engine Overhaul Capacity ................................ ......................................................................................................................................... 5.3 L (5.6 US qt.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1193 Coolant: Fluid Type Specifications Only use Honda All Season Antifreeze/Coolant Type 2 (P/N 0L999-9001) at 50 percent concentration with water. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1194 Coolant: Testing and Inspection Check 1. Look at the coolant level in the reserve tank. Make sure it is between the MAX mark (A) and MIN mark (B). 2. If the coolant level in the reserve tank is at or below the MIN mark, add coolant to bring it up to the MAX mark, and inspect the cooling system for leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1195 Coolant: Service and Repair Replacement 1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the ignition switch. Make sure the engine and radiator are cool to the touch. 2. Remove the radiator cap. 3. Remove the splash shield. 4. Loosen the drain plug (A), and drain the coolant. 5. Remove the reserve tank drain cap (A), and drain the coolant. 6. After the coolant has drained, tighten the radiator drain plug securely, and install the reserve tank drain cap securely. 7. Fill the reserve tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2 (P/N OL999-9001). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1196 8. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2 (P/N OL999-9001). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. - Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. Engine Coolant Refill Capacity [including the reserve tank capacity of 0.53 L (0.56 US qt.)]: 5.0 L (5.3 US qt.) 9. Install the radiator cap loosely. 10. Start the engine, and let it run until it warms up (the radiator fan comes on at least twice). 11. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2 if needed. 12. Put the radiator cap on tightly, then run the engine again and check for leaks. 13. Install the splash shield. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Avoiding Fluid Contamination Fluid - A/T: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Change ................................................................................................................................................ .............................................................. 1.5L (1.6 Qt) Overhaul .......................................................... .................................................................................................................................................. 1.7L (1.8 Qt) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1209 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ........................................................................................................................................ Honda Manual Transmission Fluid (MTF): P/N 08798-9016 If not available you may use 10W-30 or 10W-40 motor oil as a temporary replacement. An API Certification seal that says "For Gasoline Engines" should be used as a temporary replacement. Replace with Honda MTF as soon as it is convenient. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1210 Fluid - M/T: Service and Repair Transmission Fluid Inspection and Replacement 1. Park the vehicle on level ground, and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (B), check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. If the transmission fluid is dirty, remove the drain plug (D) and drain the fluid. 4. Reinstall the drain plug with a new washer, and refill the transmission fluid to the proper level. Oil Capacity 1.5 L (1.6 US qt.) at fluid change 1.7 L (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 contain the proper additives. 5. Reinstall the oil filler plug with a new washer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil For engine overhaul ............................................................................................................................. .............................................................. 5.3L (5.6 Qt) For oil change, including filter .............................................................................................................. ............................................................ 4.2L (4.4 Qt) For oil change, without filter ................................................................................................................. ............................................................ 4.0L (4.2 Qt) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1217 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification .................................................................................................................................... Make sure the label says "For Gasoline Engines". SAE Viscosity .............................................................................. ............................................................................................................................... 5W-20 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1218 Engine Oil: Service and Repair Engine Oil Replacement 1. Warm up the engine. 2. Remove the drain bolt (A), and drain the engine oil. 3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil. Capacity 4.0 L (4.2 US qt.) at oil change. 4.2 L (4.4 US qt.) at oil change including filter. 5.3 L (5.6 US qt.) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1223 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1224 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1225 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity or system .............................................................................................................................. ................................... 500 - 550 g (17.6 - 19.4 oz) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1228 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil Capacity of components Condenser ........................................................................................................................................... ............................................... 25 ml (5/6 fl oz) Evaporator ................................................................. .................................................................................................................... 45 ml (1 1/2 fl oz) Each line and hose ....................................................................................................................................... .................................... 10 ml (1/3 fl oz) Compressor .......................................................................... .......................................................................................... 130 - 150 ml (4 1/3 - 5 fl oz) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1233 Refrigerant Oil: Fluid Type Specifications Use only ............................................................................................................................................... ................................................. SP-10 refrigerant oil Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1234 Refrigerant Oil: Service and Repair Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1235 A/C Refrigerant Oil Replacement Recommended PAG oil: KEIHIN SP-10: - P/N 38897-P13-A01AH: 120 mL (4 fl.oz) - P/N38899-P13-A01: 40 mL(1 1/3 fl.oz) Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If it gets on the paint, wash it off immediately. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not allow dirt or other foreign matter to contaminate the brake fluid. ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleeder screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left-front, loosen the brake bleeder screw to allow air to escape from the system. Then tighten the bleeder screw securely. 5. Repeat the procedure for each wheel in the sequence shown following until air bubbles no longer appear in the fluid. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 1239 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1244 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1245 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Component Locations Fuse: Component Locations Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Component Locations > Page 1251 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Component Locations > Page 1252 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Component Locations > Page 1253 Fuse: Connector Locations Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Component Locations > Page 1254 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Connector Views (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1259 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1260 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1265 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1266 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1267 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1268 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1269 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1270 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1271 Fuse Block: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1272 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1273 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1274 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1277 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1278 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1279 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1280 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1281 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1282 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1283 Fuse Block: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1288 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1289 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1290 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1291 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1292 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1293 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1294 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1295 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1296 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1297 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1298 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1299 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1300 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1301 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1302 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1303 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1304 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1307 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1308 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Resetting the Maintenance Required Indicator How to Reset Push and hold the trip/reset button, turn the ignition switch ON (II), and continue to hold the button for more than 10 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM has been reset, these codes are set to incomplete. In some states, part of the emissions; testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are set to complete. If it blinks several times, on 2 or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1316 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect the HDS or a scan tool. 2. Turn the ignition switch ON (II) and read the HDS or a scan tool. Does the HDS or a scan tool communicate with the ECM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the HDS or a scan tool for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting Index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the malfunction indicator lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 76. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) (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 connection at ECM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM (A21) and the manifold absolute pressure (MAP) sensor. - An intermittent short in the wire between the ECM (A20) and the throttle position (TP) sensor. - An intermittent short in the wire between the ECM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IG1 (40A) (Canada: 50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (40A) (Canada: 50A) fuse and the gauge assembly. If the wire is OK, test the ignition switch. NO - Repair short in the wire between No.20 IG (40A) (Canada: 50A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1317 (Canada: 50A) fuse. 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Check for an open in the wire between the ECM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. 17. Remove the glove box and PGM-FI main relay 1. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1318 18. Check for continuity between body ground and PGM-FI main relay 14P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM) (15A) fuse and the PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or the connectors below, one at a time, and check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft Position (CMP) sensor B 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Also replace the No.6 ECU (ECM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft Position (CMP) sensor B - Crankshaft position (CKP) sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1319 21. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse from the under-dash fuse/relay box. 24. Disconnect ECM connector E (31P). 25. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 26. Remove the PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1320 27. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9), or between the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. 32. Reinstall PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1321 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it if necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9). 37. Measure voltage between ECM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 38. 38. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1322 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (E7). 42. Reconnect ECM connector E (31P). 43. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1323 44. Measure voltage between body ground and ECM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). 48. Measure voltage between PGM-FI main relay 14P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 49. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1324 50. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and ECM connector terminals A2 and A3 individually. Is there continuity? YES - Replace PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (A2, A3). 51. Measure voltage between body ground and ECM connector terminals A4, A5, A23, and A24 individually. Is there more than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s)that had more than 1.0 V between G101 and the ECM (A4, A5, A23, A24). 52. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Go to step 60. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the manifold absolute pressure (MAP) sensor 3P connector. 55. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1325 56. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Replace the MAP sensor. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect ECM connector A (31P). 59. Check for continuity between ECM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A21) and the MAP sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 60. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 61. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1326 61. Turn the ignition switch OFF. 62. Disconnect the throttle position (TP) sensor 3P connector. 63. Turn the ignition switch ON (II). 64. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Replace the throttle body (the TP sensor is not available separately). NO - Go to step 65. 65. Turn the ignition switch OFF. 66. Disconnect ECM connector A (31P). 67. Check for continuity between ECM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A20) and the TP sensor, or repair short in the wire between the ECM (A8) and the knock sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 68. Measure voltage between body ground and ECM connector terminal E5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1327 Is there about 5 V? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). 72. Measure voltage between body ground and ECM connector terminal E5 Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF 74. Disconnect ECM connector E (31P). 75. Check for continuity between ECM connector terminal E5 and body ground Is there continuity? YES - 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. If the symptom/indication goes away with a known good ECM, replace the original ECM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1328 78. Measure voltage between ECM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM connector E (31P). 81. Check for continuity between ECM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the data link connector (DLC) and the ECM (E29). NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. 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 (31P). 84. Turn the ignition switch ON (II). Does the MIL stay on? YES - Repair short in the wire between the gauge assembly and the ECM (E31). If the wire is OK, replace the gauge assembly. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), on safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B). Center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Size Of Spare Tire ............................................................................................................................... ..................................................... T125/70 D15 95M Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Aluminum Wheel Runout Standard or New: Axial ..................................................................................................................................................... ......................... 0 - 0.7 mm (0 - 0.03 inch) Radial ............................................................................... ............................................................................................. 0 - 0.7 mm (0 - 0.03 inch) Service Limit: Axial ..................................................................................................................................................... ................................... 2.0 mm (0.08 inch) Radial ............................................................................... ........................................................................................................ 1.5 mm (0.06 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Specifications > Page 1340 Wheels: Testing and Inspection Wheel Runout Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. 2. Check for a bent or deformed wheel. 3. Set up the dial gauge as shown, and measure the axial runout by turning the wheel. Front and rear wheel axial runout: Standard: Aluminum wheel: 0 - 0.7 mm (0 - 0.03 inch) Service limit: 2.0 mm (0.08 inch) 4. Reset the dial gauge to the position shown, and measure the radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0 - 0.7 mm (0 - 0.03 inch) Service limit: 1.5 mm (0.06 inch) 5. If the wheel runout is not within the specification, check the wheel bearing end play, and make sure the mating surfaces on the brake disc and the inside of the wheel are clean. 6. If the bearing end play is within the specification but the wheel runout is more than the service limit, replace the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing End Play Front .................................................................................................................................................... .................................. 0 - 0.05 mm (0 - 0.002 inch) Rear .................................................................... ................................................................................................................... 0 - 0.05 mm (0 - 0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front > Page 1346 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Page 1347 Wheel Bearing: Testing and Inspection Wheel Bearing End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. Front Rear 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc inward and outward. Bearing end play: Standard: Front/rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard. replace the wheel bearing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1350 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1351 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1352 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1353 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1354 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1355 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and rear wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1356 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Release the parking brake lever. 5. Remove the brake hose mounting bolt (A). 6. Remove the caliper bracket mounting bolts (B), and hang the caliper (C) to one side. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage. 7. Remove the brake disc retaining screws (A). 8. Screw two 8 x 1.25 mm bolts (B) into the disc (C) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Remove the brake disc. 9. Remove the hub bearing unit (A) from the spindle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1357 10. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. - Use a new spindle nut on reassembly. - After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 1363 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair Towing Information: Service and Repair Towing If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment - The operator loads the vehicle on the back of a truck. This is the only way of transporting the vehicle. To accommodate flat-bed equipment, the vehicle is equipped with towing hooks (A) and tie down hooks (B). The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots can be used to secure the vehicle to the truck. Wheel Lift Equipment - The tow truck uses two pivoting arms that go under the tires (front or rear) and lifts them off the ground. The other two wheels remain on the ground. This is an acceptable 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 off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following: - Release the parking brake. - Shift the transmission to Neutral. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE: - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission, the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), on safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B). Center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 Variable Valve Timing Actuator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1403 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1404 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 82. VTC Oil Control Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1415 Variable Valve Timing Actuator: Description and Operation VTEC/VTC - The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load. - The VTEC mechanism changes the valve lift and timing by using more than one cam profile. - The VTC changes the phase of the intake camshaft via oil pressure. It changes the intake valve timing continuously. VTC system - The VTC system makes continuous intake valve timing changes based on operating conditions. - Intake valve timing is optimized to allow the engine to produce maximum power. - Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry of the air/fuel mixture into the intake port and improve the 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 retarded position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1416 VTEC system - The VTEC system changes the cam profile to correspond to engine speed. It maximizes torque at low engine speed and output at high engine speed. - The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds. System Diagram Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator Variable Valve Timing Actuator: Testing and Inspection VTC Actuator VTC Actuator Inspection 1. Remove the cylinder head cover. 2. Remove the auto-tensioner. 3. Loosen the rocker arm adjusting screws. 4. Remove the camshaft holder. 5. Remove the intake camshaft. 6. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator. 7. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape. 8. Punch a hole through the tape over one of the advance holes. 9. Apply air to the advance hole to release the lock Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1419 10. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1420 Variable Valve Timing Actuator: Testing and Inspection VTC Actuator Removal/Test/Installation VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1421 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement Variable Valve Timing Actuator: Service and Repair VTC Actuator, Exhaust Camshaft Sprocket Replacement Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1424 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1425 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1429 84. VTEC Oil Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1430 Variable Valve Timing Solenoid: Testing and Inspection VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1431 Variable Valve Timing Solenoid: Service and Repair VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Engine Assembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1435 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the intake manifold cover. 4. Disconnect all four injector connectors. 5. Start the engine, and let it run until it stalls. 6. Remove the four ignition coils. 7. Remove the four spark plugs. 8. Attach the compression gauge to the spark plug hole. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check these items, then remeasure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Rocker Arm Assembly Torque and Sequence Tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) 6mm bolts: (21), (22), (23) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications VTC actuator bolt .............................................................................................................................................................. 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket bolt ............................................................................................................................................. 72 Nm (7.3 kgf-cm, 53 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1443 Camshaft Gear/Sprocket: Service and Repair Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications End play Standard .............................................................................................................................................. ...................... 0.05 - 0.20 mm (0.002 - 0.008 inch) Service Limit ........................................................ ............................................................................................................................... 0.4 mm (0.02 inch) Camshaft-To-Holder Oil Clearance No.1 journal Standard .......................................................................................................................................................... 0.030 - 0.069 mm (0.001 - 0.003 inch) Service Limit ........................................................................... .................................................................................................. 0.15 mm (0.006 inch) No.2, 3, 4, 5 journals Standard .......................................................................................................................................................... 0.060 - 0.099 mm (0.002 - 0.004 inch) Service Limit ........................................................................... .................................................................................................. 0.15 mm (0.006 inch) Total runout Standard .............................................................................................................................................. .................................... 0.03 mm (0.001 inch) max. Service Limit ....................................................... ............................................................................................................................ 0.04 mm (0.002 inch) Cam lobe height Intake, Primary ................................................................................................................................................ ................................ 33.925 mm (1.3356 inch) Secondary ................................................................. .......................................................................................................... 29.638 mm (1.1668 inch) Exhaust ................................................................................................................................................ ...................................... 34.092 mm (1.3422 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1447 Camshaft: Testing and Inspection Inspection NOTE: Do not rotate the camshaft during inspection. 1. Remove the rocker arm assembly, and disassemble it. 2. Put the rocker shaft holders, camshaft, and camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) 6 mm bolts: (21), (22), (23) 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 of the camshaft, then push the camshaft back and forth and read the end play. If the end play is beyond the service limit, replace the camshaft head and recheck. If it is still beyond the service limit, replace the cylinder. Camshaft End Play: Standard (New): 0.05 - 0.20 mm (0.002 - 0.008 inch) Service Limit: 0.4 mm (0.02 inch) 5. Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head. 6. Lift the camshafts out of the cylinder head, wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn. 7. Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal. 8. Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1448 9. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. ^ If the camshaft-to-holder clearance is within limits, go to step 11. ^ If the camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head. ^ If the camshaft-to-holder clearance is beyond the service limit and the camshaft has not been replaced, go to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): No. 1 Journal: 0.030 0.069 mm (0.001 - 0.003 inch) No. 2, 3, 4, 5 Journals: 0.060 - 0.099 mm (0.002 - 0.004 inch) Service Limit: 0.15 mm (0.006 inch) 10. Check the total runout with the camshaft supported on V-blocks. ^ If the total runout of the camshaft is within the service limit, replace the cylinder head. ^ If the total runout is beyond the service limit, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the service limit, replace the cylinder head. Camshaft Total Runout: Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.04 mm (0.002 inch) 11. Measure cam lobe height. Cam Lobe Height Standard (New): Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1449 Camshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arms Arm-To-Shaft Clearance: Intake: Standard or New .......................................................................................................................................... 0.025 0.052 mm (0.0010 - 0.0020 inch) Service Limit ................................................................................... .......................................................................................... 0.08 mm (0.003 inch) Exhaust: Standard or New .......................................................................................................................................... 0.018 0.056 mm (0.0007 - 0.0022 inch) Service and Repair ......................................................................... ............................................................................................ 0.08 mm (0.003 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection Rocker Arm Assembly: Testing and Inspection Rocker Arms and Shaft Inspection Inspection 1. Remove the rocker arm assembly. 2. Measure the diameter of the shaft at the first rocker location. 3. Zero the gauge (A) to the shaft diameter. 4. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.025 - 0.052 mm (0.0010 - 0.0020 inch) Exhaust: 0.018 - 0.056 mm (0.0007 - 0.0022 inch) Service Limit: 0.08 mm (0.003 inch) 5. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all over tolerance rocker arms. If any VTEC rocker arm needs replacement, replace the rocker arms (primary and secondary) as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1455 6. Inspect the rocker arm pistons (A). Push each piston manually. If it does not move smoothly, replace the rocker arm set. NOTE: Apply oil to the pistons when reassembling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1456 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test VTEC Rocker Arm Test Special Tools Required ^ Air pressure regulator 07AAJ-PNAA100 ^ VTEC air adapter 07ZAJ-PNAA100 ^ VTEC air stopper 07ZAJ-PNAA200 ^ Air joint adapter 07ZAJ-PNAA300 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). 3. Verify that the intake primary rocker arm (A) moves independently of the intake secondary rocker arm (B). ^ If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. ^ If the intake primary rocker arm moves freely, go to step 4. 4. Repeat step 3 on the remaining intake primary rocker arms with each piston at TDC. When all the primary rocker arms pass the test, go to step 5. 5. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm2, 57 psi). 6. Inspect the valve clearance. 7. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B). 8. Remove the No.2 and No.3 camshaft holder bolts, and install the VTEC air adapters (C) finger-tight. 9. Connect the air joint adapter (D), and air pressure regulator with a 0 - 100 psi gauge (E). 10. Loosen the valve on the regulator, and apply the specified air pressure. Specified air pressure: 290 kPa (3.0 kgf/cm2, 42 psi) NOTE: If the synchronizing piston does not move after applying air pressure; move the primary or secondary rocker arm up and down manually by rotating the crankshaft clockwise. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1457 11. With the specified air pressure applied, move the intake primary rocker arm (A) for the No. 1 cylinder. The primary rocker arm and secondary rocker arm (B) should move together. If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly, and check that the pistons in the primary and secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. 12. Remove the special tools. 13. Tighten the camshaft holder mounting bolts to 22 Nm (2.2 kgf-cm, 16 ft. lbs.). 14. Tighten the sealing bolt to 20 Nm (2.0 kgf-cm, 14 ft. lbs.). 15. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly Rocker Arm Assembly: Service and Repair Rocker Arms and Shafts Disassembly/Reassembly Disassembly/Reassembly NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. ^ Bundle the rocker arms with rubber bands to keep them together as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1460 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Removal Removal 1. Remove the cam chain. 2. Loosen the rocker arm adjusting screws (A). 3. 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 4. Remove the cam chain guide B, camshaft holders, and camshafts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1461 5. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1462 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Installation Installation 1. Clean and dry the No. 5 rocker shaft holder mating surfaces. 2. Reassemble the rocker arm assembly. 3. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder head mating surface of the No. 5 rocker shaft holder. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder head. 5. Remove the bolts from the rocker shaft holder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1463 6. Make sure the punch marks on the variable valve timing control (VTC) actuator and exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. 7. Set the camshaft holders (B) and cam chain guide B (C) in place. 8. Tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) 6mm bolts: (21), (22), (23) 9. Install the cam chain, and adjust the valve clearance. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Variable Valve Timing Actuator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 82. VTC Oil Control Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1503 Variable Valve Timing Actuator: Description and Operation VTEC/VTC - The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load. - The VTEC mechanism changes the valve lift and timing by using more than one cam profile. - The VTC changes the phase of the intake camshaft via oil pressure. It changes the intake valve timing continuously. VTC system - The VTC system makes continuous intake valve timing changes based on operating conditions. - Intake valve timing is optimized to allow the engine to produce maximum power. - Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry of the air/fuel mixture into the intake port and improve the 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 retarded position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1504 VTEC system - The VTEC system changes the cam profile to correspond to engine speed. It maximizes torque at low engine speed and output at high engine speed. - The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds. System Diagram Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator Variable Valve Timing Actuator: Testing and Inspection VTC Actuator VTC Actuator Inspection 1. Remove the cylinder head cover. 2. Remove the auto-tensioner. 3. Loosen the rocker arm adjusting screws. 4. Remove the camshaft holder. 5. Remove the intake camshaft. 6. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator. 7. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape. 8. Punch a hole through the tape over one of the advance holes. 9. Apply air to the advance hole to release the lock Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1507 10. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1508 Variable Valve Timing Actuator: Testing and Inspection VTC Actuator Removal/Test/Installation VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1509 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement Variable Valve Timing Actuator: Service and Repair VTC Actuator, Exhaust Camshaft Sprocket Replacement Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1512 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1513 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balancer shafts, journal diameter No.1 journal, front shaft Standard or New .............................................................................................................................. 19.938 - 19.950 mm (0.07850 - 0.7854 inch) Service Limit ................................................................. .................................................................................................... 19.92 mm (0.784 inch) No.1 journal, rear shaft Standard or New ................................................................................................................................ 23.938 - 23.950 mm (0.9424 - 0.9429 inch) Service Limit ................................................................... .................................................................................................. 23.92 mm (0.942 inch) No.2 journal, front and rear shaft Standard or New ................................................................................................................................ 32.949 - 32.961 mm (1.2972 - 1.2977 inch) Service Limit ................................................................... .................................................................................................. 32.93 mm (1.296 inch) Balancer shafts, journal taper Standard or New ................................................................................................................................................... 0.005 mm (0.0002 inch) maximum Balancer shafts, end play Front Standard or New .................................................................................................................................... 0.070 - 0.135 mm (0.0028 - 0.0053 inch) Service limit .............................................................................................. ........................................................................... 0.15 mm (0.006 inch) Rear Standard or New .................................................................................................................................... 0.070 - 0.135 mm (0.0028 - 0.0053 inch) Service Limit ............................................................................................. .......................................................................... 0.15 mm (0.006 inch) Balancer shafts, shaft-to-bearing clearance No.1 journal, front shaft Standard or New .................................................................................................................................... 0.050 - 0.082 mm (0.0020 - 0.0032 inch) Service Limit ............................................................................................. .......................................................................... 0.10 mm (0.004 inch) No.1 journal, rear shaft Standard or New .................................................................................................................................... 0.050 - 0.082 mm (0.0020 - 0.0032 inch) Service Limit ............................................................................................. .......................................................................... 0.10 mm (0.004 inch) No.2 journal, front and rear shaft Standard or New .................................................................................................................................... 0.060 - 0.120 mm (0.0024 - 0.0047 inch) Service Limit ............................................................................................. .......................................................................... 0.15 mm (0.006 inch) Balancer shaft bearings, I.D. No.1 journal, front shaft Standard or New ................................................................................................................................ 20.000 - 20.020 mm (0.7874 - 0.7882 inch) Service Limit ................................................................... .................................................................................................. 20.03 mm (0.789 inch) No.1 journal, rear shaft Standard or New ................................................................................................................................ 24.000 - 24.020 mm (0.9449 - 0.9457 inch) Service Limit ................................................................... .................................................................................................. 24.03 mm (0.948 inch) No.2 journal, front and rear shaft Standard or New ................................................................................................................................ 33.021 - 33.069 mm (1.3000 - 1.3019 inch) Service Limit ................................................................... .................................................................................................. 33.09 mm (1.303 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1518 Balance Shaft: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Oil Pump, Engine; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Connecting Rod to Journal Clearance Connecting Rod Bearing: Specifications Connecting Rod to Journal Clearance Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.020 - 0.050 mm (0.0008 - 0.0020 inch) Service Limit: 0.060 mm (0.0024 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Connecting Rod to Journal Clearance > Page 1523 Connecting Rod Bearing: Specifications Rod and Main Bearing Selection 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 (0.0009 inch), in 0.006 mm (0.0002 inch) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3 or 4/I, II, III, or IIII) indicating the range. You may find any combination of numbers and bars in any engine. (Half the number or bar is stamped on the bearing cap, the other half on the rod.) If you can't read the code because of an accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent. Normal Bore Size: 48.0 mm (1.89 inch) Connecting Rod Journal Code Location 3. The connecting rod journal codes are stamped on the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Connecting Rod to Journal Clearance > Page 1524 Connecting Rod Journal Code Location (Letters or Bars) 4. Use the big end bore codes and rod journal codes to 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Connecting Rod to Journal Clearance > Page 1525 Main Bearing Selection Crankshaft Bore Code Location 1. Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the five main journal 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. Main Journal Code Location 2. The main journal codes are stamped on the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Connecting Rod to Journal Clearance > Page 1526 3. Use the crank bore codes and crank journal codes to select the 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1527 Connecting Rod Bearing: Service and Repair Rod Bearing Clearance Inspection 1. Remove the oil pump. 2. Remove the baffle plates. 3. Remove the connecting rod cap and bearing half. 4. Clean the crankshaft rod journal and bearing half with a clean shop towel. 5. Place plastigage across the rod journal. 6. Reinstall the bearing half and cap, and torque the bolts to 20 Nm (2.0 kgf-cm, 14 ft. lbs.) + 90°. NOTE: Do not rotate the crankshaft during inspection. 7. Remove the rod cap and bearing half, and measure the widest part of the plastigage. Connecting Rod Bearing-to-Journal Oil Clearance: Standard (New): 0.020 - 0.050 mm (0.0008 0.0020 inch) Service Limit: 0.060 mm (0.0024 inch) 8. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 9. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearing, replace the 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 (0.0009 inch), in 0.006 mm (0.0002 inch) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3 or 4/I, II, III, or IIII) indicating the range. You may find any combination of numbers and bars in any engine. (Half the number or bar is stamped on the bearing cap, the other half on the rod.) If you can't read the code because of an accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent. Normal Bore Size: 48.0 mm (1.89 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1528 Connecting Rod Journal Code Location 3. The connecting rod journal codes are stamped on the crankshaft. Connecting Rod Journal Code Location (Letters or Bars) 4. Use the big end bore codes and rod journal codes to select appropriate replacement bearings from the following table. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1529 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Connecting Rod Damage Information Connecting Rod: Technical Service Bulletins Engine - Connecting Rod Damage Information Why Do Connecting Rods Break? Curious why connecting rods break? Afier all, these are heavy-duty parts specifically designed to endure punishing forces and temperatures. Yet, every once in a while they do bend or break and wind up as cool conversation pieces for a coffee table or desk. Connecting rods break only after they've gotten bent. And they won't get bent unless the engine hydro-locks or the rod bearings fail. When troubleshooting a bent or broken connecting rod, here are some things to consider: ^ The number one culprit for connecting rod breakage is hydro-lock. This happens when liquid (water or fuel) entering the combustion chamber exceeds the chamber's volume. Since liquids don't compress, that extra volume in the chamber causes the rod to bend. You won't really notice anything wrong, until that bent rod finally gives out and breaks. This could happen if you're driving through deep, standing water and someone coming the other way splashes water over your hood. On very rare occasions, a bad ECM/PCM or fuel injector can cause too much fuel to enter a cylinder, causing hydro-lock and resulting in a bent rod. Before this happens, though, there are usually some kind of drive ability problems that crop up and remain afier the engine is fixed. A bent rod might not show any symptoms until it actually breaks. But bent rods leave a wider-than-normal carbon witness line in the cylinder because they're shorter. Typically, a healthy engine has a carbon line that's 6 mm deep. An engine that's suffering from bent rods has a second carbon line that's 9 to 12 mm deep. ^ Connecting rod bearings fail for a number of reasons. To properly determine what actually caused a rod bearing to fail, you've got to take apart all rod bearings and main bearings and compare them side by side. If all or most of the bearings and journals show similar damage (scoring, exposed copper, or heat discoloration) the likely cause is oil starvation, poor maintenance, customer abuse, or running the engine with an aftermarket power booster (nitrous oxide setup, supercharger, turbocharger). If only the bearing or journal for the failed rod looks bad but all the other ones look good (no scoring, no exposed copper or heat discoloration) and the crankshaft journals are smooth with no heat discoloration, then that particular bearing/ clearance would be suspect. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Service Specifications Connecting Rod: Specifications Service Specifications Connecting rod Pin-to-rod clearance Standard or New .......................................................................................................................................... 0.005 0.015 mm (0.0002 - 0.0006 inch) Service Limit ................................................................................... ........................................................................................ 0.02 mm (0.0008 inch) Small-end bore diameter Standard or New ...................................................................................................................................... 21.970 21.976 mm (0.8650 - 0.8652 inch) Large-end bore diameter (Normal) Standard or New .................................................................................................................................. ........................................ 48.0 mm (1.69 inch) End play installed on crankshaft Standard or New .................................................................................................................................................. 0.15 0.30 mm (0.006 - 0.012 inch) Service Limit ......................................................................................... .................................................................................... 0.40 mm (0.016 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Service Specifications > Page 1536 Connecting Rod: Specifications Torque Specifications Connecting Rods Point A-Point B = Difference in Diameter Difference in Diameter: Specification: 0 - 0.1 mm (0 0.004 inch) Apply engine oil to the threads of the connecting rod bolts. Tighten the connecting rod bolts to 20 Nm (2.0 kgf-cm, 14 ft. lbs.). Tighten the connecting rod bolts an additional 90°. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bolt Inspection Connecting Rod: Testing and Inspection Connecting Rod Bolt Inspection Inspection 1. Measure the diameter of each connecting rod bolt at point A and point B. 2. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter: Specification: 0 - 0.1 mm (0 0.004 inch) 3. If the difference in diameter is out of tolerance, replace the connecting rod bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bolt Inspection > Page 1539 Connecting Rod: Testing and Inspection End Play Inspection Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump. 2. Remove the baffle plates. 3. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft. Connecting Rod End Play Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 inch) Service Limit: 0.40 mm (0.016 inch) 4. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance, replace the crankshaft. 5. Install a dial indicator as shown. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10 - 0.35 mm (0.004 - 0.014 inch) Service Limit: 0.45 mm (0.018 inch) 6. If the end play is out-of-tolerance, replace the thrust washers and recheck. If it is still out-of-tolerance, replace the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 1540 Connecting Rod: Service and Repair Disassembly 1. Remove the piston from the cylinder block. 2. Apply engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damage the ring grooves. 3. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. 4. Heat the piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin. Inspection NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 1541 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 21.961 - 21.965 mm (0.8646 - 0.8648 inch) Service Limit: 21.953 mm (0.8643 inch) 2. Zero 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 +0.002 mm (-0.00020 to +0.00008 inch) Service Limit: 0.005 mm (0.0002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 1542 4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.005 - 0.015 mm (0.0002 - 0.0006 inch) Service Limit: 0.02 mm (0.0008 inch) Reassembly 1. Install a piston pin snap ring (A). 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. 3. Heat the piston to about 158°F (70°C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 1543 4. Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D) and the embossed mark (E) on the same side. 5. install the remaining snap ring (F). 6. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pully Bolt .......................................................................................................................................................... 245 Nm (25,0 kgf.m, 181 lbf.ft.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes Crankshaft Main Bearing: Specifications Bearing Size Codes 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 (0.0009 inch), in 0.006 mm (0.0002 inch) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3 or 4/I, II, III, or IIII) indicating the range. You may find any combination of numbers and bars in any engine. (Half the number or bar is stamped on the bearing cap, the other half on the rod.) If you can't read the code because of an accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent. Normal Bore Size: 48.0 mm (1.89 inch) Connecting Rod Journal Code Location 3. The connecting rod journal codes are stamped on the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes > Page 1551 Connecting Rod Journal Code Location (Letters or Bars) 4. Use the big end bore codes and rod journal codes to 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes > Page 1552 Main Bearing Selection Crankshaft Bore Code Location 1. Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the five main journal 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. Main Journal Code Location 2. The main journal codes are stamped on the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes > Page 1553 3. Use the crank bore codes and crank journal codes to select the 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes > Page 1554 Crankshaft Main Bearing: Specifications Service Specifications Crankshaft bearing Main bearing-to-journal oil clearance No.1, 2, 4 & 5 journals Standard or New .................................................................................................................................... 0.017 - 0.041 mm (0.0007 - 0.0016 inch) Service Limit ............................................................................................. ...................................................................... 0.050 mm (0.0020 inch) No.3 journal Standard or New .................................................................................................................................... 0.025 - 0.049 mm (0.0010 - 0.0019 inch) Service Limit ............................................................................................. ...................................................................... 0.055 mm (0.0022 inch) Rod bearing clearance Standard or New .......................................................................................................................................... 0.021 0.049 mm (0.0008 - 0.0019 inch) Service Limit ................................................................................... ...................................................................................... 0.060 mm (0.0024 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Bearing Size Codes > Page 1555 Crankshaft Main Bearing: Specifications Torque Specifications Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf-cm, 22 ft. lbs.). Tighten the bearing cap bolts an additional 56°. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf-cm, 16 ft. lbs.). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1556 Crankshaft Main Bearing: Service and Repair Main Bearing Clearance Inspection 1. To check main bearing-to-journal oil clearance, remove the lower block and bearing halves. 2. Clean each main journal and bearing half with a clean shop towel. 3. Place one strip of plastigage across each main journal. 4. Reinstall the bearings and lower block, then torque the bolts to 29 Nm (3.0 kgf-cm, 22 ft. lbs.) + 56°. NOTE: Do not rotate the crankshaft during inspection. 5. Remove the lower block and bearings again, and measure the widest part of the plastigage. Main Bearing-to-Journal Oil Clearance No. 1, 2, 4, 5 Journals: Standard (New): 0.017 - 0.041 mm (0.0007 - 0.0016 inch) Service Limit: 0.050 mm (0.0020 inch) No. 3 Journal: Standard (New): 0.025 - 0.049 mm (0.0010 - 0.0019 inch) Service Limit: 0.055 mm (0.0022 inch) 6. If the plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing with the same color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. Main Bearing Selection Crankshaft Bore Code Location 1. Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the five main journal 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 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1557 only with solvent or detergent. Main Journal Code Location 2. The main journal codes are stamped on the crankshaft. 3. Use the crank bore codes and crank journal codes to select the 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 the top or bottom. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main journal diameter No.1, 2, 4, 5 journal Standard or New ................................................................................................................................ 54.984 - 55.008 mm (2.1648 - 2.1657 inch) No.3 journal Standard or New ................................................................................................................................ 54.976 - 55.000 mm (2.1644 - 2.1654 inch) Rod journal diameter Standard or New ...................................................................................................................................... 44.976 45.000 mm (1.7707 - 1.7717 inch) Rod/main journal taper Standard or New ................................................................................................................................................... 0.005 mm (0.0002 inch) maximum Service Limit .......................................................................................... ............................................................................... 0.010 mm (0.0004 inch) Rod/main journal out-of-round Standard or New ................................................................................................................................................... 0.005 mm (0.0002 inch) maximum Service Limit .......................................................................................... ............................................................................... 0.010 mm (0.0004 inch) End play Standard or New .................................................................................................................................................. 0.10 0.35 mm (0.004 - 0.014 inch) Service Limit ......................................................................................... .................................................................................... 0.45 mm (0.018 inch) Runout Standard or New ..................................................................................................................................................... 0.03 mm (0.0012 inch) maximum Service Limit .......................................................................................... ................................................................................. 0.04 mm (0.0016 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Crankshaft Inspection Crankshaft: Testing and Inspection Crankshaft Inspection Out-of-Round and Taper 1. Remove the crankshaft from the cylinder block. 2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 3. Clean the key way and threads. 4. Measure out-of round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round Standard (New): 0.005 mm (0.0002 inch) max. Service Limit: 0.010 mm (0.0004 inch) 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 inch) max. Service Limit: 0.010 mm (0.0004 inch) Straightness 6. Place the cylinder block on the surface plate. 7. Clean and install the bearings on the No.1 and No.5 journal of the cylinder block. 8. Lower the crankshaft into the block. 9. Measure runout on all main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Runout Standard (New): 0.03 mm (0.0012 inch) max. Service Limit: 0.04 mm (0.0016 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Crankshaft Inspection > Page 1563 Crankshaft: Testing and Inspection End Play Inspection Connecting Rod and Crankshaft End Play Inspection 1. Remove the oil pump. 2. Remove the baffle plates. 3. Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft. Connecting Rod End Play Standard (New): 0.15 - 0.30 mm (0.006 - 0.012 inch) Service Limit: 0.40 mm (0.016 inch) 4. If the connecting rod end play is out-of-tolerance, install a new connecting rod, and recheck. If it is still out-of-tolerance, replace the crankshaft. 5. Install a dial indicator as shown. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back toward the indicator; the dial reading should not exceed the service limit. Crankshaft End Play Standard (New): 0.10 - 0.35 mm (0.004 - 0.014 inch) Service Limit: 0.45 mm (0.018 inch) 6. If the end play is out-of-tolerance, replace the thrust washers and recheck. If it is still out-of-tolerance, replace the crankshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal Crankshaft: Service and Repair Crankshaft and Piston Removal Removal 1. Remove the engine assembly. 2. Remove the transmission. 3. Remove the oil pan. 4. Remove the oil pump. 5. Remove the cylinder head. 6. Remove the baffle plates. 7. Remove the 8 mm bolts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1566 8. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all bolts are loosened. 9. Remove the lower block and bearings. Keep all bearings in order. 10. Remove the rod caps/bearings. Keep all caps/ bearings in order. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1567 11. Lift the crankshaft out of the engine, being careful not to damage the journals. 12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps. 13. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out. 14. Use the wooden handle of a hammer (A) to drive out the pistons (B). 15. Reinstall the lower block and bearings on the engine in the proper order. 16. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly. 17. To avoid mix up on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1568 Crankshaft: Service and Repair Crankshaft Installation Installation Special Tools Required ^ Driver 07749-0010000 ^ Attachment, 24 x 26 mm 07746-0010700 ^ Oil seal driver attachment 96 07ZAD-PNAA100 1. Install the crankshaft end bushing with the special tools when replacing the crankshaft. Drive in the crankshaft end bushing until the special tools bottom against the crankshaft. 2. Check the connecting rod bearing clearance with plastigage. 3. Check the main bearing clearance with plastigage. 4. Inspect the connecting rod bolts. 5. Install the bearing halves in the cylinder block and connecting rods. 6. Apply a coat of engine oil to the main bearings and rod bearings. 7. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the block. 8. Install the thrust washers (A) in the No. 4 journal of the cylinder block. 9. Apply engine oil to the threads of the connecting rod bolts. 10. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (B) on the connecting rod and cap, then install the caps and bolts finger-tight. 11. Rotate the crankshaft clockwise, 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 bolts to 20 Nm (2.0 kgf-cm, 14 ft. lbs.). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1569 13. Tighten the connecting rod bolts an additional 90°. 14. Remove old liquid gasket from the lower block mating surfaces, bolts and bolt holes. 15. Clean and dry the lower block mating surfaces. 16. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the lower block and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 17. Put the lower block on the cylinder block. 18. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf-cm, 22 ft. lbs.). 19. Tighten the bearing cap bolts an additional 56°. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1570 20. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf-cm, 16 ft. lbs.). 21. Use the special tools to drive a new oil seal squarely into the block to the specified installed height. 22. Measure the distance between the crankshaft (A) and oil seal (B). Oil Seal Installed Height: 5.5 - 6.5 mm (0.22 - 0.26 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1571 23. Install the baffle plates. 24. Install the oil pump. 25. Install the oil pan. 26. Install the cylinder head. 27. Install the transmission. 28. Install the engine assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pully Bolt .......................................................................................................................................................... 245 Nm (25,0 kgf.m, 181 lbf.ft.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1575 Harmonic Balancer - Crankshaft Pulley: Service and Repair Removal and Installation Special Tools Required ^ Holder handle 07JAB-001020A ^ Holder attachment, 50 mm 07NAB-001040A ^ Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket Removal 1. Remove front tires/wheels. 2. Remove the splash shield. 3. Hold the pulley with holder handle (A) and holder attachment (B). 4. Remove the bolt with a 19 mm socket (C) and breaker bar. Installation 1. Clean the crankshaft pulley (A), crankshaft (B), bolt (C), and washer (D). Lubricate as shown. 2. Install the crankshaft pulley, and hold the pulley with holder handle (A) and holder attachment (B). 3. Tighten the bolt to 245 Nm (25.0 kgf-cm, 181 ft. lbs.) with a torque wrench and 19 mm socket (C). Do not use an impact wrench. 4. Install the splash shield. 5. Install front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Skirt O.D. at 11 mm (0.04 inch) from bottom of skirt No. letter or A Standard or New ................................................................................................................................ 85.980 - 85.990 mm (3.3850 - 3.3854 inch) Service Limit ................................................................... ................................................................................................ 85.930 mm (3.381 inch) Letter B Standard or New ................................................................................................................................ 85.970 - 85.980 mm (3.3846 - 3.3850 inch) Service Limit ................................................................... .............................................................................................. 85.920 mm (3.3827 inch) Clearance in cylinder Standard or New ............................................................................................................................................ 0.020 0.040 mm (0.0008 - 0.016 inch) Service Limit ..................................................................................... ........................................................................................ 0.05 mm (0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1579 Piston: Testing and Inspection Inspection 1. Remove the crankshaft and pistons. 2. Check the piston for distortion or cracks. 3. Measure the piston diameter at a point 11 mm (0.4 inch) from the bottom of the skirt. There are two standard-size pistons (No Letter or A, and B). The letter is stamped on the top of the piston. Letters are also stamped on the block as cylinder bore sizes. Piston Diameter: Standard (New): No Letter (or A): 85.980 - 85.990 mm (3.3850 3.3854 inch) B: 85.970 - 85.980 mm (3.3846 - 3.3850 inch) Service Limit: No Letter (or A): 85.930 mm (3.3831 inch) B: 85.920 mm (3.3827 inch) Oversize Piston Diameter: 0.25: 86.230 - 86.240 mm (3.3949 - 3.3953 inch) 4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1580 bore service limit, replace the block. If the block is to be rebored, Refer to step 7 after reboring. Cylinder Bore Size Standard (New): A or I: 86.010 - 86.020 mm (3.3862 - 3.3866 inch) B or II: 86.000 - 86.010 mm (3.3858 - 3.3862 inch) Service Limit: 86.070 mm (3.3886 inch) Oversize: 0.25: 86.250 - 86.260 mm (3.3957 - 3.3961 inch) Reboring limit: 0.25 mm (0.01 inch) max. Bore Taper: Limit: (Difference between first and third measurement) 0.05 mm (0.002 inch) 5. Scored or scratched cylinder bores must be honed. 6. Check the top of the block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.003 inch) max. Service Limit: 0.10 mm (0.004 inch) 7. Calculate the difference between the cylinder bore diameter and the piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder block for excessive wear. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1581 Piston-to-Cylinder Clearance Standard (New): 0.020 - 0.040 mm (0.0008 - 0.0016 inch) Service Limit: 0.05 mm (0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal Piston: Service and Repair Crankshaft and Piston Removal Removal 1. Remove the engine assembly. 2. Remove the transmission. 3. Remove the oil pan. 4. Remove the oil pump. 5. Remove the cylinder head. 6. Remove the baffle plates. 7. Remove the 8 mm bolts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1584 8. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all bolts are loosened. 9. Remove the lower block and bearings. Keep all bearings in order. 10. Remove the rod caps/bearings. Keep all caps/ bearings in order. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1585 11. Lift the crankshaft out of the engine, being careful not to damage the journals. 12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps. 13. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out. 14. Use the wooden handle of a hammer (A) to drive out the pistons (B). 15. Reinstall the lower block and bearings on the engine in the proper order. 16. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly. 17. To avoid mix up on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1586 Piston: Service and Repair Piston, Pin and Connecting Rod Replacement Disassembly 1. Remove the piston from the cylinder block. 2. Apply engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damage the ring grooves. 3. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. 4. Heat the piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin. Inspection NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1587 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 21.961 - 21.965 mm (0.8646 - 0.8648 inch) Service Limit: 21.953 mm (0.8643 inch) 2. Zero 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 +0.002 mm (-0.00020 to +0.00008 inch) Service Limit: 0.005 mm (0.0002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1588 4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.005 - 0.015 mm (0.0002 - 0.0006 inch) Service Limit: 0.02 mm (0.0008 inch) Reassembly 1. Install a piston pin snap ring (A). 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. 3. Heat the piston to about 158°F (70°C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1589 4. Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D) and the embossed mark (E) on the same side. 5. install the remaining snap ring (F). 6. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1590 Piston: Service and Repair Piston Installation Installation If the crankshaft is already installed 1. Set the crankshaft to bottom dead center (BDC) for each cylinder. 2. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. 3. Position the arrow (A) facing the cam chain side of the engine. 4. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore. 5. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place. 6. Check the connecting rod bearing clearance with plastigage. 7. Inspect the connecting rod bolts. 8. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 20 Nm (2.0 kgf-cm, 14 ft. lbs.) + 90°. If the crankshaft is not installed 1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. 2. Position the arrow (A) facing the cam chain side of the engine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Crankshaft and Piston Removal > Page 1591 3. Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore. 4. Position all pistons at top dead center. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin: O.D.: Standard .................................................................................................................................................. 21.961 - 21.965 mm (0.8646 - 0.8648 inch) Service Limit ............................................................................... ........................................................................................ 21.953 mm (0.8643 inch) Pin-To-Piston Clearance: Standard .......................................................................................................................................... -0.005 - +0.002 mm (-0.00020 - +0.00008 inch) Service Limit ............................................................ ............................................................................................................. 0.005 mm (0.0002 inch) Pin-To-Rod Clearance: Standard ...................................................................................................................................................... 0.005 - 0.015 mm (0.0002 - 0.0006 inch) Service Limit ....................................................................... .................................................................................................... 0.02 mm (0.0008 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1595 Piston Pin: Service and Repair Disassembly 1. Remove the piston from the cylinder block. 2. Apply engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damage the ring grooves. 3. Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection. 4. Heat the piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin. Inspection NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1596 1. Measure the diameter of the piston pin. Piston Pin Diameter Standard (New): 21.961 - 21.965 mm (0.8646 - 0.8648 inch) Service Limit: 21.953 mm (0.8643 inch) 2. Zero 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 +0.002 mm (-0.00020 to +0.00008 inch) Service Limit: 0.005 mm (0.0002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1597 4. Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance Standard (New): 0.005 - 0.015 mm (0.0002 - 0.0006 inch) Service Limit: 0.02 mm (0.0008 inch) Reassembly 1. Install a piston pin snap ring (A). 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. 3. Heat the piston to about 158°F (70°C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1598 4. Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D) and the embossed mark (E) on the same side. 5. install the remaining snap ring (F). 6. Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring groove width Top Standard or New .................................................................................................................................... 1.220 - 1.230 mm (0.0481 - 0.0484 inch) Service Limit ............................................................................................. .......................................................................... 1.25 mm (0.049 inch) Second Standard or New .................................................................................................................................... 1.220 - 1.230 mm (0.0481 - 0.0484 inch) Service Limit ............................................................................................. .......................................................................... 1.25 mm (0.049 inch) Oil Standard or New .................................................................................................................................... 2.005 - 2.025 mm (0.0789 - 0.0797 inch) Service Limit ............................................................................................. .......................................................................... 2.05 mm (0.081 inch) Piston ring Ring-to-groove clearance Top Standard or New .................................................................................................................................... 0.035 - 0.060 mm (0.0014 - 0.0024 inch) Service Limit ............................................................................................. .......................................................................... 0.13 mm (0.005 inch) Second (REKEN) Standard or New .................................................................................................................................... 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit ............................................................................................. .......................................................................... 0.13 mm (0.005 inch) Second (FEDERAL MOGUL) Standard or New .................................................................................................................................... 0.025 - 0.060 mm (0.0010 - 0.0024 inch) Service Limit ............................................................................................. .......................................................................... 0.13 mm (0.005 inch) Ring end gap Top Standard or New ............................................................................................................................................ 0.20 0.35 mm (0.008 - 0.014 inch) Service Limit ......................................................................................... .............................................................................. 0.60 mm (0.024 inch) Second Standard or New ............................................................................................................................................ 0.40 0.55 mm (0.016 - 0.022 inch) Service Limit ......................................................................................... .............................................................................. 0.70 mm (0.028 inch) Oil (REKEN) Standard or New ............................................................................................................................................ 0.25 0.65 mm (0.010 - 0.026 inch) Service Limit ......................................................................................... .............................................................................. 0.75 mm (0.030 inch) Oil (FEDERAL MOGUL) Standard or New ............................................................................................................................................ 0.20 0.70 mm (0.008 - 0.028 inch) Service Limit ......................................................................................... .............................................................................. 0.80 mm (0.031 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1602 Piston Ring: Service and Repair Replacement 1. Remove the piston from the cylinder block. 2. Using a ring expander (A), remove the old piston rings (B). 3. Clean all ring grooves thoroughly with a square doff broken ring or ring groove cleaner with a blade to fit the piston grooves. The top and 2nd ring grooves are 1.2 mm (0.05 inch) wide. The oil ring groove is 2.0 mm (0.08 inch) wide. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools. NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet. 4. Using a piston, push a new ring (A) into the cylinder bore 15 - 20 mm (0.6 - 0.8 inch) from the bottom. 5. Measure the piston ring end-gap (B) with a feeler gauge: ^ If the gap is too small, check to see if you have the proper rings for your engine. ^ If the gap is too large, recheck the cylinder bore diameter against the wear limits. ^ If the bore is over the service limit, the cylinder block must be rebored. Piston Ring End-Gap Top Ring Standard (New): 0.20 - 0.35 mm (0.008 - 0.014 inch) Service Limit: 0.60 mm (0.024 inch) Second Ring Standard (New): 0.40 - 0.55 mm (0.016 - 0.022 inch) Service Limit: 0.70 mm (0.028 inch) Oil Ring REKEN manufactured ring Standard (New): 0.25 - 0.65 mm (0.010 - 0.026 inch) Service Limit: 0.75 mm (0.030 inch) FEDERAL MOGUL manufactured ring Standard (New): 0.20 0.70 mm (0.008 - 0.028 inch) Service Limit:0.80 mm (0.031 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1603 6. Install the top ring and second ring as shown.The top ring (A) has a 1R mark or no mark and the second ring (B) has a 2R mark or 2ND mark. The marks must be facing upward. 7. Rotate the rings in their grooves to make sure they do not bind. 8. Position the ring end gaps as shown: 9. After installing a new set of rings, measure the ring-to-groove clearances: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1604 Top Ring Clearance Standard (New): 0.035 - 0.060 mm (0.0014 - 0.0024 inch) Service Limit: 0.13 mm (0.005 inch) Second Ring Clearance Standard (New): REKEN manufactured ring 0.030 - 0.055 mm (0.0012 - 0.0022 inch) FEDERAL MOGUL manufactured ring 0.025 - 0.060 mm (0.010 0.0024 inch) Service Limit: 0.13 mm 10.005 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ..................... 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust ................................................................ ...................................................................................................... 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1609 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket. 3. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust: 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1610 4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag. 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 6. Tighten the locknut, and recheck the clearance. Repeat the adjustment if necessary. 7. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 8. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1611 9. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 10. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 11. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 12. Check and, if necessary, adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 1615 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arms Arm-To-Shaft Clearance: Intake: Standard or New .......................................................................................................................................... 0.025 0.052 mm (0.0010 - 0.0020 inch) Service Limit ................................................................................... .......................................................................................... 0.08 mm (0.003 inch) Exhaust: Standard or New .......................................................................................................................................... 0.018 0.056 mm (0.0007 - 0.0022 inch) Service and Repair ......................................................................... ............................................................................................ 0.08 mm (0.003 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection Rocker Arm Assembly: Testing and Inspection Rocker Arms and Shaft Inspection Inspection 1. Remove the rocker arm assembly. 2. Measure the diameter of the shaft at the first rocker location. 3. Zero the gauge (A) to the shaft diameter. 4. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.025 - 0.052 mm (0.0010 - 0.0020 inch) Exhaust: 0.018 - 0.056 mm (0.0007 - 0.0022 inch) Service Limit: 0.08 mm (0.003 inch) 5. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all over tolerance rocker arms. If any VTEC rocker arm needs replacement, replace the rocker arms (primary and secondary) as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1621 6. Inspect the rocker arm pistons (A). Push each piston manually. If it does not move smoothly, replace the rocker arm set. NOTE: Apply oil to the pistons when reassembling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1622 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test VTEC Rocker Arm Test Special Tools Required ^ Air pressure regulator 07AAJ-PNAA100 ^ VTEC air adapter 07ZAJ-PNAA100 ^ VTEC air stopper 07ZAJ-PNAA200 ^ Air joint adapter 07ZAJ-PNAA300 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). 3. Verify that the intake primary rocker arm (A) moves independently of the intake secondary rocker arm (B). ^ If the intake primary rocker arm does not move, remove the primary and secondary rocker arms as an assembly and check that the pistons in the secondary and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. ^ If the intake primary rocker arm moves freely, go to step 4. 4. Repeat step 3 on the remaining intake primary rocker arms with each piston at TDC. When all the primary rocker arms pass the test, go to step 5. 5. Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4 kgf/cm2, 57 psi). 6. Inspect the valve clearance. 7. Remove the sealing bolt (A) from the relief hole, and install the VTEC air stopper (B). 8. Remove the No.2 and No.3 camshaft holder bolts, and install the VTEC air adapters (C) finger-tight. 9. Connect the air joint adapter (D), and air pressure regulator with a 0 - 100 psi gauge (E). 10. Loosen the valve on the regulator, and apply the specified air pressure. Specified air pressure: 290 kPa (3.0 kgf/cm2, 42 psi) NOTE: If the synchronizing piston does not move after applying air pressure; move the primary or secondary rocker arm up and down manually by rotating the crankshaft clockwise. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Testing and Inspection > Rocker Arms and Shaft Inspection > Page 1623 11. With the specified air pressure applied, move the intake primary rocker arm (A) for the No. 1 cylinder. The primary rocker arm and secondary rocker arm (B) should move together. If the intake secondary rocker arm does not move, remove the primary and secondary rocker arms as an assembly, and check that the pistons in the primary and secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary and secondary rocker arms as an assembly, and test. 12. Remove the special tools. 13. Tighten the camshaft holder mounting bolts to 22 Nm (2.2 kgf-cm, 16 ft. lbs.). 14. Tighten the sealing bolt to 20 Nm (2.0 kgf-cm, 14 ft. lbs.). 15. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly Rocker Arm Assembly: Service and Repair Rocker Arms and Shafts Disassembly/Reassembly Disassembly/Reassembly NOTE: ^ Identify parts as they are removed to ensure reinstallation in original location. ^ Inspect the rocker shafts and rocker arms. ^ The rocker arms must be installed in the same positions if reused. ^ When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. ^ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact points. ^ Bundle the rocker arms with rubber bands to keep them together as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1626 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Removal Removal 1. Remove the cam chain. 2. Loosen the rocker arm adjusting screws (A). 3. 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 4. Remove the cam chain guide B, camshaft holders, and camshafts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1627 5. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1628 Rocker Arm Assembly: Service and Repair Rocker Arm Assembly Installation Installation 1. Clean and dry the No. 5 rocker shaft holder mating surfaces. 2. Reassemble the rocker arm assembly. 3. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder head mating surface of the No. 5 rocker shaft holder. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 4. Insert the bolts (A) into the rocker shaft holder, then install the rocker arm assembly (B) on the cylinder head. 5. Remove the bolts from the rocker shaft holder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arms and Shafts Disassembly/Reassembly > Page 1629 6. Make sure the punch marks on the variable valve timing control (VTC) actuator and exhaust camshaft sprocket are facing up, then set the camshafts (A) in the holder. 7. Set the camshaft holders (B) and cam chain guide B (C) in place. 8. Tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 Nm (2.2 kgf-cm, 16 ft. lbs.) 6 mm bolts: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) 6mm bolts: (21), (22), (23) 9. Install the cam chain, and adjust the valve clearance. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Cylinder Head Cover Removal 1. Remove the intake manifold cover. 2. Remove the four ignition coils. 3. Remove the dipstick (A) and breather hose (B). 4. Remove the cylinder head cover. Cylinder Head Cover Installation 1. Thoroughly clean the head cover gasket and the groove. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1633 2. Install the head cover gasket (A) in the groove of the cylinder head cover (B). 3. Check that the mating surfaces are clean and dry. 4. Apply liquid gasket, P/N 08718-0009, on the chain case and the No. 5 rocker shaft holder mating areas. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 5. Set the spark plug seals (A) on the spark plug tubes. Once the cylinder head cover (B) is on the cylinder head, slide the cover slightly back and forth to seat the head cover gasket. 6. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1634 7. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 9.8 Nm (1.0 kgf-cm, 7.2 ft. lbs.). 8. Install the dipstick (A) and breather hose (B). 9. Install the four ignition coils. 10. Check that all tubes, hoses, and connectors are installed correctly. 11. Install the intake manifold cover. 12. After assembly, wait at least 30 minutes before filling the engine with oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guides I.D. Intake Standard ................................................................................................................................................ 5.515 5.530 mm (0.2171 - 0.2177 inch) Service Limit ................................................................................... .................................................................................... 5.55 mm (0.219 inch) Exhaust Standard ............................................................................................................................................... 5.515 5.530 mm (0.2171 - 0.2177 inch) Service Limit ................................................................................... .................................................................................... 5.55 mm (0.219 inch) Installed height Standard Intake .............................................................................................................................................................. 15.2 - 16.2mm (0.598 - 0.638 inch) Service Limit Exhaust .......................................................................................................................................................... 15.5 - 16.5 mm (0.610 - 0.650 inch) Valve Stem-to-guide clearance Intake Standard ...................................................................................................................................................... 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit ....................................................................... ...................................................................................................... 0.08 mm (0.003 inch) Exhaust Standard ...................................................................................................................................................... 0.055 - 0.080 mm (0 - 0022 - 0.003 inch) Service Limit ...................................................................... ....................................................................................................... 0.11 mm (0.004 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1638 Valve Guide: Testing and Inspection Inspection 1. Remove the valves. 2. Slide the valve out calf its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method). ^ If the measurement exceeds the service limit, recheck it using a new valve. ^ If the measurement is now within the service limit, reassemble using a new valve. ^ If the measurement with a new valve still exceeds the service limit, go to step 3. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.06 - 0.11 mm (0.002 - 0.004 inch) Service Limit: 0.16 mm (0.006 inch) Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.11 - 0.16 mm (0.004 - 0.006 inch) Service Limit: 0.22 mm 10.009 inch) 3. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit: 0.08 mm (0.003 inch) Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.055 - 0.080 mm (0.0022 - 0.0031 inch) Service Limit: 0.11 mm (0.004 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1639 Valve Guide: Service and Repair Replacement Special Tools Required ^ Valve guide driver, 5.5 mm 07742-0010100 ^ Valve guide reamer, 5.5 mm 07HAH-PJ7010B 1. Inspect valve stem-to-guide clearance. 2. As illustrated, use a commercially available air-impact valve guide driver (A) modified to fit the diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer. 3. Select the proper replacement guides, and chill them in the freezer section of a refrigerator for about an hour. 4. Use a hot plate or oven to evenly heat the cylinder head to 300°F (150°C). Monitor the temperature with a cooking thermometer. Do not get the head hotter than 300°F (150°C); excessive heat may loosen the valve seats. 5. Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 inch) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1640 6. Turn the head over, and drive the guide out toward the camshaft side of the head. 7. If a valve guide won't move, drill it out with a 8 mm (5/16 inch) bit, then try again. Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks. 8. Remove the new guide(s) from the freezer, one at a time, as you need them. 9. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height (A) of the guide (B). If you have all 16 guides to do, you may have to reheat the head. Valve Guide Installed Height: Intake: 15.2 - 16.2 mm (0.598 0.638 inch) Exhaust:15.5 - 16.5 mm (0.610 - 0.650 inch) 10. Coat both reamer and valve guide with cutting oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1641 11. Rotate the reamer clockwise the full length of the valve guide bore. 12. Continue to rotate the reamer clockwise while removing it from the bore. 13. Thoroughly wash the guide in detergent and water to remove any cutting residue. 14. Check the clearances with a valve. Verify that a valve slides in the intake and exhaust valve guides without exerting pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seats Width Intake Standard ............................................................................................................................................................. 1.25 - 1.55 mm (0.049 - 0.061 inch) Service Limit ............................................................................... ............................................................................................ 2.00 mm (0 - 079 inch) Exhaust Standard ............................................................................................................................................................. 1.25 - 1.55 mm (0.049 - 0.061 inch) Service Limit ............................................................................... .............................................................................................. 2.00 mm (0.079 inch) Stem installed height Intake Standard .............................................................................................................................................. ................. 40.8 - 41.0 mm (1.606 - 1.614 inch) Exhaust Service Limit ....................................................................................................................................................... 54.6 - 54.8 mm (2.150 - 2.157 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1645 Valve Seat: Service and Repair Reconditioning 1. Inspect valve stem-to-guide clearance. If the valve guides are worn, replace them before cutting the valve seats. 2. Renew the valve seats in the cylinder head using a valve seat cutter. 3. Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentric seat. 4. Bevel the upper and lower edges at the angles shown in the illustration. Check the width of the seat and adjust accordingly. 5. Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width: Standard (New): 1.25 - 1.55 mm (0.049 - 0.061 inch) Service Limit: 2.00 mm (0.079 inch) 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 location in the head, then lift it and snap it closed against the seat several times. 7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. ^ If it is too high (closer to the valve stem), you must make a second cut with the 67.5° cutter to move it down, then one more cut with the 45° cutter to restore seat width. ^ If it is too low (close to the valve edge), you must make a second cut with the 35° cutter (intake side) or the 30° cutter (exhaust side) to move it up, then make one more cut with the 45° cutter to restore seat width. NOTE: The final cut should always be made with the 45° cutter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1646 8. Insert the intake and exhaust valves in the head, and measure valve stem installed height (A). Intake Valve Stem Installed Height: Standard (New): 40.8 - 41.0 mm (1.606 - 1.614 inch) Exhaust Valve Stem Installed Height: Standard (New): 54.6 - 54.8 mm (2.150 - 2.157 inch) 9. If valve stem installed height is over the standard, replace the valve and recheck. If it is still over the standard, replace the cylinder head; the valve seat in the head is too deep. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs Free Length Intake ................................................................................................................................................... .......................................... 47.61 mm (1.874 inch) Exhaust ................................................................ .......................................................................................................................... 49.64 mm (1.954 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal Valve Spring: Service and Repair Valves, Springs and Valve Seals Removal Removal Special Tools Required Valve spring compressor attachment 07VAE-001010A Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Remove the cylinder head. 2. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. 3. Install the spring compressor. Compress the spring, and remove the valve keepers. 4. Install the valve guide seal remover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1652 5. Remove the valve seal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1653 Valve Spring: Service and Repair Valves, Springs and Valve Installation Installation Special Tools Required Valve spring compressor attachment 07VAE-001010A 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve retainer. 7. Install the valve spring compressor. Compress the spring, and install the valve keepers. Remove the valve spring compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1654 8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Stem O.D. Intake Standard or New ...................................................................................................................................... 5.475 - 5.485 mm (0 - 2156 - 0.2159 inch) Service Limit ........................................................................................... ................................................................................ 5.445 mm (0.214 inch) Exhaust Standard or New ......................................................................................................................................... 5.450 5.460 mm (0.2146 - 0.2150 inch) Service Limit ................................................................................... .......................................................................................... 5.42 mm (0.213 inch) Valve Stem-To-Guide Clearance Intake Standard or New ......................................................................................................................................... 0.030 0.055 mm (0.0012 - 0.0022 inch) Service Limit ................................................................................... .......................................................................................... 0.08 mm (0.003 inch) Exhaust Standard or New ........................................................................................................................................... 0.055 0.080 mm (0.0022 - 0.003 inch) Service Limit ..................................................................................... ........................................................................................ 0.11 mm (0.004 inch) Stem Installed Height Intake Standard or New .................................................................................................................................................. 40.8 41.0 mm (1.606 - 1.614 inch) Exhaust Standard or New .................................................................................................................................................. 54.6 54.8 mm (2.150 - 2.157 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Valve Inspection Valve: Testing and Inspection Valve Inspection Inspection 1. Remove the valves. 2. Measure the valve in these areas. Intake Valve Dimensions A Standard (New): 34.85 - 35.15 mm (1.372 - 1.384 inch) B Standard (New): 108.7 - 109.5 mm (4.280 - 4.311 inch) C Standard (New): 5.475 - 5.485 mm (0.2156 0.2159 inch) C Service Limit: 5.445 mm (0.214 inch) Exhaust Valve Dimensions A Standard (New): 29.85 - 30.15 mm (1.175 - 1.187 inch) B Standard (New): 108.3 - 109.1 mm (4.264 - 4.295 inch) C Standard (New): 5.450 - 5.460 mm (0.2146 - 0.2150 inch) C Service Limit: 5.42 mm (0.213 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Valve Inspection > Page 1660 Valve: Testing and Inspection Valve Stem-to-Guide Clearance Inspection Inspection 1. Remove the valves. 2. Slide the valve out calf its guide about 10 mm, then measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust (wobble method). ^ If the measurement exceeds the service limit, recheck it using a new valve. ^ If the measurement is now within the service limit, reassemble using a new valve. ^ If the measurement with a new valve still exceeds the service limit, go to step 3. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.06 - 0.11 mm (0.002 - 0.004 inch) Service Limit: 0.16 mm (0.006 inch) Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.11 - 0.16 mm (0.004 - 0.006 inch) Service Limit: 0.22 mm 10.009 inch) 3. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside micrometer or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance: Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 inch) Service Limit: 0.08 mm (0.003 inch) Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.055 - 0.080 mm (0.0022 - 0.0031 inch) Service Limit: 0.11 mm (0.004 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal Valve: Service and Repair Valves, Springs and Valve Seals Removal Removal Special Tools Required Valve spring compressor attachment 07VAE-001010A Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Remove the cylinder head. 2. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. 3. Install the spring compressor. Compress the spring, and remove the valve keepers. 4. Install the valve guide seal remover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1663 5. Remove the valve seal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1664 Valve: Service and Repair Valves, Springs and Valve Installation Installation Special Tools Required Valve spring compressor attachment 07VAE-001010A 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve retainer. 7. Install the valve spring compressor. Compress the spring, and install the valve keepers. Remove the valve spring compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1665 8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications HVAC Compressor: Drive Belt Tension .............................................................................................................................................. Auto Tensioner (Needs No Adjustment) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1670 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1671 Drive Belt: Testing and Inspection Drive Belt Inspection Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If it is out of the standard range, replace the drive belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1672 Drive Belt: Service and Repair Drive Belt Replacement 1. Move the auto-tensioner (A) to relieve tension from the drive belt (B), and remove the drive belt. 2. Install the new belt in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1673 Drive Belt: Tools and Equipment Honda Serpintine Belt Wrench AST tool# HON1419 -Lightweight and slim design -Equipped with 14mm and 19mm, 12 point securing attachments Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1674 -Works on most Honda applications Contact AST for pricing Assenmacher Specialty Tools 1 800 525 2943 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Auto-tensioner Inspection 1. Check whether there is a change in the position of the auto-tensioner indicator before starting the engine and after starting the engine. If there is a change in the position, replace the auto-tensioner. 2. Check for abnormal noise from the tensioner pulley. If you hear abnormal noise is heard, replace the tensioner pulley. 3. Remove the drive belt. 4. Move the auto-tensioner within its limit with the belt tension release tool in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. If the tensioner does not move smoothly or you hear abnormal noise, replace the auto-tensioner. 5. Remove the auto-tensioner. 6. Install the tensioner pulley. 7. Clamp the auto-tensioner (A) by using two 8 mm bolts (B) and a vise (C) as shown. Do not clamp the auto-tensioner itself. 8. Set the torque wrench (D) on the pulley bolt. 9. Align the indicator (E) on the tensioner base with center mark (F) on the tensioner arm by using the torque wrench, and measure the torque. If the torque value is out of specification, replace the auto-tensioner. NOTE: If the indicator exceeds the center mark, recheck the torque. Auto-tensioner Spring Torque: 26.5 - 36.3 N.m (2.7 - 3.7 kgf.m, 19.5 - 26.8 lbf.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 1678 Drive Belt Tensioner: Service and Repair Drive Belt Auto-tensioner Replacement 1. Remove the drive belt. 2. Remove the idler pulley. 3. Remove the tensioner pulley. 4. Remove the auto-tensioner. 5. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pump Relief valve, oil pressure with oil temperature at 176°F (80°C) At idle ............................................................................................................................................................. 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm ................................................................................................................................................. 300 kPa (3.1 kgf/cm2, 44 psi) minimum Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1683 Engine Oil Pressure: Testing and Inspection Oil Pressure Test If the oil pressure indicator stays on with 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 (A). 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (80°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 300 kPa (3.1 kgf/cm2, 44 psi) minimum 5. If the oil pressure is NOT within specifications, inspect these items: ^ Check the oil screen for clogging. ^ Check the oil pump. ^ Check crankshaft and connecting rod bearing clearances. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Recommendation GF-4 Standard Engine Oil: Technical Service Bulletins Engine - Oil Recommendation GF-4 Standard SOURCE: Honda Service News TITLE: Use ONLY New GF-4 Standard Engine Oil APPLIES TO: All Models SERVICE TIP: There's a new performance standard for engine oil: GF-4. It was jointly developed by automotive and oil experts, and it represents a significant performance upgrade and improvement in fuel economy. GF-4 engine oils must pass grueling tests totaling over 500 hours. On top of this, Honda Genuine engine oils are also tested to ensure specific compatibility with Honda vehicles. GF-4 engine oil is compatible with all current and earlier model year Honda cars and trucks. It also provides these added benefits: - Improved oxidation resistance (reduced thickening of the oil) - Improved deposit protection and better wear protection - Better low-temperature performance over the life of the oil - Environmental protection by extending the life of emissions systems While Honda has upgraded its engine oil to GF-4, other brands may not yet be at this new standard. Keep in mind you must use Honda Genuine engine oil for all warranty repairs. If you use some other brand of oil for non-warranty repairs, make sure that oil meets the GF-4 standard. We recommend you stop using non-GF-4 engine oils and check with your supplier that you're purchasing GF-4 oil. Engine oil produced after April 1, 2005, that meets the GF-4 standard, must post this starburst certification mark on the container. Always look for this mark; some oil container labels won't specifically refer to GF-4. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil For engine overhaul ............................................................................................................................. .............................................................. 5.3L (5.6 Qt) For oil change, including filter .............................................................................................................. ............................................................ 4.2L (4.4 Qt) For oil change, without filter ................................................................................................................. ............................................................ 4.0L (4.2 Qt) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1693 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification .................................................................................................................................... Make sure the label says "For Gasoline Engines". SAE Viscosity .............................................................................. ............................................................................................................................... 5W-20 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1694 Engine Oil: Service and Repair Engine Oil Replacement 1. Warm up the engine. 2. Remove the drain bolt (A), and drain the engine oil. 3. Reinstall the drain bolt with a new washer (B). 4. Refill with the recommended oil. Capacity 4.0 L (4.2 US qt.) at oil change. 4.2 L (4.4 US qt.) at oil change including filter. 5.3 L (5.6 US qt.) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair Engine Oil Filter Replacement Special Tool Required Oil filter wrench 07HAA-PJ70100 Engine Oil Filter (3/4-turn type) 1. Remove the oil filter with the special tool. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 3/4 turn clockwise. Tightening torque: 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Page 1698 5. If 4 numbers or marks (1 to 4 or V to VVVV) are printed around the outside of the filter, use the following procedure to tighten the filter. ^ Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom. ^ Tighten the filter by turning it clockwise 3 numbers or marks from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. Oil Filter Feed Pipe Replacement 1. Remove the oil filter. 2. Remove the oil filter feed pipe. 3. Install the two 20 x 1.5 mm nuts (A) 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 49 Nm (5.0 kgf-cm, 36 ft. lbs.), then remove the nuts from the oil filter feed pipe. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Feed Pipe Replacement 1. Remove the oil filter. 2. Remove the oil filter feed pipe. 3. Install the two 20 x 1.5 mm nuts (A) onto the new oil filter feed pipe. Hold one nut with a wrench, then tighten the other nut. 4. Tighten the oil filter feed pipe to the block to 49 Nm (5.0 kgf.m, 36 lbf.ft), then remove the nuts from the oil filter feed pipe. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts ........................................................................................................................................ ..................................... 12 Nm (1.2 kgf.m, 8.7lbf.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal Oil Pan: Service and Repair Removal Removal 1. Drain the engine oil. 2. If the engine is still in the vehicle, remove the subframe. -1 Attach the chain hoist to the engine. -2 Disconnect the suspension lower arm ball joints. -3 Remove the rear mount mounting bolts. -4 Remove the front mount mounting bolt. -5 Use a marker to make alignment marks on the reference lines that align with the centers of the rear subframe mounting bolts. Remove the front subframe. 3. Remove the bolts/nuts securing the oil pan. 4. Drive an oil pan seal cutter between the oil pan and cylinder block. 5. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan. 6. Remove the oil pan. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 1707 Oil Pan: Service and Repair Installation Installation 1. Remove old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes. 2. Clean and dry the oil pan mating surfaces. 3. Apply liquid gasket, P/N 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 if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 4. Install the oil pan. 5. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.). 6. If the engine is still in the vehicle, install the subframe. -1 Install the subframe. Align the reference lines on the subframe with the bolt head center, then tighten the bolts. -2 Tighten the front mounting bolt. -3 Tighten the rear mount mounting bolts. -4 Connect the suspension lower arm ball joints. 7. After assembly, wait at least 30 minutes before filling the engine with oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations 15. Lower Right Rear of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1711 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1712 8. Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1713 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1714 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 2. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pump Relief valve, oil pressure with oil temperature at 176°F (80°C) At idle ............................................................................................................................................................. 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm ................................................................................................................................................. 300 kPa (3.1 kgf/cm2, 44 psi) minimum Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1719 Engine Oil Pressure: Testing and Inspection Oil Pressure Test If the oil pressure indicator stays on with 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 (A). 3. Start the engine. Shut it off immediately if the gauge registers no oil pressure. Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176°F (80°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm2, 10 psi) minimum At 3,000 rpm: 300 kPa (3.1 kgf/cm2, 44 psi) minimum 5. If the oil pressure is NOT within specifications, inspect these items: ^ Check the oil screen for clogging. ^ Check the oil pump. ^ Check crankshaft and connecting rod bearing clearances. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Tighten all intake manifold mounting bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1723 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1724 Intake Manifold: Service and Repair Removal 1. Remove the intake manifold cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1725 2. Remove the evaporative emission (EVAP) canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C). 3. Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing cover/intake air duct assembly (C). 4. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1726 5. Be prepared to catch and clean up spilled coolant. Remove the water bypass hoses, then plug the water bypass hoses. 6. Relieve fuel pressure. 7. Remove the fuel line. 8. Remove the positive crankcase ventilation (PCV) hose (A), harness holder mounting bolt (B) and harness clamp mounting bolt (C). 9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. ^ Four injector connectors ^ Idle air control (IAC) valve connector ^ Throttle position (TP) sensor connector ^ Manifold absolute pressure (MAP) sensor connector ^ Evaporative emission (EVAP) canister purge valve connector 10. Remove the bolt securing the intake manifold and bracket. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1727 11. Remove all the intake manifold mounting bolts/nuts. 12. Remove the two stud bolts (A), then remove the intake manifold (B). Installation 1. Install the intake manifold (A) with a new gasket (B), then install and tighten the two stud bolts (C). 2. Tighten all intake manifold mounting bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. 3. Tighten the bolt securing the intake manifold and bracket. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1728 4. Install the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C). 5. Install the fuel line. 6. Install the water bypass hoses. 7. Install the throttle cable, then adjust the cable. 8. Install the cruise control cable, then adjust the cable. 9. Install the air cleaner housing cover (A), and connect the IAT sensor connector (B). 10. Install the breather hose (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1729 11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C). 12. Install the intake manifold cover. 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 ignition switch ON (II) (do not operate the starter) 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. 16. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Transmission End Crankshaft Seal Installation - In Car Special Tools Required ^ Driver 07749-0010000 ^ Oil seal driver attachment 96 07ZAD-PNAA100 1. Dry the crankshaft oil seal housing. 2. Use the special tools to drive a new oil seal squarely into the block to the specified installed height. 3. Measure the distance between the crankshaft (A) and oil seal (B). Oil Seal Installed Height: 5.5 - 6.5 mm (0.22 - 0.26 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Chain Case Oil Seal Installation Special Tools Required ^ Driver 07749-0010000 ^ Attachment, 52 x 55 mm 07746-0010400 1. Use the special tools to drive a new oil seal squarely into the chain case to the specified installed height. 2. Measure the distance between the chain case surface (A) and oil seal (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal Valve Guide Seal: Service and Repair Valves, Springs and Valve Seals Removal Removal Special Tools Required Valve spring compressor attachment 07VAE-001010A Identify the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Remove the cylinder head. 2. Using an appropriate-sized socket (A) and plastic mallet (B), lightly tap the valve retainer to loosen the valve keepers. 3. Install the spring compressor. Compress the spring, and remove the valve keepers. 4. Install the valve guide seal remover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1741 5. Remove the valve seal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1742 Valve Guide Seal: Service and Repair Valves, Springs and Valve Installation Installation Special Tools Required Valve spring compressor attachment 07VAE-001010A 1. Coat the valve stems with engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. 3. Install the spring seats on the cylinder head. 4. Install the new valve seals (A) using the valve guide seal installer (B). NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F). They are not interchangeable. 5. Install the valve spring. Place the end of the valve spring with closely wound coils toward the cylinder head. 6. Install the valve retainer. 7. Install the valve spring compressor. Compress the spring, and install the valve keepers. Remove the valve spring compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valves, Springs and Valve Seals Removal > Page 1743 8. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve keepers. Tap the valve stem only along its axis so you do not bend the stem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations 15. Lower Right Rear of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1748 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1749 8. Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1750 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1751 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 2. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balancer shafts, journal diameter No.1 journal, front shaft Standard or New .............................................................................................................................. 19.938 - 19.950 mm (0.07850 - 0.7854 inch) Service Limit ................................................................. .................................................................................................... 19.92 mm (0.784 inch) No.1 journal, rear shaft Standard or New ................................................................................................................................ 23.938 - 23.950 mm (0.9424 - 0.9429 inch) Service Limit ................................................................... .................................................................................................. 23.92 mm (0.942 inch) No.2 journal, front and rear shaft Standard or New ................................................................................................................................ 32.949 - 32.961 mm (1.2972 - 1.2977 inch) Service Limit ................................................................... .................................................................................................. 32.93 mm (1.296 inch) Balancer shafts, journal taper Standard or New ................................................................................................................................................... 0.005 mm (0.0002 inch) maximum Balancer shafts, end play Front Standard or New .................................................................................................................................... 0.070 - 0.135 mm (0.0028 - 0.0053 inch) Service limit .............................................................................................. ........................................................................... 0.15 mm (0.006 inch) Rear Standard or New .................................................................................................................................... 0.070 - 0.135 mm (0.0028 - 0.0053 inch) Service Limit ............................................................................................. .......................................................................... 0.15 mm (0.006 inch) Balancer shafts, shaft-to-bearing clearance No.1 journal, front shaft Standard or New .................................................................................................................................... 0.050 - 0.082 mm (0.0020 - 0.0032 inch) Service Limit ............................................................................................. .......................................................................... 0.10 mm (0.004 inch) No.1 journal, rear shaft Standard or New .................................................................................................................................... 0.050 - 0.082 mm (0.0020 - 0.0032 inch) Service Limit ............................................................................................. .......................................................................... 0.10 mm (0.004 inch) No.2 journal, front and rear shaft Standard or New .................................................................................................................................... 0.060 - 0.120 mm (0.0024 - 0.0047 inch) Service Limit ............................................................................................. .......................................................................... 0.15 mm (0.006 inch) Balancer shaft bearings, I.D. No.1 journal, front shaft Standard or New ................................................................................................................................ 20.000 - 20.020 mm (0.7874 - 0.7882 inch) Service Limit ................................................................... .................................................................................................. 20.03 mm (0.789 inch) No.1 journal, rear shaft Standard or New ................................................................................................................................ 24.000 - 24.020 mm (0.9449 - 0.9457 inch) Service Limit ................................................................... .................................................................................................. 24.03 mm (0.948 inch) No.2 journal, front and rear shaft Standard or New ................................................................................................................................ 33.021 - 33.069 mm (1.3000 - 1.3019 inch) Service Limit ................................................................... .................................................................................................. 33.09 mm (1.303 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1756 Balance Shaft: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Oil Pump, Engine; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications VTC actuator bolt .............................................................................................................................................................. 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket bolt ............................................................................................................................................. 72 Nm (7.3 kgf-cm, 53 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1760 Camshaft Gear/Sprocket: Service and Repair Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pully Bolt .......................................................................................................................................................... 245 Nm (25,0 kgf.m, 181 lbf.ft.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal Timing Chain: Service and Repair Cam Chain Removal Removal NOTE: Keep the cam chain away from magnetic fields. 1. Turn the crankshaft pulley so its top dead center (TDC) mark (A) lines up with the pointer (B). 2. Remove the front tires/wheels. 3. Remove the splash shield. 4. Remove the drive belt. 5. Remove the cylinder head cover. 6. Remove the crankshaft pulley. 7. Disconnect the crankshaft position (CKP) sensor connector (A) and variable valve timing control (VTC) oil control solenoid valve connector (B). 8. Remove the VTC oil control solenoid valve. 9. Support the engine with a jack and wood block under the oil pan. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1768 10. Remove the ground cable (A), and remove the upper bracket (B). 11. Remove the side engine mount bracket. 12. Remove the chain case. 13. Loosely install the crankshaft pulley. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1769 14. Turn the crankshaft counterclockwise to compress the auto-tensioner. 15. Align the holes on the lock (A) and the auto tensioner (B), then insert a 1.5 mm (0.06 inch) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin. 16. Remove the auto-tensioner. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1770 17. Remove the cam chain guide B. 18. Remove the cam chain guide A (A) and tensioner arm (B). 19. Remove the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1771 Timing Chain: Service and Repair Cam Chain Installation Installation NOTE: Keep the cam chain away from magnetic fields. 1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the cylinder block. 2. Set the camshafts to TDC. The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket. 3. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the punch mark (B) on the crankshaft sprocket. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1772 4. Install the cam chain on the VTC actuator and exhaust camshaft sprocket with the punch marks (A) aligned with the two colored pieces (B). 5. Install the cam chain guide A (A) and tensioner arm (B). 6. Install the auto-tensioner. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1773 7. Install the cam chain guide B. 8. Remove the pin from the auto-tensioner. 9. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 10. Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes. 11. Clean and dry the chain case mating surfaces. 12. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 13. Apply liquid gasket to the cylinder block upper surface contact areas (A) on the chain case. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1774 14. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 15. Install the new O-ring (A) on the chain case. Set the edge of the chain case (B) to the edge of the oil pan (C), then install the chain case on the cylinder block (D). NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1775 16. Install the side engine mount bracket. 17. Install the upper bracket (A), then tighten the bolt/ nuts in the numbered sequence shown. 18. Install the ground cable (B). 19. Install the variable valve timing control (VTC) oil control solenoid valve. 20. Connect the crankshaft position (CKP) sensor connector (A) and VTC oil control solenoid valve connector (B). 21. Install the crankshaft pulley. 22. Install the cylinder head cover. 23. Install the drive belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Cam Chain Removal > Page 1776 24. Install the splash shield. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1780 Timing Chain Tensioner: Service and Repair Removal 1. Remove the chain case cover. 2. Turn the crankshaft counterclockwise to compress the auto-tensioner. 3. Align the holes on the lock (A) and the auto tensioner (B), then insert a 1.5 mm (0.06 inch) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1781 4. Remove the auto-tensioner. Installation 1. Install the auto-tensioner. 2. Remove the pin from the auto-tensioner. 3. Remove old liquid gasket from the chain case cover mating surfaces, bolts, and bolt holes. 4. Clean and dry the chain case cover mating surfaces. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 1782 5. Apply liquid gasket, P/N 08718-0009, evenly to the chain case mating surface of the chain case cover and to the inner threads of the holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 6. Install the chain case cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Caution: Incorrect removal or installation of the timing chain can result in damage to internal engine components. For complete Timing Chain Removal and Installation information, please refer to Timing Chain; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Specified Torque Chain case Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1795 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1796 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1797 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1798 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1799 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 Variable Valve Timing Actuator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 82. VTC Oil Control Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1829 Variable Valve Timing Actuator: Description and Operation VTEC/VTC - The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load. - The VTEC mechanism changes the valve lift and timing by using more than one cam profile. - The VTC changes the phase of the intake camshaft via oil pressure. It changes the intake valve timing continuously. VTC system - The VTC system makes continuous intake valve timing changes based on operating conditions. - Intake valve timing is optimized to allow the engine to produce maximum power. - Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry of the air/fuel mixture into the intake port and improve the 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 retarded position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1830 VTEC system - The VTEC system changes the cam profile to correspond to engine speed. It maximizes torque at low engine speed and output at high engine speed. - The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds. System Diagram Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator Variable Valve Timing Actuator: Testing and Inspection VTC Actuator VTC Actuator Inspection 1. Remove the cylinder head cover. 2. Remove the auto-tensioner. 3. Loosen the rocker arm adjusting screws. 4. Remove the camshaft holder. 5. Remove the intake camshaft. 6. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator. 7. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape. 8. Punch a hole through the tape over one of the advance holes. 9. Apply air to the advance hole to release the lock Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1833 10. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1834 Variable Valve Timing Actuator: Testing and Inspection VTC Actuator Removal/Test/Installation VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 1835 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement Variable Valve Timing Actuator: Service and Repair VTC Actuator, Exhaust Camshaft Sprocket Replacement Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1838 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 1839 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Pressure Switch > Component Information > Locations Variable Valve Timing Pressure Switch: Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 1843 13. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 1844 83. VTEC Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1848 84. VTEC Oil Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1849 Variable Valve Timing Solenoid: Testing and Inspection VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1850 Variable Valve Timing Solenoid: Service and Repair VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure....................................................................................................................................... ..........320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 54 psi). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1855 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1856 Fuel Pressure: Testing and Inspection Fuel Pressure Test See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment set 07AAJ-S6MA150 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, go to step 5. - If the pump does not run, do the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 52 psi). - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Engine idle Idle speed without load M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam) M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1860 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the idle air control (IAC) valve connected. - Before checking the idle speed, check these items: The malfunction indicator lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - Pull the parking brake lever up. Start the engine, and make sure the headlights are off. 1. Disconnect the evaporative emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer (A) to the test tachometer connector (B), or connect the HDS or a scan tool to the data link connector (DLC) (C) located under the driver's side of the dashboard. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner off. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm 5. Let the engine idle for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures 6. Reconnect the EVAP canister purge valve 2P connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 1865 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Disconnect the PCV hose (A). 2. Open the air cleaner housing cover (B). 3. Remove the air cleaner (C) from the air cleaner housing (D). 4. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1870 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1881 Ignition System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1882 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1883 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. - Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling - Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of indium tip plugs (A); replace the spark plug if the gap is out of specification. 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs as listed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1884 4. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head, finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Engine Assembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1888 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the intake manifold cover. 4. Disconnect all four injector connectors. 5. Start the engine, and let it run until it stalls. 6. Remove the four ignition coils. 7. Remove the four spark plugs. 8. Attach the compression gauge to the spark plug hole. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check these items, then remeasure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ..................... 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust ................................................................ ...................................................................................................... 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1892 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket. 3. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust: 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1893 4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag. 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 6. Tighten the locknut, and recheck the clearance. Repeat the adjustment if necessary. 7. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 8. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1894 9. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 10. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 11. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 12. Check and, if necessary, adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: Technical Service Bulletins Drive Belt Noise? Could Be A Bad Water Pump Bearing SOURCE: Honda Service News August 2004 TITLE: Drivebelt Noise? Could Be a Bad Water Pump Bearing APPLIES TO: 2002-04 CR-Vs and 2002-04 Civic Sis with over 10,000 miles. SERVICE TIP: Do you hear a growling that sounds like drive belt noise? The problem could be a bad bearing in the water pump. To make sure the bearing is the culprit, hook up a STEELMAN (R) ChassisEAR (R) diagnostic tool (T/N JSP-SM06600) to the water pump. If you hear the noise coming from the pump, then replace the pump. STEELMAN (R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 1899 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 1900 Water Pump: Testing and Inspection Inspection 1. Remove the drive belt. 2. Turn the water pump pulley counterclockwise. Check that it turns freely. 3. Check for signs of seal leakage. A small amount of "weeping" from the bleed holes (A) is normal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Passage Installation Water Pump: Service and Repair Water Passage Installation Water Passage Installation 1. Clean and dry the water passage mating surfaces. 2. Apply liquid gasket P/N 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 3. Install the water passage (A) with a new O-ring (B). 4. After assembly, wait at least 30 minutes before filling the engine with oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 1903 Water Pump: Service and Repair Water Pump Replacement Replacement 1. Remove the drive belt. 2. Drain the engine coolant. 3. Remove the crankshaft pulley. 4. Remove the six bolts securing the water pump, then remove the water pump (A). 5. Inspect and clean the O-ring groove and mating surface with the water passage. 6. Install the water pump with new O-rings in the reverse order of removal. 7. Clean up any spilled engine coolant. 8. Install the crankshaft pulley. 9. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 1904 Water Pump: Service and Repair Water Passage Replacement Water Passage Replacement 1. Drain the engine coolant. 2. Remove the alternator. 3. Remove the A/C compressor without disconnecting the A/C hoses. 4. Remove the intake manifold. 5. Remove a bolt (A) securing the connecting pipe. 6. Remove the connecting pipe (B), water bypass hose (C), and Positive Crankcase Ventilation (PCV) hose (D). 7. Remove the water passage (A). 8. Remove the thermostat housing (B). 9. Remove the water pump. 10. Clean and dry the water passage mating surfaces. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 1905 11. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 12. Install the water pump. 13. Install the thermostat housing (A) with a new O-ring (B). 14. Install the water passage (C) with a new O-ring (D). 15. Install the connecting pipe (A) with a new O-ring (B). 16. Install the water bypass hose (C), and PCV hose (D), then tighten a bolt (E) securing the connecting pipe. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 1906 17. Tighten bolt securing the connecting pipe. 18. Install the intake manifold. 19. Install the A/C compressor. 20. Install the alternator. 21. After assembly, wait at least 30 minutes before filling the engine with coolant or oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Refill Capacity ............................................................................................................ ..................................................... 5.0 L (5.3 US qt.) Reserve Tank Capacity ....................................................................................................................... ................................................. 0.53 L (0.56 US qt.) Engine Overhaul Capacity ................................ ......................................................................................................................................... 5.3 L (5.6 US qt.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1912 Coolant: Fluid Type Specifications Only use Honda All Season Antifreeze/Coolant Type 2 (P/N 0L999-9001) at 50 percent concentration with water. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1913 Coolant: Testing and Inspection Check 1. Look at the coolant level in the reserve tank. Make sure it is between the MAX mark (A) and MIN mark (B). 2. If the coolant level in the reserve tank is at or below the MIN mark, add coolant to bring it up to the MAX mark, and inspect the cooling system for leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1914 Coolant: Service and Repair Replacement 1. Start the engine. Set the heater temperature control dial to maximum heat, then turn off the ignition switch. Make sure the engine and radiator are cool to the touch. 2. Remove the radiator cap. 3. Remove the splash shield. 4. Loosen the drain plug (A), and drain the coolant. 5. Remove the reserve tank drain cap (A), and drain the coolant. 6. After the coolant has drained, tighten the radiator drain plug securely, and install the reserve tank drain cap securely. 7. Fill the reserve tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2 (P/N OL999-9001). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1915 8. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2 (P/N OL999-9001). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. - Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. Engine Coolant Refill Capacity [including the reserve tank capacity of 0.53 L (0.56 US qt.)]: 5.0 L (5.3 US qt.) 9. Install the radiator cap loosely. 10. Start the engine, and let it run until it warms up (the radiator fan comes on at least twice). 11. Turn off the engine. Check the level in the radiator, and add Honda All Season Antifreeze/Coolant Type 2 if needed. 12. Put the radiator cap on tightly, then run the engine again and check for leaks. 13. Install the splash shield. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair Coolant Outlet: Service and Repair Water Outlet Installation Install the water outlet (A) with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations 21. Left Front of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids Radiator Cooling Fan Motor: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1925 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1926 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1927 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1928 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1929 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1930 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1931 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1932 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1933 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1934 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1935 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1936 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1937 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1938 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1939 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1940 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1941 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1942 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1943 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1944 56. Radiator Fan Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1945 Radiator Cooling Fan Motor: Testing and Inspection Fan Motor Test 1. Disconnect the 2P connectors from the radiator fan motor and condenser fan motor. 2. Test the motor by connecting battery power to the B terminal and ground to the A terminal. 3. If the motor fails to run or does not run smoothly, replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1946 Radiator Cooling Fan Motor: Service and Repair Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the front bumper. 3. Remove the bulkhead. 4. Remove the upper radiator hose and lower radiator hose. 5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out. 6. Remove the fan shroud assemblies and other parts from the radiator. 7. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely. 8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts. 9. Fill the radiator with engine coolant and bleed the air. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1950 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1951 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1952 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Radiator Fan Switch Switching Temperature Turns ON ............................................................................................................................................. .................................. 196 - 203°F (91 - 95°C) Turns OFF ............................................................................................................................ Subtract 5 - 15°F (3 - 8°C) from actual ON temperature Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1956 3. Under Side of Radiator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1957 57. Radiator Fan Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1958 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch. 1. Remove the radiator fan switch from the radiator. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water, and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between terminal No. 1 and terminal No. 2 according to the table. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1959 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1964 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1965 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Radiator Fan Switch Switching Temperature Turns ON ............................................................................................................................................. .................................. 196 - 203°F (91 - 95°C) Turns OFF ............................................................................................................................ Subtract 5 - 15°F (3 - 8°C) from actual ON temperature Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1969 3. Under Side of Radiator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1970 57. Radiator Fan Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1971 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch. 1. Remove the radiator fan switch from the radiator. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water, and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between terminal No. 1 and terminal No. 2 according to the table. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 1972 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection Coolant Temperature Gauge Circuit Troubleshooting Before testing, check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the malfunction indicator lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshoot the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnostic function. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM. Check for an open in the WHT/GRN wire (gauge connector terminal B13). If no open is found, go to step 5. NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnostic function. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM and recheck. Did the symptom/indication go away? YES - Replace the ECM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air > Page 1981 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 1982 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 1983 Heater Control Valve Cable: Adjustments Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C) 2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (B) from the air mix control linkage (C). 3. Set the temperature control dial on Max Cool with the ignition switch ON (II). 4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown, then snap the heater valve cable housing into the cable clamp (A). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and the precautions and procedures before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the bolt and the heater valve, then remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 8. Remove the dashboard. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1987 9. Disconnect the connectors (A) from the blower motor, the recirculation control motor, the mode control motor, and the power transistor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screws and the bracket (D). 10. Disconnect the connectors (A) from the evaporator temperature sensor and the air mix control motor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screw and the cover (D). Disconnect the heater valve cable (E). 11. Remove the mounting bolts, the mounting nuts, and the heater unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1988 12. Remove the self-tapping screws and the expansion valve cover (A). Carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the grommet (C), then remove the self-tapping screws and the flange cover (D). Remove the self-tapping screws and the pipe cover (E), then carefully pull out the heater core (F) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. - Refill the cooling system with engine coolant. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Refer to evaporator core replacement. - Do the engine control module (ECM) idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Diagrams > Page 1992 Radiator: Testing and Inspection Test 1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck. 2. Attach the pressure tester (A) (commercially available) to the radiator. 3. Apply a pressure of 93 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi). 4. Inspect for engine coolant leaks and a drop in pressure. 5. Remove the tester, and reinstall the radiator cap. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Diagrams > Page 1993 Radiator: Service and Repair Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the front bumper. 3. Remove the bulkhead. 4. Remove the upper radiator hose and lower radiator hose. 5. Disconnect the fan motor connectors and radiator fan switch connector, then pull the radiator up and out. 6. Remove the fan shroud assemblies and other parts from the radiator. 7. Install the radiator in the reverse order of removal. Make sure the upper and lower cushions are set securely. 8. Install the bulkhead in the reverse order of removal. Apply body paint to the bulkhead mounting bolts. 9. Fill the radiator with engine coolant and bleed the air. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Radiator Cap Opening Pressure ..................................................................................................................................... 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 1997 Radiator Cap: Testing and Inspection Test 1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on the pressure tester (B) (commercially available). 2. Apply a pressure of 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 18 psi). 3. Check for a drop in pressure. 4. If the pressure drops, replace the cap. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2002 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2003 Radiator Cooling Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2004 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2010 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2011 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Radiator Fan Switch Switching Temperature Turns ON ............................................................................................................................................. .................................. 196 - 203°F (91 - 95°C) Turns OFF ............................................................................................................................ Subtract 5 - 15°F (3 - 8°C) from actual ON temperature Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2015 3. Under Side of Radiator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2016 57. Radiator Fan Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2017 Radiator Cooling Fan Temperature Sensor / Switch: Testing and Inspection Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch. 1. Remove the radiator fan switch from the radiator. 2. Suspend the radiator fan switch (A) in a container of water as shown. 3. Heat the water, and check the temperature with a thermometer. Do not let the thermometer (B) touch the bottom of the hot container. 4. Measure the continuity between terminal No. 1 and terminal No. 2 according to the table. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2018 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then remove the radiator fan switch (A). 2. Install the radiator fan switch with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection Coolant Temperature Gauge Circuit Troubleshooting Before testing, check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the malfunction indicator lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshoot the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnostic function. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM. Check for an open in the WHT/GRN wire (gauge connector terminal B13). If no open is found, go to step 5. NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnostic function. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM and recheck. Did the symptom/indication go away? YES - Replace the ECM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications Thermostat: Mechanical Specifications Thermostat Valve lift at fully open ......................................................................................................................................................... 8.0 mm (0.31 inch) minimum Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 2026 Thermostat: Pressure, Vacuum and Temperature Specifications Thermostat Opening temperature Begins to open ..................................................................................................................................... .................................. 169 - 176°F (76 - 80°C) Fully open .................................................................. ............................................................................................................................. 194°F (90°C) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2027 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2028 Thermostat: Testing and Inspection Test Replace the thermostat if it is open at room temperature. To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of the hot container. 2. Heat the water, and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open. 3. Measure the lift height of the thermostat when it is fully open. STANDARD THERMOSTAT Lift height: above 8.0 mm (0.31 inch) Starts opening: 169 - 176°F (76 - 80°C) Fully open: 194°F (90°C) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2029 Thermostat: Service and Repair Replacement 1. Drain the engine coolant. 2. Remove the splash shield. 3. Remove the lower hose, then remove the thermostat. 4. Install the thermostat with a new O-ring, then install the lower hose. 5. Install the splash shield. 6. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: Technical Service Bulletins Drive Belt Noise? Could Be A Bad Water Pump Bearing SOURCE: Honda Service News August 2004 TITLE: Drivebelt Noise? Could Be a Bad Water Pump Bearing APPLIES TO: 2002-04 CR-Vs and 2002-04 Civic Sis with over 10,000 miles. SERVICE TIP: Do you hear a growling that sounds like drive belt noise? The problem could be a bad bearing in the water pump. To make sure the bearing is the culprit, hook up a STEELMAN (R) ChassisEAR (R) diagnostic tool (T/N JSP-SM06600) to the water pump. If you hear the noise coming from the pump, then replace the pump. STEELMAN (R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 2034 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 2035 Water Pump: Testing and Inspection Inspection 1. Remove the drive belt. 2. Turn the water pump pulley counterclockwise. Check that it turns freely. 3. Check for signs of seal leakage. A small amount of "weeping" from the bleed holes (A) is normal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Passage Installation Water Pump: Service and Repair Water Passage Installation Water Passage Installation 1. Clean and dry the water passage mating surfaces. 2. Apply liquid gasket P/N 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes. NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue. 3. Install the water passage (A) with a new O-ring (B). 4. After assembly, wait at least 30 minutes before filling the engine with oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 2038 Water Pump: Service and Repair Water Pump Replacement Replacement 1. Remove the drive belt. 2. Drain the engine coolant. 3. Remove the crankshaft pulley. 4. Remove the six bolts securing the water pump, then remove the water pump (A). 5. Inspect and clean the O-ring groove and mating surface with the water passage. 6. Install the water pump with new O-rings in the reverse order of removal. 7. Clean up any spilled engine coolant. 8. Install the crankshaft pulley. 9. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 2039 Water Pump: Service and Repair Water Passage Replacement Water Passage Replacement 1. Drain the engine coolant. 2. Remove the alternator. 3. Remove the A/C compressor without disconnecting the A/C hoses. 4. Remove the intake manifold. 5. Remove a bolt (A) securing the connecting pipe. 6. Remove the connecting pipe (B), water bypass hose (C), and Positive Crankcase Ventilation (PCV) hose (D). 7. Remove the water passage (A). 8. Remove the thermostat housing (B). 9. Remove the water pump. 10. Clean and dry the water passage mating surfaces. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 2040 11. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 12. Install the water pump. 13. Install the thermostat housing (A) with a new O-ring (B). 14. Install the water passage (C) with a new O-ring (D). 15. Install the connecting pipe (A) with a new O-ring (B). 16. Install the water bypass hose (C), and PCV hose (D), then tighten a bolt (E) securing the connecting pipe. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Passage Installation > Page 2041 17. Tighten bolt securing the connecting pipe. 18. Install the intake manifold. 19. Install the A/C compressor. 20. Install the alternator. 21. After assembly, wait at least 30 minutes before filling the engine with coolant or oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Noise Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2047 Catalytic Converter: Description and Operation Catalytic Converter System Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO(2)), nitrogen (N(2)), and water vapor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts ............................................................................................................................................................ 44 Nm (4.5 kgf.m, 33 lbf.ft.) Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2051 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2052 Exhaust Manifold: Service and Repair Removal and Installation 1. Remove the VTEC solenoid valve. 2. Remove the driveshaft heat shield. 3. Remove the cover and exhaust manifold bracket, then remove the exhaust manifold. 4. Install the exhaust manifold and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. 5. Install the other parts in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Diagrams > Page 2056 Exhaust Pipe: Service and Repair Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2067 DTC P0A94 thru P0157 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2068 DTC P0158 thru P0400 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2069 DTC P0401 thru P0562 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2070 DTC P0563 thru P0748 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2071 DTC P0750 thru P0977 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2072 DTC P0979 thru P1193 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2073 DTC P1253 thru P1459 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2074 DTC P1486 thru P1585 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2075 DTC P1586 thru P1678 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2076 DTC P1679 thru P1860 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2077 DTC P1861 thru P2238 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2078 DTC P2240 thru U0073 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2079 DTC U0100 thru U1288 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2082 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2083 54. Behind Glove Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views 194. ECM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2086 ECM Inputs And Outputs At Connector A (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2087 ECM Inputs And Outputs At Connector A (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2088 ECM Inputs And Outputs At Connectors B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2089 ECM Inputs And Outputs At Connectors E (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2090 ECM Inputs And Outputs At Connectors E (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2093 ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2094 ECM Inputs And Outputs At Connector B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2095 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2096 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2097 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation Engine Control Module: Service and Repair Removal/Installation How to Remove the ECM for Testing 1. Remove the passenger's dashboard lower cover, the passenger's kick panel, and the glove box. 2. Disconnect the connectors (A) and remove the ECM mounting bolts (B). 3. Remove the ECM (C). 4. Install the ECM in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2100 Engine Control Module: Service and Repair Updating the ECM/PCM ECM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM in a troubleshooting procedure. Update the ECM only if the ECM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM can be damaged. How to Update the ECM NOTE: - To ensure the latest program is installed, do an ECM update whenever the ECM is substituted or replaced. - Before you update the ECM, make sure the vehicle's battery is fully charged. - To prevent ECM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM update procedure as described on the HIM label and in the ECM update system. If the software in the ECM is the latest version, replace the ECM. How to Substitute the ECM 1. Remove the ECM from the vehicle. 2. Install a known-good ECM in the vehicle. 3. Rewrite the immobilizer code with the ECM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM and rewrite the immobilizer code with the ECM replacement procedure in the HDS again. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2101 Engine Control Module: Service and Repair Idle Learn Procedure ECM Idle Learn Procedure The idle learn procedure must be done so the ECM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions; - Disconnect the battery. - Replace the ECM or disconnect its connector. - Reset the ECM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.,) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2105 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2106 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2107 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2108 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2109 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2113 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2114 134. A/F Sensor Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2115 Oxygen Sensor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2116 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2121 Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2122 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2123 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2124 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2125 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2129 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2130 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2131 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2132 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2133 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO 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 injection discharge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2146 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2147 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2148 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2149 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2152 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2153 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2154 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2158 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2159 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2163 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2164 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2165 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2168 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2169 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2178 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2179 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2180 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2181 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2187 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2188 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2189 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2190 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2191 Electric Load Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2192 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2193 100. ELD Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2194 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that's proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2199 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2200 38. Under Left Rear Of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2201 101. FTP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2202 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2206 9. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2207 44. IAT Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2211 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2212 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2213 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2214 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2218 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2219 106. MAP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2220 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2225 36. Rear Underside of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2226 Oxygen Sensor: Diagrams 114. A/F Sensor 128. Secondary HO2S Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) Sensor The A/F Sensor operates over a wide air/fuel range. The A/F Sensor is installed upstream of the TWC, and sends signals to the ECM which varies the duration of fuel injection accordingly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor > Page 2229 Oxygen Sensor: Description and Operation Secondary Oxygen Sensor Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the three way catalytic converter (TWC) and sends signals to the ECM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement Oxygen Sensor: Service and Repair A/F Sensor Replacement A/F Sensor Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the A/F sensor 4P connector (A), then remove the A/F sensor (B). 2. Install the A/F sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement > Page 2232 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2239 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2240 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2241 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2250 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2251 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2257 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2258 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations Variable Valve Timing Pressure Switch: Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2262 13. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2263 83. VTEC Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2268 Vehicle Speed Sensor: Locations 12. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2269 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2270 113. VSS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2271 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2272 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required Test harness 07LAJ-PT3020A Before testing, inspect the No. 4 (10 A) and No. 10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an Ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Connect the test harness to the VSS. 7. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 8. NO - Repair open in the BLK/YEL or BLK/ORN wire between the VSS and the under-dash fuse/relay box, repair ground or open in BLK wire between VSS and G101. 8. Disconnect the WHT test harness clip (B). 9. Disconnect the test harness from the VSS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2273 10. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 11. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, the gauge assembly or the ECM. 11. Turn the ignition switch OFF. 12. Connect the other test harness connector (A) to the VSS (B). 13. Raise the front of the vehicle, and make sure it is securely supported. 14. Put the vehicle in neutral with the ignition switch ON (II). 15. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Go to step 16. NO - Replace the VSS. 16. Disconnect the 22P connector "B" from the gauge assembly. 17. Connect the positive probe of a voltmeter to the BLU/WHT wire and the negative probe to ground. 18. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Replace the speedometer assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2274 NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2275 Vehicle Speed Sensor: Service and Repair VSS Replacement 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 removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2280 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2281 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2282 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2287 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2288 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2289 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2290 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2293 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2294 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2295 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2299 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2300 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2301 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2304 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2305 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2311 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2312 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2313 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2314 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2315 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2316 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2317 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2318 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2319 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 2320 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2324 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2325 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2326 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2327 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure....................................................................................................................................... ..........320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 54 psi). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2332 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2333 Fuel Pressure: Testing and Inspection Fuel Pressure Test See: Fuel Delivery and Air Induction/Service Precautions Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment set 07AAJ-S6MA150 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, go to step 5. - If the pump does not run, do the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 52 psi). - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Engine idle Idle speed without load M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam) M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2337 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the idle air control (IAC) valve connected. - Before checking the idle speed, check these items: The malfunction indicator lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - Pull the parking brake lever up. Start the engine, and make sure the headlights are off. 1. Disconnect the evaporative emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer (A) to the test tachometer connector (B), or connect the HDS or a scan tool to the data link connector (DLC) (C) located under the driver's side of the dashboard. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner off. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm 5. Let the engine idle for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures 6. Reconnect the EVAP canister purge valve 2P connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2342 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Disconnect the PCV hose (A). 2. Open the air cleaner housing cover (B). 3. Remove the air cleaner (C) from the air cleaner housing (D). 4. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Fuel Delivery and Air Induction/Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2347 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2358 Ignition System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2359 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2360 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. - Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling - Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of indium tip plugs (A); replace the spark plug if the gap is out of specification. 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs as listed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2361 4. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head, finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Engine Assembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2365 Compression Check: Testing and Inspection Engine Compression Inspection 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 3. Remove the intake manifold cover. 4. Disconnect all four injector connectors. 5. Start the engine, and let it run until it stalls. 6. Remove the four ignition coils. 7. Remove the four spark plugs. 8. Attach the compression gauge to the spark plug hole. 9. Open the throttle fully, then crank the engine with the starter motor and measure the compression. Compression Pressure Above 930 kPa (9.5 kgf/cm2, 135 psi) 10. Measure the compression on the remaining cylinders. Maximum variation Within 200 kPa (2.0 kgf/cm2, 28 psi) 11. If the compression is not within specifications, check these items, then remeasure the compression. ^ Damaged or worn valves and seats ^ Damaged cylinder head gasket ^ Damaged or worn piston rings ^ Damaged or worn piston and cylinder bore Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ..................... 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust ................................................................ ...................................................................................................... 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2369 Valve Clearance: Adjustments Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100°F (38°C). 1. Remove the cylinder head cover. 2. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the variable valve timing control (VTC) actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust camshaft sprocket. 3. Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.21 - 0.25 mm (0.008 - 0.010 inch) Exhaust: 0.28 - 0.32 mm (0.011 - 0.013 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2370 4. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem, and slide it back and forth; you should feel a slight amount of drag. 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 6. Tighten the locknut, and recheck the clearance. Repeat the adjustment if necessary. 7. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 8. Check and, if necessary, adjust the valve clearance on No. 3 cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2371 9. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 10. Check and, if necessary, adjust the valve clearance on No. 4 cylinder. 11. Rotate the crankshaft 180° clockwise (camshaft pulley turns 90°). 12. Check and, if necessary, adjust the valve clearance on No.2 cylinder. 13. Install the cylinder head cover. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Testing and Inspection A/C Signal: Testing and Inspection A/C Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Momentarily connect ECM connector terminals A24 and E18 with a jumper wire several times. Is there a clicking noise from the A/C compressor clutch? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the blower switch ON. 5. Turn the A/C switch ON. Does the A/C operate? YES - The air conditioning signal is OK. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 6. Momentarily connect under-hood fuse/relay box 14P connector terminal No.10 to body ground with a jumper wire several times. Is there a clicking noise from the A/C compressor clutch? YES - Repair open in the wire between the ECM (E18) and the A/C clutch relay. NO - Check the A/C system for other symptoms. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2383 9. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2384 44. IAT Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 2388 Vacuum Hose Routing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 2389 Auxiliary Air Valve (Idle Speed): Testing and Inspection Intake Air Bypass Control Thermal Valve Test Special Tools Required Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX 1. Start the engine. Then let it idle. NOTE: The engine coolant temperature must be below 149 °F (65 °C). 2. Remove the vacuum hose (A) from the intake air duct, and connect a vacuum pump/gauge to the hose. 3. Raise and lower the engine speed, and make sure the vacuum gauge reading changes as the engine speed changes. 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 thermal valve. 4. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 5. Raise and lower the engine speed, and make sure the vacuum gauge reading does not change as the rpm changes. If the vacuum reading changes, check for these problems: Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines. - A cracked or damaged intake air bypass control thermal valve. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO 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 injection discharge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2396 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2397 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2398 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2399 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2402 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2403 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2404 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2408 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2409 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2413 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2414 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2415 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2418 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2419 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2423 71. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2424 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2425 182. DLC Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2426 Data Link Connector: Testing and Inspection DLC Circuit Troubleshooting If the ECM does not communicate with the HDS or a scan tool, or I/M test equipment, do this troubleshooting procedure. 1. Measure voltage between DLC terminal No.16 and body ground. Is there battery voltage? YES - Go to step 2. NO - Repair open in the wire between DLC terminal No.16 and the No.9 BACK UP (7.5A) fuse in the under-hood fuse/relay box. 2. Measure voltage between DLC terminals No.4 and No.16. Is there battery voltage? YES - Go to step 3. NO - Repair open in the wire between DLC terminal No.4 and body ground. 3. Measure voltage between DLC terminals No.5 and No.16. Is there battery voltage? YES - Go to step 4. NO - Repair open in the wire between DLC terminal No.5 and the ECM (E3) or ECM (A23, A24) and body ground. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2427 4. Turn the ignition switch ON (II). 5. Measure voltage between DLC terminals No.5 and No.7. Is there 8.5 V or more? YES - Go to step 10 NO - Go to step 6. 6. Turn the ignition switch OFF 7. Disconnect ECM connector E (31P). Make sure the HDS or a scan tool is disconnected from the DLC. 8. Check for continuity between DLC terminal No.7 and body ground. Is there continuity? YES - Repair short to ground in the wire between DLC terminal No.7 and the ECM (E23). After repairing the wire, check the DTC with the HDS or a scan tool, and go to the indicated DTC's troubleshooting. NO - Go to step 9. 9. Check for continuity between DLC terminal No.7 and ECM terminal E23. Is there continuity? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2428 NO - Repair open in the wire between DLC terminal No.7 and the ECM (E23). After repairing the wire, check the DTC with the HDS or a scan tool, and go to the indicated DTC's troubleshooting. 10. Turn the ignition switch OFF. 11. Disconnect ECM connector E (31P). Make sure the HDS or a scan tool is disconnected from the DLC. 12. Turn the ignition switch ON (II). 13. Measure voltage between DLC terminals No.5 and No.7. Is there 0 V? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Repair short to power in the wire between the DLC terminal No.7 and the ECM (E23). After repairing the wire, check the DTC with the HDS or a scan tool, and go to the indicated DTC's troubleshooting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2437 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2438 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2439 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2440 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2446 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2447 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2448 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2449 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2450 Electric Load Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2451 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2452 100. ELD Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2453 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that's proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2458 DTC P0A94 thru P0157 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2459 DTC P0158 thru P0400 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2460 DTC P0401 thru P0562 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2461 DTC P0563 thru P0748 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2462 DTC P0750 thru P0977 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2463 DTC P0979 thru P1193 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2464 DTC P1253 thru P1459 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2465 DTC P1486 thru P1585 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2466 DTC P1586 thru P1678 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2467 DTC P1679 thru P1860 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2468 DTC P1861 thru P2238 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2469 DTC P2240 thru U0073 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2470 DTC U0100 thru U1288 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2473 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2474 54. Behind Glove Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views 194. ECM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2477 ECM Inputs And Outputs At Connector A (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2478 ECM Inputs And Outputs At Connector A (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2479 ECM Inputs And Outputs At Connectors B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2480 ECM Inputs And Outputs At Connectors E (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2481 ECM Inputs And Outputs At Connectors E (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2484 ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2485 ECM Inputs And Outputs At Connector B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2486 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2487 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2488 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation Engine Control Module: Service and Repair Removal/Installation How to Remove the ECM for Testing 1. Remove the passenger's dashboard lower cover, the passenger's kick panel, and the glove box. 2. Disconnect the connectors (A) and remove the ECM mounting bolts (B). 3. Remove the ECM (C). 4. Install the ECM in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2491 Engine Control Module: Service and Repair Updating the ECM/PCM ECM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM in a troubleshooting procedure. Update the ECM only if the ECM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM can be damaged. How to Update the ECM NOTE: - To ensure the latest program is installed, do an ECM update whenever the ECM is substituted or replaced. - Before you update the ECM, make sure the vehicle's battery is fully charged. - To prevent ECM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM update procedure as described on the HIM label and in the ECM update system. If the software in the ECM is the latest version, replace the ECM. How to Substitute the ECM 1. Remove the ECM from the vehicle. 2. Install a known-good ECM in the vehicle. 3. Rewrite the immobilizer code with the ECM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM and rewrite the immobilizer code with the ECM replacement procedure in the HDS again. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2492 Engine Control Module: Service and Repair Idle Learn Procedure ECM Idle Learn Procedure The idle learn procedure must be done so the ECM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions; - Disconnect the battery. - Replace the ECM or disconnect its connector. - Reset the ECM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.,) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2497 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2498 38. Under Left Rear Of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2499 101. FTP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2500 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2504 104. IAC Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 2505 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve To maintain the proper idle speed, the IAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations Information Bus: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 2509 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 2510 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 Information Bus: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2535 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2536 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2537 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2538 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2539 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2540 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 Information Bus: Electrical Diagrams Wiring Diagrams Diagram 50-0 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Diagram 50-1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Diagram 50-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 Multiplex Control System - Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Multiplex Control System - Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > System Description Information Bus: Description and Operation System Description System Description The Multiplex Control System has four internal functions: - Multiplexing (send multiple signals over shared wires) - Wake up/sleep (runs at full power only on demand to reduce battery draw) - Fail-safe (fixes or ignores faulty signals) - Self-diagnosis (Mode 1 for the system. Mode 2 for input lines) The system controls the function of these circuits: - Entry light control (ignition key light and ceiling light) - Wiper/washer intermittent wipe and park functions - Keyless/power door lock - Meter assembly, temperature gauge, and indicator lights - HVAC (compressor and fan control) - Key-in reminder - Headlight reminder - Seat belt reminder Multiplex Communication To reduce the number of wire harnesses, digital signals are sent via shared multiplex communication lines rather than sending normal electrical signals through individual wires. - The input signals from each switch are converted to digital signals at the central processing unit (CPU). - The digital signals are sent from the transmitting unit to the receiving unit as serial signals. - The transmitted signal is converted to a switch signal at the receiving unit, and it operates the related component or monitors a switch. - There are exclusive communication lines between the ECM, the gauge assembly, keyless receiver unit, and the under-dash fuse/relay box. Wake-up and Sleep The multiplex control system has "wake-up" and "sleep" functions to decrease parasitic draw on the battery when the ignition switch is OFF. - In the sleep mode, the multiplex control unit stops functioning (communication and CPU control) when it is not necessary for the system to operate. - As soon as any operation is requested (for example, a door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function. - When the ignition switch is turned OFF, and the driver's or front passenger's door is opened, then closed, there is about a 10 second delay before the control unit goes from the wake-up mode to the sleep mode. - If any door is open, the sleep mode will not function. - If a key is in the ignition switch, the sleep mode will not function. - When in sleep mode, the draw is reduced from 70 - 80 mA to less than 10 mA. Fail-safe To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode, the output signal is fixed when any part of the system malfunctions (for example a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > System Description > Page 2551 Information Bus: Description and Operation Circuit Description MULTIPLEX CONTROL SYSTEM How the Circuit Works The conventional portion of the electrical system carries DC power through separate wires to each component. The multiplex portion of the system, however, sends digital signals between control units through shared wires to reduce the number and weight of wire harnesses. The signals from each switch are converted to digital signals within the receiving multiplex control unit. The digital signals are sent from the multiplex control unit to components as serial data over dedicated communication lines. When the appropriate control unit receives the digital signal, it converts it back to a switch signal and operates the related components. The multiplex control system schematic shows it's power, grounds, and communication lines. The ignition key light, ceiling and spotlights are also shown because they are used to blink DTCs in the system's self-diagnosis function. The rest of the multiplex control system wiring is shown in the following circuit schematics: - Low Oil Pressure Indicator Light - Seat Belt Reminder - Lights-on Reminder - Key-in Reminder - Entry Light Control System - Power Door Locks - Wiper/Washers - Keyless Security Alarm System - Interlock System - Map Light/Spotlight - Headlights Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test Information Bus: Testing and Inspection Mode 1 Test Troubleshooting Special Tools Required MPCS service connector 07WAZ-001010A MODE 1 Test 1. Remove the driver's dashboard lower cover. 2. Check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 3. NO - Find and repair the cause of the blown fuse. 3. Turn the ignition switch ON (II). If the driver's seat belt is unbuckled the seat belt reminder will chime 6 times. 4. Set the ceiling light to the center position and close all the doors. 5. Connect the special tool (A) to the multiplex inspection connector (B). 6. After about 5 seconds the spotlight and ceiling light should come on for 2 seconds, go out, then blink on for 0.2 second to show the system is now in mode 1. Did the spotlight and ceiling light indicate mode 1? YES - Go to step 8. NO - Go to step 7. 7. Check for continuity between terminal 4 of the under-dash fuse/relay box connector J and body ground. Is there continuity? YES - Replace the under-dash fuse/relay box. NO - Repair the open in the wire. If the wire is OK, repair G301. 8. If the DTCs are present, the spotlight and ceiling light will blink to indicate the DTC(s). If more than one DTC is present, the DTCs will be Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test > Page 2554 displayed in ascending order. If there are no DTCs the spotlight and ceiling light will not blink again after the Mode 1 indication. Are there any DTCs? YES - Go to step 9. NO - Go to the Mode 2 test. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test > Page 2555 9. Troubleshoot the DTC(s) in the order indicated using the above charts. If a faulty control unit is suspected, substitute it with a known food part and recheck for DTCs. If the DTC(s) is still present, go to the next step listed for the DTC. - If the DTC(s) is no longer present replace the original part. - Before replacing a Faulty ECM make sure it has the latest software revision. Update if necessary before swapping or replacing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test > Page 2556 Information Bus: Testing and Inspection Mode 2 Test MODE 2 Test 1. From Mode 1, disconnect the special tool from the multiplex inspection connector for 5 to 10 seconds, and then reconnect it. 2. The spotlight and ceiling light should come on for 2 seconds, go out, then blink twice, 0.2 seconds each time. The system is now in Mode 2. 3. Operate the switches listed: If the circuit is OK, the spotlight and ceiling light will blink once. If the circuit is faulty, the lights will not blink. Tip: Operate the switches most closely related to the problem you are diagnosing is a quick way of testing the circuits integrity. 4. If all inputs were confirmed, or multiple circuits failed at the same time in Mode 2, go to the multiplex sleep mode test. If a single switch fails in Mode 2, troubleshoot its circuit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test > Page 2557 Information Bus: Testing and Inspection Multiplex Control Unit Input Test Multiplex Control Unit Input Test 1. Remove the driver's dashboard lower cover. 2. Disconnect the under-dash fuse/relay box connectors C, E, F, J, K, O, P, Q, X and Y. NOTE: All connectors are wire side of female terminals. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Mode 1 Test > Page 2558 4. Reconnect the connectors to the under-dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make sure these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2562 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2563 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2564 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2565 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2569 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2570 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2571 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2572 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2573 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM has been reset, these codes are set to incomplete. In some states, part of the emissions; testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are set to complete. If it blinks several times, on 2 or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2577 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect the HDS or a scan tool. 2. Turn the ignition switch ON (II) and read the HDS or a scan tool. Does the HDS or a scan tool communicate with the ECM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the HDS or a scan tool for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting Index. See: Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the malfunction indicator lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 76. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) (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 connection at ECM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM (A21) and the manifold absolute pressure (MAP) sensor. - An intermittent short in the wire between the ECM (A20) and the throttle position (TP) sensor. - An intermittent short in the wire between the ECM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IG1 (40A) (Canada: 50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (40A) (Canada: 50A) fuse and the gauge assembly. If the wire is OK, test the ignition switch. NO - Repair short in the wire between No.20 IG (40A) (Canada: 50A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) (Canada: 50A) fuse. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2578 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Check for an open in the wire between the ECM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. 17. Remove the glove box and PGM-FI main relay 1. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2579 18. Check for continuity between body ground and PGM-FI main relay 14P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM) (15A) fuse and the PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or the connectors below, one at a time, and check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft Position (CMP) sensor B 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Also replace the No.6 ECU (ECM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft Position (CMP) sensor B - Crankshaft position (CKP) sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2580 21. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse from the under-dash fuse/relay box. 24. Disconnect ECM connector E (31P). 25. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 26. Remove the PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2581 27. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9), or between the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. 32. Reinstall PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2582 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it if necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9). 37. Measure voltage between ECM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 38. 38. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2583 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (E7). 42. Reconnect ECM connector E (31P). 43. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2584 44. Measure voltage between body ground and ECM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). 48. Measure voltage between PGM-FI main relay 14P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 49. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2585 50. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and ECM connector terminals A2 and A3 individually. Is there continuity? YES - Replace PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (A2, A3). 51. Measure voltage between body ground and ECM connector terminals A4, A5, A23, and A24 individually. Is there more than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s)that had more than 1.0 V between G101 and the ECM (A4, A5, A23, A24). 52. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Go to step 60. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the manifold absolute pressure (MAP) sensor 3P connector. 55. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2586 56. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Replace the MAP sensor. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect ECM connector A (31P). 59. Check for continuity between ECM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A21) and the MAP sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 60. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 61. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2587 61. Turn the ignition switch OFF. 62. Disconnect the throttle position (TP) sensor 3P connector. 63. Turn the ignition switch ON (II). 64. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Replace the throttle body (the TP sensor is not available separately). NO - Go to step 65. 65. Turn the ignition switch OFF. 66. Disconnect ECM connector A (31P). 67. Check for continuity between ECM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A20) and the TP sensor, or repair short in the wire between the ECM (A8) and the knock sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 68. Measure voltage between body ground and ECM connector terminal E5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2588 Is there about 5 V? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). 72. Measure voltage between body ground and ECM connector terminal E5 Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF 74. Disconnect ECM connector E (31P). 75. Check for continuity between ECM connector terminal E5 and body ground Is there continuity? YES - 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. If the symptom/indication goes away with a known good ECM, replace the original ECM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2589 78. Measure voltage between ECM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM connector E (31P). 81. Check for continuity between ECM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the data link connector (DLC) and the ECM (E29). NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. 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 (31P). 84. Turn the ignition switch ON (II). Does the MIL stay on? YES - Repair short in the wire between the gauge assembly and the ECM (E31). If the wire is OK, replace the gauge assembly. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2593 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2594 106. MAP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2595 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2600 36. Rear Underside of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2601 Oxygen Sensor: Diagrams 114. A/F Sensor 128. Secondary HO2S Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) Sensor The A/F Sensor operates over a wide air/fuel range. The A/F Sensor is installed upstream of the TWC, and sends signals to the ECM which varies the duration of fuel injection accordingly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor > Page 2604 Oxygen Sensor: Description and Operation Secondary Oxygen Sensor Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the three way catalytic converter (TWC) and sends signals to the ECM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement Oxygen Sensor: Service and Repair A/F Sensor Replacement A/F Sensor Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the A/F sensor 4P connector (A), then remove the A/F sensor (B). 2. Install the A/F sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement > Page 2607 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2611 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2612 134. A/F Sensor Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2613 Oxygen Sensor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2614 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors Engine Control Module: Technical Service Bulletins Emissions - OBD II DTC's And Associated Monitors 03-020 April 2, 2010 Applies To: All OBD II-equipped models except Passport OBD II DTCs and Their Associated Monitors (Supersedes 03-020, dated March 29, 2003, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Numerous DTCs were added. Refer to the list for details.* Following is a list of all OBD II DTCs and their associated monitors for all Honda automobiles with OBD II. No one model has every DTC in the list. DTC P0AA6 thru P0A9E Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2623 DTC P0A94 thru P0157 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2624 DTC P0158 thru P0400 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2625 DTC P0401 thru P0562 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2626 DTC P0563 thru P0748 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2627 DTC P0750 thru P0977 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2628 DTC P0979 thru P1193 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2629 DTC P1253 thru P1459 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2630 DTC P1486 thru P1585 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2631 DTC P1586 thru P1678 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2632 DTC P1679 thru P1860 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2633 DTC P1861 thru P2238 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2634 DTC P2240 thru U0073 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Emissions - OBD II DTC's And Associated Monitors > Page 2635 DTC U0100 thru U1288 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations Engine Control Module: Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2638 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 2639 54. Behind Glove Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views 194. ECM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2642 ECM Inputs And Outputs At Connector A (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2643 ECM Inputs And Outputs At Connector A (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2644 ECM Inputs And Outputs At Connectors B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2645 ECM Inputs And Outputs At Connectors E (31P) Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2646 ECM Inputs And Outputs At Connectors E (31P) Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values Engine Control Module: Testing and Inspection ECM/PCM Terminal Values ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2649 ECM Inputs And Outputs At Connector A (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2650 ECM Inputs And Outputs At Connector B (24P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2651 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2652 ECM Inputs And Outputs At Connector E (31P) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > ECM/PCM Terminal Values > Page 2653 Engine Control Module: Testing and Inspection How to Troubleshoot Circuits At the ECM/PCM How to Troubleshoot Circuits at the ECM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation Engine Control Module: Service and Repair Removal/Installation How to Remove the ECM for Testing 1. Remove the passenger's dashboard lower cover, the passenger's kick panel, and the glove box. 2. Disconnect the connectors (A) and remove the ECM mounting bolts (B). 3. Remove the ECM (C). 4. Install the ECM in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2656 Engine Control Module: Service and Repair Updating the ECM/PCM ECM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) P/N EQS05A35570 Use this procedure when you have to substitute a known-good ECM in a troubleshooting procedure. Update the ECM only if the ECM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM can be damaged. How to Update the ECM NOTE: - To ensure the latest program is installed, do an ECM update whenever the ECM is substituted or replaced. - Before you update the ECM, make sure the vehicle's battery is fully charged. - To prevent ECM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, door locks, etc.) during the update. - If you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON (II) position when you disconnect the HIM from the Data Link Connector (DLC). This will prevent ECM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the HIM to the DLC (A) located under the driver's side of dashboard. 3. Do the ECM update procedure as described on the HIM label and in the ECM update system. If the software in the ECM is the latest version, replace the ECM. How to Substitute the ECM 1. Remove the ECM from the vehicle. 2. Install a known-good ECM in the vehicle. 3. Rewrite the immobilizer code with the ECM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM and rewrite the immobilizer code with the ECM replacement procedure in the HDS again. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal/Installation > Page 2657 Engine Control Module: Service and Repair Idle Learn Procedure ECM Idle Learn Procedure The idle learn procedure must be done so the ECM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions; - Disconnect the battery. - Replace the ECM or disconnect its connector. - Reset the ECM. NOTE: Erasing DTCs with the Honda PGM Tester does not require you to do the idle learn procedure. - Remove the No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 battery (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fuse/relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear defogger, lights, etc.,) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2661 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2662 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2663 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2664 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2665 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2669 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2670 134. A/F Sensor Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2671 Oxygen Sensor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2672 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P0171 Set Absolute Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P0171 Set SOURCE: Honda Service News TITLE: Got a DTC P0171? Check the Short-Term Fuel Trim APPLIES TO: 03-04 Accord 01-04 Civic 02-04 CR-V 03-04 Element 02-04 Odyssey 03-04 Pilot SERVICE TIP: Got a vehicle in your shop that purrs like a kitten but it sets a DTC P0171 (fuel system too lean)? Check the short-term fuel trim (ST FUEL TRIM B1). If the value reads higher than 1.05, then check the MAP SENSOR value with the engine turned off and the ignition switch turned to ON (II). - If the MAP SENSOR and BARO SENSOR values match, the MAP sensor is working OK. Do the normal troubleshooting for DTC P0171. - If the MAP SENSOR and BARO SENSOR values don't match, install a known-good MAP sensor, and retest. If the sensor values now match, clear the DTC, and make sure the ST FUEL TRIM B1 value is normal (it reads about 1.0). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation Barometric Pressure (BARO) Sensor The BARO 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 injection discharge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2684 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2685 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2686 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2687 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2690 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2691 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 2692 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2696 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2697 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ECT Sensor Replacement 1. Remove the air cleaner. 2. Disconnect the ECT sensor 2P connector. 3. Remove the ECT sensor (A). 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2701 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2702 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2703 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2706 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 2707 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: Customer Interest Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2716 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2717 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2718 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Customer Interest for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2719 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2725 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2726 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2727 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Load Sensor: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2728 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2729 Electric Load Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2730 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2731 100. ELD Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2732 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early 1990's, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that's proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Fuel System - FTP Sensor Diagnostics/DTC P0497 Fuel Tank Pressure Sensor: Technical Service Bulletins Fuel System - FTP Sensor Diagnostics/DTC P0497 How to Tell a Bad FTP Sensor From an EVAP Leak Troubleshooting a '01-05 Civic with DTC P0497 (EVAP system low purge flow)? When the fuel tank pressure (FTP) sensor doesn't respond to vacuum testing, it's really easy to think you've got a leak in the FVAP system. Here's an simple way to tell if the problem is just a bad FTP sensor or an actual system leak: 1. Connect the HDS to the 16P DLC. Turn the ignition switch to ON (II). Turn on the HDS. 2. At the screen prompts, enter the VIN (if you're asked) and the odometer reading. 3. From the Select Mode screen, select Honda Systems. From the System Selection Menu, select PGM-FI. From the Mode Menu, select All Data List. 4. Disconnect the two FTP sensor vacuum lines. Look at the FTP Sensor value on the display screen. ^ If the value reads between 2.45 and 2.55 volts, go to step 6. ^ If the value doesn't read between 2.45 and 2.55 volts, check the electrical connections. If you find any problems, fix them, then go to step 5. If the circuits are OK, replace the FTP sensor, then go to step 5. 5. Look at the FTP Sensor value on the display screen. ^ If the value now reads between 2.45 and 2.55 volts, reconnect the vacuum lines and disconnect the HDS. Return the vehicle to your customer. ^ If the value still doesn't read between 2.45 and 2.55 volts, go to step 6. 6. Connect a vacuum pump to the larger FTP sensor hose (the smaller hose is the FTP vent) Slowly squeeze the pump handle to pull a vacuum on the FTP sensor. Look at the sensor value on the display screen. ^ If the value changes, continue troubleshooting for DTC P0497. ^ If the value stays the same, the FTP sensor has a leak. Replace the sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2737 Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2738 38. Under Left Rear Of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2739 101. FTP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Page 2740 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor The FTP sensor converts fuel tank absolute pressure into an electrical input to the ECM during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2744 9. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2745 44. IAT Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2749 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2750 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2751 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2752 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2756 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2757 106. MAP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2758 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor converts manifold absolute pressure into electrical signals to the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2763 36. Rear Underside of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2764 Oxygen Sensor: Diagrams 114. A/F Sensor 128. Secondary HO2S Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor Oxygen Sensor: Description and Operation Air Fuel (A/F) Ratio Sensor Air Fuel Ratio (A/F) Sensor The A/F Sensor operates over a wide air/fuel range. The A/F Sensor is installed upstream of the TWC, and sends signals to the ECM which varies the duration of fuel injection accordingly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor > Page 2767 Oxygen Sensor: Description and Operation Secondary Oxygen Sensor Secondary Heated Oxygen Sensor (Secondary HO2S) The secondary HO2S detects the oxygen content in the exhaust gas downstream of the three way catalytic converter (TWC) and sends signals to the ECM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The secondary HO2S is installed in the TWC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement Oxygen Sensor: Service and Repair A/F Sensor Replacement A/F Sensor Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the A/F sensor 4P connector (A), then remove the A/F sensor (B). 2. Install the A/F sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement > Page 2770 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench. Snap-on YA8875, SP Tools 93750, or equivalent, commercially available 1. Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B). 2. Install the secondary HO2S in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2777 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2778 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2779 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2788 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2789 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls MIL ON/DTC's P0706 or P1706 > Page 2795 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls MIL ON/DTC's P0706 or P1706 > Page 2796 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations Variable Valve Timing Pressure Switch: Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2800 13. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2801 83. VTEC Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2806 Vehicle Speed Sensor: Locations 12. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2807 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2808 113. VSS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2809 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2810 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required Test harness 07LAJ-PT3020A Before testing, inspect the No. 4 (10 A) and No. 10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an Ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Connect the test harness to the VSS. 7. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 8. NO - Repair open in the BLK/YEL or BLK/ORN wire between the VSS and the under-dash fuse/relay box, repair ground or open in BLK wire between VSS and G101. 8. Disconnect the WHT test harness clip (B). 9. Disconnect the test harness from the VSS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2811 10. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 11. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, the gauge assembly or the ECM. 11. Turn the ignition switch OFF. 12. Connect the other test harness connector (A) to the VSS (B). 13. Raise the front of the vehicle, and make sure it is securely supported. 14. Put the vehicle in neutral with the ignition switch ON (II). 15. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Go to step 16. NO - Replace the VSS. 16. Disconnect the 22P connector "B" from the gauge assembly. 17. Connect the positive probe of a voltmeter to the BLU/WHT wire and the negative probe to ground. 18. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Replace the speedometer assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2812 NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2813 Vehicle Speed Sensor: Service and Repair VSS Replacement 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 removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2817 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2818 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2819 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2828 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2829 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2835 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2836 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions Variable Valve Timing Actuator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 Variable Valve Timing Actuator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 82. VTC Oil Control Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Variable Valve Timing Actuator: Electrical Diagrams Diagram 31 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2876 Variable Valve Timing Actuator: Description and Operation VTEC/VTC - The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load. - The VTEC mechanism changes the valve lift and timing by using more than one cam profile. - The VTC changes the phase of the intake camshaft via oil pressure. It changes the intake valve timing continuously. VTC system - The VTC system makes continuous intake valve timing changes based on operating conditions. - Intake valve timing is optimized to allow the engine to produce maximum power. - Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry of the air/fuel mixture into the intake port and improve the 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 retarded position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2877 VTEC system - The VTEC system changes the cam profile to correspond to engine speed. It maximizes torque at low engine speed and output at high engine speed. - The low lift cam is used at low engine speeds, and the high lift cam is used at high engine speeds. System Diagram Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator Variable Valve Timing Actuator: Testing and Inspection VTC Actuator VTC Actuator Inspection 1. Remove the cylinder head cover. 2. Remove the auto-tensioner. 3. Loosen the rocker arm adjusting screws. 4. Remove the camshaft holder. 5. Remove the intake camshaft. 6. Check that the variable valve timing control (VTC) actuator is locked by turning the VTC actuator clockwise and counterclockwise. If the VTC actuator is not locked, replace the VTC actuator. 7. Seal the advance holes (A) and retard holes (B) in the No. 1 camshaft journal with tape. 8. Punch a hole through the tape over one of the advance holes. 9. Apply air to the advance hole to release the lock Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 2880 10. Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 2881 Variable Valve Timing Actuator: Testing and Inspection VTC Actuator Removal/Test/Installation VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Testing and Inspection > VTC Actuator > Page 2882 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement Variable Valve Timing Actuator: Service and Repair VTC Actuator, Exhaust Camshaft Sprocket Replacement Removal 1. Remove the cam chain. 2. Hold the camshaft with an open-end wrench, then loosen the variable valve timing control (VTC) actuator mounting bolt and exhaust camshaft sprocket mounting bolt. 3. Remove the VTC actuator and exhaust camshaft sprocket. Installation 1. Install the VTC actuator and exhaust camshaft sprocket. 2. Apply engine oil to the threads of the VTC actuator mounting bolt and exhaust camshaft mounting bolt then install them. 3. Hold the camshaft with an open-end wrench, then tighten the bolts. Specified torque: VTC actuator mounting bolt: 113 Nm (11.5 kgf-cm, 83 ft. lbs.) Exhaust camshaft sprocket mounting bolt: 72 Nm (7.3 kgf-cm, 53 ft. lbs.) 4. Install the cam chain. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 2885 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and the VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve strainer for clogging. If the strainer is clogged, replace the VTC oil control solenoid valve. 4. Note the amount of valve opening by observing the position of the piston shoulder (A) through the valve retard drain port. If you see the shoulder of the piston, the valve is open and must be replaced. 5. Connect the battery positive terminal to VTC oil control solenoid valve 2P connector terminal No.2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Service and Repair > VTC Actuator, Exhaust Camshaft Sprocket Replacement > Page 2886 6. Connect the battery negative terminal to VTC oil control solenoid valve 2P connector terminal No.1. Appearance of inner valve (A) in the port should be at least 1.2 mm (1/16 in.). If the inner valve does not open, replace it; then go to step 7. 7. Replace the VTC valve O-ring (A). 8. Coat a new O-ring (A) with engine oil, then install it. 9. Clean and dry the mating surface of the valve. 10. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations Variable Valve Timing Pressure Switch: Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2890 13. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 2891 83. VTEC Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 2895 84. VTEC Oil Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 2896 Variable Valve Timing Solenoid: Testing and Inspection VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 2897 Variable Valve Timing Solenoid: Service and Repair VTEC Solenoid Valve Removal/Inspection 1. Disconnect the VTEC solenoid valve 2P connector. 2. Measure resistance between VTEC solenoid valve connector terminals No.1 and No.2. 3. If the resistance is within specifications, remove the VTEC solenoid valve assembly (A) from the cylinder head, and check the VTEC solenoid valve filter (B) for clogging. If it is clogged, replace the solenoid valve filter, the engine oil filter, and the engine oil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Vehicle Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2902 Vehicle Speed Sensor: Locations 12. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2903 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2904 113. VSS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2905 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) The VSS is driven by the differential. It generates a pulsed signal from an input of 5 volts. The number of pulses per minute increases/decreases with the speed of the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2906 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required Test harness 07LAJ-PT3020A Before testing, inspect the No. 4 (10 A) and No. 10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an Ohmmeter. Cover the white (C) and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS and G101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Connect the test harness to the VSS. 7. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 8. NO - Repair open in the BLK/YEL or BLK/ORN wire between the VSS and the under-dash fuse/relay box, repair ground or open in BLK wire between VSS and G101. 8. Disconnect the WHT test harness clip (B). 9. Disconnect the test harness from the VSS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2907 10. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 11. NO - Repair short or open in the BLU/WHT or WHT/GRN wire between the VSS and the cruise control unit, the gauge assembly or the ECM. 11. Turn the ignition switch OFF. 12. Connect the other test harness connector (A) to the VSS (B). 13. Raise the front of the vehicle, and make sure it is securely supported. 14. Put the vehicle in neutral with the ignition switch ON (II). 15. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Go to step 16. NO - Replace the VSS. 16. Disconnect the 22P connector "B" from the gauge assembly. 17. Connect the positive probe of a voltmeter to the BLU/WHT wire and the negative probe to ground. 18. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5 V? YES - Replace the speedometer assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2908 NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2909 Vehicle Speed Sensor: Service and Repair VSS Replacement 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 removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Testing and Inspection Voltage Signal: Testing and Inspection Alternator FR Signal Circuit Troubleshooting 1. Disconnect the alternator 4P connector from the alternator. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM connector terminals A24 and B13. Is there about 5 V? YES - Go to step 4. NO - Go to step 13. 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator 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 alternator FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM connector B (24P). 10. Disconnect the alternator 4P connector. 11. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Testing and Inspection > Page 2913 12. Check for continuity between body ground and ECM connector terminal B13. Is there continuity? YES - Test the alternator. NO - Repair open in the wire between the ECM (B13) and the alternator. 13. Turn the ignition switch OFF. 14. Disconnect ECM connector B (24P). 15. Check for continuity between body ground and ECM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM (B13) and the alternator. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Noise Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Noise SOURCE: Honda Service News TITLE: Catalytic Converter Noise? Check the Heat Shield APPLIES TO: All models SERVICE TIP: Got a vehicle in your shop that buzzes or rattles, and you suspect the catalytic converter is the culprit? Before you start replacing the converter, first check the heat shield area. If there any stones or debris trapped inside, they can cause buzzing or rattling. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2919 Catalytic Converter: Description and Operation Catalytic Converter System Three Way Catalytic Converter (TWC) The TWC converts hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO(2)), nitrogen (N(2)), and water vapor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Connector Views 34. EVAP Canister Purge Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Connector Views > Page 2926 Vacuum Hose Routing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 2927 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve When the engine coolant temperature is below 149 °F (65 °C), the ECM turns off the EVAP canister purge valve which cuts vacuum to the EVAP canister. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Locations > Page 2931 Canister Purge Volume Control Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank. It also relieves excess vacuum in the tank by allowing fresh air to be drawn into the tank through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P1457 Set 08-016 March 18, 2008 Applies To: 2001-05 Civic 2/4-Door-ALL 2002-05 Civic 3-Door - ALL 2003-05 Civic Hybrid ULEV ALL 2002-04 CR-V - ALL MIL Comes On With DTC P1457 SYMPTOM The MIL comes on with DTC P1457 (EVAP control system leakage). PROBABLE CAUSE The EVAP solenoid valve (fuel vent module) is blocked or restricted. CORRECTIVE ACTION Install an EVAP solenoid valve kit. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 17380-55A-A32 H/C 7083124 Defect Code: 03214 Symptom Code: 03203 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2940 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. Connect the HDS to the DLC (data link connector), and check for DTCs. Is DTC P1457 stored? Yes - Clear the DTC, then go to step 2. No - This service bulletin does not apply; continue with normal troubleshooting. 2. Follow the HDS screen prompts, and do the EVAP Function Test. Did the EVAP solenoid valve pass the test? Yes - This service bulletin does not apply; continue with normal troubleshooting. No - If you're working on a Civic, go to REPAIR PROCEDURE A. If you're working on a CR-V, go to REPAIR PROCEDURE B. REPAIR PROCEDURE A 1. Relieve the fuel pressure: ^ Refer to the Fuel and Emissions section of the appropriate service manual, or ^ Online, enter keywords FUEL PRESSURE, and select Fuel Pressure Relieving from the list. 2. Drain the fuel, then remove the fuel tank: ^ Refer to the Fuel and Emissions section of the appropriate service manual, or ^ Online, enter keyword TANK, and select Fuel Tank Replacement from the list. 3. Remove the EVAP solenoid valve: ^ Remove pressure sensor tube B; it will be reused. ^ Remove fuel vent tube B; it will not be reused. ^ Disconnect fuel vent tube C from the EVAP solenoid valve. The tube will be reused. ^ Disconnect the 2P connector from the EVAP solenoid valve. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2941 ^ Remove the EVAP solenoid valve (two bolts). The bolts will be reused. The valve will not be reused. 4. Attach the tubes and the joint from the kit onto the new EVAP solenoid valve as shown. 5. Install the new EVAP solenoid valve using the original bolts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2942 6. Connect the original hoses and the new tubes as shown. 7. Reinstall the fuel tank. 8. Reinstall the fuel tank unit with a new base gasket and a new locknut. 9. Reinstall the fuel line to the tank with a new fuel feed retainer. 10. Refill the tank with the fuel you removed in step 2. REPAIR PROCEDURE B 1. Relieve the fuel pressure: ^ Refer to page 11-161 of the 2002-2004 CR-V Service Manual, or ^ Online, enter keywords FUEL PRESSURE, and select Fuel Pressure Relieving from the list. 2. Drain the fuel, then remove the fuel tank: ^ Refer to page 11-171 of the service manual, or ^ Online, enter keyword TANK, and select Fuel Tank Replacement from the list. 3. Remove the EVAP canister: ^ Refer to page 11-217 of the service manual, or ^ Online, enter keyword CANISTER, and select EVAP Canister Replacement from the list. 4. Remove the EVAP solenoid valve from the EVAP canister: ^ Remove pressure sensor tube B; it will not be reused. ^ Remove fuel vent tube C; it will not be reused. ^ Remove fuel vent tube D; it will not be reused. ^ Disconnect the 2P connector. ^ Remove the EVAP solenoid valve bolts. The bolts will be reused. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2943 ^ Disconnect the remaining hoses connected to the EVAP solenoid valve, then remove the valve. The valve will not be reused. 5. Attach the tubes, the vacuum chamber, the joint, and the clips from the kit onto the new EVAP solenoid valve as shown. 6. Install the new EVAP solenoid valve on the EVAP canister using the original bolts. 7. Reinstall the EVAP canister. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2944 8. Connect the original hoses and the new tube as shown. 9. Reinstall the fuel tank. 10. Reinstall the fuel tank unit with a new base gasket and a new locknut. 11. Reinstall the fuel line to the tank with a new fuel feed retainer. 12. Refill the tank with the fuel you removed in step 2. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P1457 Set 08-016 March 18, 2008 Applies To: 2001-05 Civic 2/4-Door-ALL 2002-05 Civic 3-Door - ALL 2003-05 Civic Hybrid ULEV ALL 2002-04 CR-V - ALL MIL Comes On With DTC P1457 SYMPTOM The MIL comes on with DTC P1457 (EVAP control system leakage). PROBABLE CAUSE The EVAP solenoid valve (fuel vent module) is blocked or restricted. CORRECTIVE ACTION Install an EVAP solenoid valve kit. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 17380-55A-A32 H/C 7083124 Defect Code: 03214 Symptom Code: 03203 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2950 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. Connect the HDS to the DLC (data link connector), and check for DTCs. Is DTC P1457 stored? Yes - Clear the DTC, then go to step 2. No - This service bulletin does not apply; continue with normal troubleshooting. 2. Follow the HDS screen prompts, and do the EVAP Function Test. Did the EVAP solenoid valve pass the test? Yes - This service bulletin does not apply; continue with normal troubleshooting. No - If you're working on a Civic, go to REPAIR PROCEDURE A. If you're working on a CR-V, go to REPAIR PROCEDURE B. REPAIR PROCEDURE A 1. Relieve the fuel pressure: ^ Refer to the Fuel and Emissions section of the appropriate service manual, or ^ Online, enter keywords FUEL PRESSURE, and select Fuel Pressure Relieving from the list. 2. Drain the fuel, then remove the fuel tank: ^ Refer to the Fuel and Emissions section of the appropriate service manual, or ^ Online, enter keyword TANK, and select Fuel Tank Replacement from the list. 3. Remove the EVAP solenoid valve: ^ Remove pressure sensor tube B; it will be reused. ^ Remove fuel vent tube B; it will not be reused. ^ Disconnect fuel vent tube C from the EVAP solenoid valve. The tube will be reused. ^ Disconnect the 2P connector from the EVAP solenoid valve. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2951 ^ Remove the EVAP solenoid valve (two bolts). The bolts will be reused. The valve will not be reused. 4. Attach the tubes and the joint from the kit onto the new EVAP solenoid valve as shown. 5. Install the new EVAP solenoid valve using the original bolts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2952 6. Connect the original hoses and the new tubes as shown. 7. Reinstall the fuel tank. 8. Reinstall the fuel tank unit with a new base gasket and a new locknut. 9. Reinstall the fuel line to the tank with a new fuel feed retainer. 10. Refill the tank with the fuel you removed in step 2. REPAIR PROCEDURE B 1. Relieve the fuel pressure: ^ Refer to page 11-161 of the 2002-2004 CR-V Service Manual, or ^ Online, enter keywords FUEL PRESSURE, and select Fuel Pressure Relieving from the list. 2. Drain the fuel, then remove the fuel tank: ^ Refer to page 11-171 of the service manual, or ^ Online, enter keyword TANK, and select Fuel Tank Replacement from the list. 3. Remove the EVAP canister: ^ Refer to page 11-217 of the service manual, or ^ Online, enter keyword CANISTER, and select EVAP Canister Replacement from the list. 4. Remove the EVAP solenoid valve from the EVAP canister: ^ Remove pressure sensor tube B; it will not be reused. ^ Remove fuel vent tube C; it will not be reused. ^ Remove fuel vent tube D; it will not be reused. ^ Disconnect the 2P connector. ^ Remove the EVAP solenoid valve bolts. The bolts will be reused. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2953 ^ Disconnect the remaining hoses connected to the EVAP solenoid valve, then remove the valve. The valve will not be reused. 5. Attach the tubes, the vacuum chamber, the joint, and the clips from the kit onto the new EVAP solenoid valve as shown. 6. Install the new EVAP solenoid valve on the EVAP canister using the original bolts. 7. Reinstall the EVAP canister. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 2954 8. Connect the original hoses and the new tube as shown. 9. Reinstall the fuel tank. 10. Reinstall the fuel tank unit with a new base gasket and a new locknut. 11. Reinstall the fuel line to the tank with a new fuel feed retainer. 12. Refill the tank with the fuel you removed in step 2. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2960 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2961 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2967 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Check Valve: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2968 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 2969 EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 2970 Evaporative Check Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank. It also relieves excess vacuum in the tank by allowing fresh air to be drawn into the tank through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve during the EVAP leak check. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 2971 Evaporative Check Valve: Testing and Inspection EVAP Two Way Valve Test Special Tools Required - Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX - Vacuum/pressure gauge, 0-4 in.Hg 07JAZ-001000B 1. Remove the fuel fill cap. 2. Disconnect the vapor line from the EVAP two way valve (A). Connect it to a T-fitting (B) from the vacuum gauge and the vacuum pump as shown. 3. Apply vacuum slowly and continuously while watching the gauge. The vacuum should stabilize momentarily at 0.8-2.1 kPa (6-16 mmHg, 0.2-0.6 in.Hg). If the vacuum stabilizes (valve opens) below 0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kPa (16 mmHg, 0.6 in.Hg), install a new valve and retest. 4. Move the vacuum pump hose from the vacuum fitting to the pressure fitting, and move the vacuum gauge hose from the vacuum side to the pressure side (A) as shown. 5. Slowly pressurize the vapor line while watching the gauge. The pressure should stabilize momentarily above 1.0 kPa (8 mmHg, 0.3 in.Hg). - If the pressure momentarily stabilizes (valve opens) above 1.0 kPa (8 mmHg, 0.3 in.Hg), the valve is OK. - If the pressure stabilizes below 1.0 kPa (8 mmHg, 0.3 in.Hg), install a new valve and retest. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams 35. EVAP Canister Vent Shut Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Shut Valve > Component Information > Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Shut Valve > Component Information > Locations > Page 2979 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Locations 38. Under Left Rear Of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Locations > Page 2983 33. EVAP Bypass Solenoid Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > Refueling Control Valve, Evaporative System > Component Information > Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > Refueling Control Valve, Evaporative System > Component Information > Locations > Page 2988 Refueling Control Valve: Testing and Inspection Fuel Tank Vapor Control Valve Test Special Tools Required Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX Float Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap to relieve fuel tank pressure, then reinstall the cap. 3. Disconnect the fuel tank vapor recirculation tube (A), and connect a vacuum pump to it. 4. Plug the line (B). 5. Apply vacuum to the fuel tank vapor recirculation tube. - If the vacuum holds, replace the fuel tank vapor control valve. - If the vacuum does not hold, the float is OK. Do the valve test. Valve Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap. 3. Disconnect the fuel tank vapor signal tube (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > Refueling Control Valve, Evaporative System > Component Information > Locations > Page 2989 4. Disconnect the vacuum hoses (A) from the EVAP canister (B), then plug the ports with plugs (C). 5. Disconnect the vacuum hose (D) from the EVAP canister vent shut valve (E), and connect a vacuum pump to the vacuum hose. 6. Pump the vacuum pump 80 times. - If the vacuum holds, go to step 7. - If the vacuum does not hold, go to step 10. 7. Connect a second vacuum pump to the fuel tank vapor signal tube (A). 8. Apply vacuum (1 pump) to the fuel tank vapor signal tube (A), then check the vacuum on the pump in step 6. - If the vacuum holds, replace the fuel tank vapor control valve. - If the vacuum is released, go to step 9. 9. Fill the fuel tank with fuel, then check for fuel in the EVAP two way valve (A), and fuel tank vapor recirculation hose (B). NOTE: At either location, tiny droplets of fuel are normal. If fuel runs out of the hoses at either location, replace the fuel tank vapor control valve. - If the fuel does not run out of the hoses, the fuel tank vapor system function is normal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > Refueling Control Valve, Evaporative System > Component Information > Locations > Page 2990 10. Disconnect the fuel tank vapor quick disconnect from the EVAP canister, then plug the port on the canister. Reapply vacuum (80 pumps). - If the vacuum holds, replace the fuel tank control valve. - If the vacuum does not hold, inspect the EVAP canister vent shut valve O-ring. If the O-ring is OK, replace the EVAP canister, and repeat step 4. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > Refueling Control Valve, Evaporative System > Component Information > Locations > Page 2991 Refueling Control Valve: Service and Repair Fuel Tank Vapor Control Valve Replacement 1. Remove the fuel tank. 2. Remove the fuel tank vapor control valve (A) from the fuel tank (B). 3. Install the fuel tank vapor control valve. 4. Install the fuel tank. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection PCV Valve Inspection and Test 1. Check the PCV valve (A), hoses (B), and connections for leaks or restrictions. 2. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your fingers or pliers. If there is no clicking sound, check the PCV valve grommet for cracks or damage. If the grommet is OK, replace the PCV valve and recheck. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection > Page 2996 Positive Crankcase Ventilation Valve: Service and Repair PCV Valve Replacement 1. Disconnect the PCV hose. 2. Remove the PCV valve (A). 3. Install the parts in the reverse order of removal with a new gasket (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure....................................................................................................................................... ..........320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 54 psi). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3001 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3002 Fuel Pressure: Testing and Inspection Fuel Pressure Test See: Service Precautions Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment set 07AAJ-S6MA150 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, go to step 5. - If the pump does not run, do the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 52 psi). - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 3006 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Engine idle Idle speed without load M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam) M/T in neutral ....................................................................................................................................... .................................................. 750 ± 50 rpm Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3010 Idle Speed: Testing and Inspection Idle Speed Inspection NOTE: - Leave the idle air control (IAC) valve connected. - Before checking the idle speed, check these items: The malfunction indicator lamp (MIL) has not been reported on. - Ignition timing - Spark plugs - Air cleaner - PCV system - Pull the parking brake lever up. Start the engine, and make sure the headlights are off. 1. Disconnect the evaporative emission (EVAP) canister purge valve 2P connector. 2. Connect a tachometer (A) to the test tachometer connector (B), or connect the HDS or a scan tool to the data link connector (DLC) (C) located under the driver's side of the dashboard. 3. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 4. Check the idle speed with no-load conditions: headlights, blower fan, radiator fan, and air conditioner off. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm 5. Let the engine idle for 1 minute with the heater fan switch on HI and air conditioner on, then check the idle speed. Idle speed should be: .......................................................................................................................... .................................................... 750 ± 50 rpm NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures 6. Reconnect the EVAP canister purge valve 2P connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3015 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Disconnect the PCV hose (A). 2. Open the air cleaner housing cover (B). 3. Remove the air cleaner (C) from the air cleaner housing (D). 4. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 3019 Vacuum Hose Routing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 3020 Auxiliary Air Valve (Idle Speed): Testing and Inspection Intake Air Bypass Control Thermal Valve Test Special Tools Required Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX 1. Start the engine. Then let it idle. NOTE: The engine coolant temperature must be below 149 °F (65 °C). 2. Remove the vacuum hose (A) from the intake air duct, and connect a vacuum pump/gauge to the hose. 3. Raise and lower the engine speed, and make sure the vacuum gauge reading changes as the engine speed changes. 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 thermal valve. 4. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 5. Raise and lower the engine speed, and make sure the vacuum gauge reading does not change as the rpm changes. If the vacuum reading changes, check for these problems: Misrouted, leaking, broken, or clogged intake air bypass control system vacuum lines. - A cracked or damaged intake air bypass control thermal valve. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel required ................................................................................................................. UNLEADED gasoline with Pump Octane Number of 86 or higher Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relieving See: Service Precautions Before disconnecting fuel lines or hoses, relieve pressure from the system by disconnecting the fuel tube/quick connect fitting in the engine compartment. 1. Turn the ignition switch OFF. 2. Remove PGM-FI main relay 2 (A). 3. Start the engine, and let it idle until it is stalls. NOTE: The DTCs or Temporary DTCs P0301, P0302, P0303, P0304 may come on during this procedure. If any DTCs are stored, ignore them. 4. Turn the ignition switch OFF. 5. Remove the fuel fill cap, and relieve fuel pressure in the fuel tank. 6. Remove the engine cover. 7. Disconnect the negative cable from the battery. 8. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 9. Place a rag or shop towel over the quick-connect fitting (A). 10. Disconnect the quick-connect fitting (A): Hold the connector (B) with one hand, and squeeze the retainer tabs (C) with the other hand to release them from the locking tabs (D). Pull the connector off. NOTE: To prevent the remaining fuel in the fuel feed line or hose from flowing out, with a rag or shop towel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3031 - Be careful not to damage the line (E) or other parts. - Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 11. After disconnecting the quick-connect fitting, check it for dirt or damage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Information not supplied by the manufacturer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3036 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3037 PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3038 40. Injectors Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3039 Fuel Injector: Service and Repair Injector Replacement See: Service Precautions 1. Relieve fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the connectors from the injectors (A), disconnect the ground cable (B), and remove the bracket (C). 3. Disconnect the quick-connect fittings (D). 4. Remove the fuel rail mounting nuts (E) from the fuel rail (F) then remove the fuel rail and injectors as an assembly. 5. Remove the injector clip (G) from the injector. 6. Remove the injector from the fuel rail. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3040 7. Coat the new O-rings (A) with clean engine oil, and insert the injectors (B) into the fuel rail (C). 8. Install the injector clip (D). 9. Coat the injector O-rings (E) with clean engine oil 10. Install the injectors into the fuel rail, then install the fuel rail into the intake manifold (G). 11. Install the fuel rail mounting nuts, ground cable, and bracket. 12. Connect the connectors to the injectors. 13. Connect the quick-connect fittings. 14. Turn the ignition switch ON (II), but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel pressure in the fuel line rises. Repeat this two or three times, then check for fuel leakage Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3044 Fuel Line Coupler: Service Precautions Fuel Line/Quick-Connect Fitting Precaution The fuel tube/quick-connect fittings connect the fuel rail (A) to fuel feed hose (B), the fuel feed hose (B) to the fuel line (C), and the fuel tube (D) to the fuel pump assembly (E). When removing or installing the fuel feed hose, fuel pump assembly, or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose, fuel tube, and quick-connect fittings are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures. - The fuel feed hose, fuel tube and quick-connect fittings are not acid-proof; do not touch them 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, fuel tube, and quick-connect fittings, be careful not to bend or twist them excessively. Replace them it they are damaged. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3045 A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Replace the retainer when: - replacing the fuel rail. - replacing the fuel line. - replacing the fuel pump. - replacing the fuel filter - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3046 Fuel Line Coupler: Service and Repair Fuel Line/Quick-Connect Fitting Precaution See: Service Precautions The fuel tube/quick-connect fittings connect the fuel rail (A) to fuel feed hose (B), the fuel feed hose (B) to the fuel line (C), and the fuel tube (D) to the fuel pump assembly (E). When removing or installing the fuel feed hose, fuel pump assembly, or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose, fuel tube, and quick-connect fittings are not heat-resistant; be careful not to damage them during welding or other heat-generating procedures. - The fuel feed hose, fuel tube and quick-connect fittings are not acid-proof; do not touch them 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, fuel tube, and quick-connect fittings, be careful not to bend or twist them excessively. Replace them it they are damaged. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3047 A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Replace the retainer when: - replacing the fuel rail. - replacing the fuel line. - replacing the fuel pump. - replacing the fuel filter - replacing the fuel gauge sending unit. - it has been removed from the line. - it is damaged. Fuel Line/Quick-Connect Fitting Removal 1. Relieve fuel pressure.See: Fuel Pressure/Testing and Inspection 2. Check the fuel quick-connect fittings (A) for dirt, and clean if necessary Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3048 3. Hold the connector (A) with one hand and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily - Do not remove the retainer from the line, once removed, the retainer must be replaced with a new one 4. Check the contact area (A) of the line (B) for dirt and damage - If the surface is dirty, clean it - if the surface is rusty or damaged, replace the fuel pump, fuel filter, fuel feed line. 5. To prevent damaged and keep foreign matter out, cover the disconnected connector and line end with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the line. - Replaced the retainer when: replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel gauge sending unit. - it has been removed from the line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3049 - it is damaged. Fuel Line/Quick-Connect Fitting Installation 1. Check the contact area (A) of the line (B) for dirt and damage, and clean if needed. 2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after: - replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. - replacing the fuel filter. - replacing the fuel gauge sending unit - removing the retainer from the line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3050 3. Before connecting a new fuel tube/quick connect fitting assembly (A), remove the old retainer from the mating line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3051 4. Align the quick connect fittings with the line (A), and align the retainer locking tabs (B) with the connector tabs (C). Then press the quick-connect fittings onto the line until both retainer pawls lock with a clicking sound NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. 5. Make sure the connection is secure and that the tabs are firmly locked into place; check visually and by pulling the connector. 6. Reconnect the negative cable to the battery, and turn the ignition switch ON (II). The fuel pump will run for about 2 seconds, and fuel pressure will rise Repeat 2 or 3 times, and check that there are no fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3055 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement 1. Remove the fuel pump. 2. Remove the fuel pressure regulator (A). 3. Install the part in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations > Page 3059 Fuel Pressure Pulsation Damper: Service and Repair Fuel Pulsation Damper Replacement 1. Relieve the fuel pressure. 2. Remove the engine cover. 3. Remove the fuel rail mounting nuts from the fuel rail. 4. Remove the ground cable (G101). 5. Raise the fuel rail. 6. Place a wrench (A) on the fuel rail (B). 7. Place a wrench (C) on the fuel pulsation damper (D). 8. Remove the pulsation damper. 9. Install the fuel pulsation damper in the reverse order of removal with new washers. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. - If the drain hole (A) of the fuel pulsation damper cover does not face bottom, reinstall it as shown. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure....................................................................................................................................... ..........320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 54 psi). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3064 Fuel Pressure: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F). - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3065 Fuel Pressure: Testing and Inspection Fuel Pressure Test See: Service Precautions Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment set 07AAJ-S6MA150 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the quick-connect fitting (A). Attach the fuel pressure gauge set and fuel pressure gauge. 3. Start the engine and let it idle. - If the engine starts, go to step 5. - If the engine does not start, go to step 4. 4. Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed. The fuel pump should run for 2 seconds when the ignition switch is first turned on. If the pump runs, go to step 5. - If the pump does not run, do the fuel pump circuit troubleshooting. 5. Read the pressure gauge. The pressure should be 320 - 370 kPa (3.3 - 3.8 kgf/sq.cm, 47 - 52 psi). - If the pressure is OK, the test is complete. - If the pressure is out of specification, replace the fuel pressure regulator and the fuel filter, then recheck the fuel pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3069 Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3070 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3071 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3072 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3073 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations > Page 3080 Fuel Return Line: Testing and Inspection Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations > Page 3081 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 3085 Fuel Supply Line: Testing and Inspection Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 3086 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Evaporative Shut Valve > Component Information > Locations EVAP System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Evaporative Shut Valve > Component Information > Locations > Page 3091 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3095 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3096 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07AAA-S0XA100 NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel (A) from the floor. 6. Disconnect the fuel pump 5P connector (B). 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is as specified, go to step 8. - If the voltage is not as specified, check for: an open in the YEL/BLK or BLK wire. - poor ground (G 551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3097 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer does not indicate "F", replace the gauge. - If the pointer indicates "F", inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3098 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the above readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3099 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07AAA-S0XA100 See: Service Precautions 1. Relieve the fuel pressure.See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3100 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install the fuel tank unit in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Fuel Tank Unit: Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3104 92. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Connector Views 139. Fuel Tank Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Idle Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3110 104. IAC Valve Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3111 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve To maintain the proper idle speed, the IAC valve changes the amount of air bypassing the throttle body in response to an electrical signal from the ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3115 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3116 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3117 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3118 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3119 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3124 Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3125 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3126 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3127 Fuel Pump Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3128 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations 47. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3132 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3133 145. PGM-FI Main Relays 1 & 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3134 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI main relay consists of two separate relays. Relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM power to the injectors, and power for relay. Relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is running. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3135 Main Relay (Computer/Fuel System): Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3136 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3141 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3142 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3143 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3147 Throttle Body: Description and Operation Throttle Body The throttle body is a single-barrel side draft type. It houses the TP sensor and the IAC valve. The lower portion of the IAC valve is heated by engine coolant from the cylinder head. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3148 Throttle Body: Testing and Inspection Throttle Body Test NOTE: - Do not adjust the throttle stop screw. It is preset at the factory. - If the malfunction indicator lamp (MIL) has been reported on, check for diagnostic trouble codes (DTCs). 1. With the engine off, check the throttle cable movement. The cable should move without binding or sticking. - If the cable moves OK, go to step 2. - If the cable binds or sticks, check it and its routing. - If the cable is faulty, reroute it or replace it and adjust it, then go to step 2. 2. 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 in the throttle valve at the fully closed position, replace the throttle body. - If the throttle valve and shaft are OK, go to step 3. 3. Connect the HDS or a scan tool to the DLC. 4. Turn the ignition switch ON (II). 5. Check the throttle position with the HDS or a scan tool. The reading should be about 10 % when the throttle is fully closed and about 90 % when the throttle is fully opened. If the throttle position is correct, the throttle body is OK. - If the throttle position is not correct, replace the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal/Installation Throttle Body: Service and Repair Removal/Installation Throttle Body Removal/Installation 1. Remove the intake air duct (A). 2. Disconnect the connectors from the IAC valve (B), EVAP canister purge valve (C), MAP sensor (D), and TP sensor (E). 3. Disconnect the water bypass hoses (F), and plug the water bypass hoses. 4. Disconnect the vacuum hoses (G). 5. Remove the throttle cable (H) and the actuator cable (with cruise control) (I). 6. Remove the throttle body (J). 7. Install the parts in the reverse order of removal with a new gasket (K), then recheck these items: - Do not adjusting the throttle stop screw (L). - Do the ECM idle learn procedure after throttle body has been replaced. - Refill the radiator with engine coolant. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal/Installation > Page 3151 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations Intake Air System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 3155 Throttle Cable/Linkage: Adjustments Throttle Cable Adjustment 1. Check cable free play at the throttle linkage. Cable free play (A) should be 10-12 mm (3/8-1/2 in.). 2. If the free play is not within spec (10-12 mm, 3/8-1/2 in.), loosen the locknut (B), turn the adjusting nut (C) until the free play is as specified, then retighten the locknut. 3. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 3156 Throttle Cable/Linkage: Service and Repair Throttle Cable Removal/Installation 1. Fully open the throttle valve, then remove the throttle cable (A) from the throttle link (B). 2. Remove the cable housing (C) from the cable bracket (D). 3. Remove the throttle cable (A) from the accelerator pedal (B). 4. Install in the reverse order of removal. 5. After installing, start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator fan comes on, then let it idle. 6. Hold the cable, removing all slack from it. 7. Set the locknut on the cable bracket (A). Turn the adjusting nut (B) so that its free play is 0 mm. 8. Position the adjusting nut on the other side of the bracket (A), then tighten the locknut (C). 9. With the cable properly adjusted, check the throttle valve to be sure it opens fully when you push the accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you release the accelerator pedal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3160 7. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3161 112. TP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3162 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM. The TP sensor is not replaceable apart from the throttle body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3174 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3175 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3176 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3177 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3180 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3181 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3182 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3186 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3187 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3188 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 3191 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 3192 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams 105. Ignition Coils Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3196 Ignition Coil: Service and Repair Ignition Coil Removal/Installation 1. Remove the ignition coil cover (A), disconnect the ignition coil connectors (B), then remove the ignition coils (C). 2. Install the ignition coils in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3200 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3201 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3202 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3203 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3208 VTEC/VTC - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3209 6. Left Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3210 Camshaft Position Sensor: Diagrams 97. CMP Sensor 111. TDC Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3211 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B The CMP sensor B detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement Camshaft Position Sensor: Service and Repair CMP Pulse Plate Replacement A Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. 3. Remove the camshaft position (CMP) pulse plate A. 4. Install the CMP pulse plate A in the reverse order of removal. B Replacement 1. Remove the cylinder head cover. 2. Hold the camshaft with an open-end wrench, then loosen the bolt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3214 3. Remove the camshaft position (CMP) pulse plate B. 4. Install the CMP pulse plate B in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3215 Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor (A) 3P connector. 3. Remove CMP sensor from the intake camshaft side of the cylinder head. 4. Install the sensor (A) in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Pulse Plate Replacement > Page 3216 Camshaft Position Sensor: Service and Repair CMP Sensor B Replacement CMP Sensor B Replacement 1. Remove the air cleaner. 2. Disconnect CMP sensor B 3P connector. 3. Remove CMP sensor B (A) from the exhaust camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3220 16. Lower Right Side of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3221 96. CKP Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3222 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed and determines ignition timing and timing for fuel injection of each cylinder as well as detecting engine misfire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement Crankshaft Position Sensor: Service and Repair CKP Pulse Plate Replacement CKP Pulse Plate Replacement 1. Remove the front tires/wheels. 2. Remove the splash shield. 3. Remove the drive belt. 4. Remove the cylinder head cover. 5. Remove the crankshaft pulley. 6. Disconnect the crankshaft position (CKP) sensor connector and variable valve timing control (VTC) oil control solenoid valve connector. 7. Remove the VTC oil control solenoid valve. 8. Support the engine with a jack and wood block under the oil pan. 9. Remove the ground cable, and remove the upper bracket. 10. Remove the side engine mount bracket. 11. Remove the chain case. 12. Remove the CKP pulse plate. 13. Install the CKP pulse plate. 14. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal. 15. Remove old liquid gasket from the chain case mating surfaces, bolt and bolt holes. 16. Clean and dry the chain case mating surfaces. 17. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes. 18. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case. 19. Apply liquid gasket, P/N 08718-0009, evenly to the oil pan mating surface of the chain case and to the inner threads of the holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. 20. Install the new 0-ring on the chain case. Set the edge of the chain case to the edge of the oil pan, then install the chain case on the cylinder block. NOTE: When installing the chain case, do not slide the bottom surface on the oil pan mounting surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 3225 21. Install the side engine mount bracket. 22. Install the upper bracket and the ground cable. 23. Install the VTC oil control solenoid valve. 24. Connect the CKP sensor connector and VTC oil control solenoid valve connector. 25. Install the crankshaft pulley. 26. Install the cylinder head cover. 27. Install the drive belt. 28. Install the splash shield. 29. Install the front tires/wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP Pulse Plate Replacement > Page 3226 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement CKP Sensor Replacement 1. Disconnect the CKP sensor 3P connector. 2. Remove the CKP sensor (A). 3. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3232 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3233 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3234 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3235 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3236 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3237 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3238 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3239 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3240 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System Unable To Key In Ignition Switch > Page 3241 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3245 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3246 7. Knock Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3247 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3248 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the intake manifold bracket (A). 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (B). 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3252 Ignition System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3253 Spark Plug: Application and ID NGK ..................................................................................................................................................... ............................................................... IZFR6K-11 DENSO ................................................................................................................................................ ......................................................... SKJ20DR-M11 Gap ...................................................................................................................................................... ................................. 1.0 -1.1 mm (0.039 - 0.043 in) Torque ................................................................................................................................................. ...................................................... 18 N.m (13 lb.ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3254 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator. - Burned or worn electrodes may be caused by: Advanced ignition timing - Loose spark plug - Plug heat range too hot - Insufficient cooling - Fouled plug may be caused by: Retarded ignition timing - Oil in combustion chamber - Incorrect spark plug gap - Plug heat range too cold - Excessive idling/low speed running - Clogged air cleaner element - Deteriorated ignition coils 2. Do not adjust the gap of indium tip plugs (A); replace the spark plug if the gap is out of specification. 3. Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark plugs as listed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3255 4. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head, finger-tight. Then torque them to 18 N.m (1.8 kgf.m, 13 lbf.ft). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Tachometer Connector > Component Information > Diagrams 73. Test Tachometer Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3270 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3271 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3277 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3278 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3292 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3293 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3299 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3300 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 PROM - Programmable Read Only Memory: Customer Interest A/T - Vehicle Won't Move/MIL ON/DTC P0730 04-036 January 7, 2005 Applies To: See VEHICLES AFFECTED Vehicle Does Not Move in Drive; MIL Comes On or D Indicator Blinks With A/T DTC P0730 (Supersedes 04-036, dated September 24, 2004) SYMPTOM The vehicle does not move when you select Drive. The MIL comes on ('01-03 models) or the D indicator blinks ('04 models) with "A" DTC P0730 (shift control system) set. PROBABLE CAUSE Excessive wear in the 2nd clutch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the A/T. Use the Honda Interface Module (HIM) to update the PGM software ('01-03 models only). TOOL INFORMATION To do the repair procedure, you need these items: ^ Interactive Network (iN) CD (July '04 or later) ^ iN Workstation ^ Honda Interface Module (HIM): T/N EQS05A35570 ^ PC Interface Cable (RS232): T/N VET-02002832 [This is the same cable you use to connect the PCM Tester to the iN workstation when updating software or when downloading DTCs to American Honda. The cable is blue with an attached adapter.] ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N VET-02002426 (This is the same adapter used by the PGM Tester.) To order additional HIMs, interface cables, or A/C adapters, call the Honda Tool and Equipment Program or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m., Central Time. You can also order through the iN. Click on SERVICE, Service Bay, and then Tool and Equipment, or click on eMail and then Tool and Equipment Program. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 3313 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 3314 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Updating Control Units And Modules 01-023 April 10, 2010 Applies To: Honda Vehicles With Programmable Control Units/Modules Updating Control Units/Modules (Supersedes 01-023, dated May 15, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^Under REQUIRED TOOLS AND EQUIPMENT, the MVCI was added. ^ Under UPDATING TIPS AND PRECAUTIONS MVCI information was added. ^ UPDATING WITH THE MVCI was added.* The procedures in this service bulletin are used and referenced in other service bulletins. Most 2002 and later Hondas have reprogrammable control units/modules. To update (reprogram) any of these control units/modules, you need the vehicle you're working on and one of these systems: *^MVCI unit with latest control module (CM) update software installed* ^ GNA600 gateway device and an iN workstation with the latest HDS software installed ^ HDS Tablet with the latest HDS software installed ^ HDS Pocket Tester with the latest HDS software installed ^ HIM and an iN workstation with the latest HDS software installed ^ A compatible J2534 device and a PC with Honda's J2534 software installed This service bulletin describes these subjects: ^ Who to contact for questions or problems when using Honda-supplied updating equipment or the iN. ^ Required Tools and Equipment - MVCI - GNA600 - HDS Tablet - HDS Pocket Tester - HIM ^ Updating Tips and Precautions ^ Updating with the MVCI ^ Updating with the GNA600 - GNA6OO Updating in Pass-Thru Mode - GNA6OO Updating in Storage Mode ^ Updating with the HDS Tablet and the HDS Pocket Tester Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3320 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3321 *MVCI: (Available through the Honda Tool and Equipment Program)* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3322 GNA600: (No longer available for purchase) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3323 HDS Tablet: HDS Pocket Tester: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3324 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3325 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3326 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3327 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3328 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3329 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3330 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3331 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3332 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3333 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3334 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3335 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3336 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3337 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3338 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3339 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3340 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3341 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3342 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Vehicle Won't Move/MIL ON/DTC P0730 04-036 January 7, 2005 Applies To: See VEHICLES AFFECTED Vehicle Does Not Move in Drive; MIL Comes On or D Indicator Blinks With A/T DTC P0730 (Supersedes 04-036, dated September 24, 2004) SYMPTOM The vehicle does not move when you select Drive. The MIL comes on ('01-03 models) or the D indicator blinks ('04 models) with "A" DTC P0730 (shift control system) set. PROBABLE CAUSE Excessive wear in the 2nd clutch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the A/T. Use the Honda Interface Module (HIM) to update the PGM software ('01-03 models only). TOOL INFORMATION To do the repair procedure, you need these items: ^ Interactive Network (iN) CD (July '04 or later) ^ iN Workstation ^ Honda Interface Module (HIM): T/N EQS05A35570 ^ PC Interface Cable (RS232): T/N VET-02002832 [This is the same cable you use to connect the PCM Tester to the iN workstation when updating software or when downloading DTCs to American Honda. The cable is blue with an attached adapter.] ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N VET-02002426 (This is the same adapter used by the PGM Tester.) To order additional HIMs, interface cables, or A/C adapters, call the Honda Tool and Equipment Program or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m., Central Time. You can also order through the iN. Click on SERVICE, Service Bay, and then Tool and Equipment, or click on eMail and then Tool and Equipment Program. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 3347 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 3348 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Updating Control Units And Modules 01-023 April 10, 2010 Applies To: Honda Vehicles With Programmable Control Units/Modules Updating Control Units/Modules (Supersedes 01-023, dated May 15, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^Under REQUIRED TOOLS AND EQUIPMENT, the MVCI was added. ^ Under UPDATING TIPS AND PRECAUTIONS MVCI information was added. ^ UPDATING WITH THE MVCI was added.* The procedures in this service bulletin are used and referenced in other service bulletins. Most 2002 and later Hondas have reprogrammable control units/modules. To update (reprogram) any of these control units/modules, you need the vehicle you're working on and one of these systems: *^MVCI unit with latest control module (CM) update software installed* ^ GNA600 gateway device and an iN workstation with the latest HDS software installed ^ HDS Tablet with the latest HDS software installed ^ HDS Pocket Tester with the latest HDS software installed ^ HIM and an iN workstation with the latest HDS software installed ^ A compatible J2534 device and a PC with Honda's J2534 software installed This service bulletin describes these subjects: ^ Who to contact for questions or problems when using Honda-supplied updating equipment or the iN. ^ Required Tools and Equipment - MVCI - GNA600 - HDS Tablet - HDS Pocket Tester - HIM ^ Updating Tips and Precautions ^ Updating with the MVCI ^ Updating with the GNA600 - GNA6OO Updating in Pass-Thru Mode - GNA6OO Updating in Storage Mode ^ Updating with the HDS Tablet and the HDS Pocket Tester Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3354 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3355 *MVCI: (Available through the Honda Tool and Equipment Program)* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3356 GNA600: (No longer available for purchase) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3357 HDS Tablet: HDS Pocket Tester: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3358 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3359 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3360 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3361 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3362 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3363 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3364 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3365 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3366 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3367 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3368 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3369 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3370 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3371 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3372 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3373 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3374 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3375 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-023 > Apr > 10 > Computers/Controls - Updating Control Units And Modules > Page 3376 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Avoiding Fluid Contamination Fluid - A/T: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Fixing Banjo Bolt Leaks Fluid Line/Hose: Technical Service Bulletins A/T - Fixing Banjo Bolt Leaks SOURCE: Honda Service News TITLE: Fixing A/T Banjo Bolt Leaks APPLIES TO: All models SERVICE TIP: Got ATF leaking from any of the A/T banjo bolts? The first thing you need to do is replace the sealing washers. Next, start threading the banjo and line bracket bolts in their holes. Finally, torque the banjo bolt to 31 Nm (22 lb-ft) and the line bracket bolt to 9.8 Nm (7.2 lb-ft.). NOTE: The banjo bolt torque spec we're recommending is slightly higher than what's listed in the S/M. This is intentional. If you torque just the banjo bolt, you won't really fix the leak. ATF leaks at the banjo bolt stem from the line bracket getting tightened before the banjo bolt. This can misalign the banjo joint, causing the banjo bolt sealing washers not to contact their mating surfaces evenly. Once the sealing washers have been used, you must replace them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3396 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3397 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3403 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3404 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Do Not Remove Torque Converter From Mainshaft Torque Converter: Technical Service Bulletins A/T - Do Not Remove Torque Converter From Mainshaft SOURCE: Honda Service News TITLE: Keep Torque Converter on Mainshaft to Avoid Damage APPLIES TO: All models SERVICE TIP: We can't emphasize enough how important it is to keep the torque converter in place when you're handling or installing a reman A/T. If the torque converter slips off the mainshaft, and you don't put it back on the shaft exactly right, you could cut the O-ring. This could result in loss of lock-up control and ATF leakage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3417 Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Equipment Information 89-022 May 16, 2008 Applies To: Vehicles With an In-Radiator ATF Cooler - ALL ATF Cooler Cleaner (Supersedes 89-022, dated June 18, 2004, to update the information marked by asterisks) Before installing an overhauled or remanufactured A/T, you must thoroughly clean the ATF cooler to prevent system contamination. Failure to do so could cause a repeat A/T failure. The ATF Cooler Cleaner (PIN GTHTTCF6H) is a portable, electrically operated special tool that cleans the ATF cooler with high- pressure, heated ATF. This cleaning action melts down waxy varnish residue left by burnt ATF and purges metal particles, clutch material, and other contaminants. The ATF Cooler Cleaner has these features: ^ Quick-connect fittings and color-coded hoses for easy hookup. ^ Uses about 9.5 gallons of Honda ATF-Z1, which gets filtered and recirculated. ^ Heats ATF to a temperature of 1400 to 150°F and then pumps it through the ATF cooler at high pressure (100 psi) using a pulsating action and air purging. Switching the hoses cleans the ATF cooler in the reverse direction. ^ Two magnetic nonbypass spin-on filters to trap purged contaminants. ^ Built-in tool tray. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire ATF cooler cleaning process. *REQUIRED MATERIALS Honda ATF-Z1: P/N 08200-9001 Magnetic Nonbypass Spin-On Filter: T/N GTHNBP12 (12-pack) T/N GTHNBP2 (6-pack) T/N GTHGNBP22 (2-pack) ORDERING INFORMATION Additional ATF cooler cleaners or magnetic nonbypass spin-on filters can be ordered through the Honda Tool and Equipment Program. To order on the iN, click on SERVICE, then Service Bay, then Tool and Equipment Program. From the Tool and Equipment Program menu, click on the Online Catalog tab, and then search for the desired filter pack by part number.* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3418 TOOL DESCRIPTION CLEANING PROCEDURE The cleaning procedure involves hot fluid under high pressure. Check the security of all hoses and connections. Always wear safety glasses or a face shield, gloves, and protective clothing. If you get ATF in your eyes or on your skin, rinse with water immediately. Improper use of the ATF cooler cleaner can result in burns and other serious injuries. Always wear eye protection and protective clothing, and follow all instructions in this bulletin. 1. Plug the ATF cooler cleaner into a 110 V grounded electrical outlet. NOTICE Make sure the outlet has no other appliances (light fixtures, drop lights, extension cords) plugged into it. Also, never plug the cooler cleaner into an extension cord or drop light cord; you would damage the unit. 2. Flip the HEAT toggle switch to ON. Wait 1 hour for the cooler cleaner to reach its operating temperature. (The cooler cleaner is ready to use when the temperature gauge reads 140° to 150°F.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3419 3. Connect the appropriate fittings to the ATF cooler inlet and outlet lines. Connect the red hose to the cooler outlet line (the line going to the external filter). Connect the blue hose to the cooler inlet line. 4. Connect a shop air hose to the air purge valve. NOTICE The quick connect fitting has a one-way check valve to keep ATF from entering your shop's air system. Do not remove or replace the fitting. Attach the coupler provided with the cooler cleaner to your shop air line if your coupler is not compatible. 5. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically to cause agitation and improve the cleaning process. 6. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 7. Disconnect the red and blue hoses from the ATF cooler, then connect the red hose to the cooler inlet line. 8. Connect the blue hose to the cooler outlet line. 9. Flip the MOTOR toggle switch to ON, and let the pump run for 5 minutes. While the pump is running, open and close the air purge valve periodically. 10. Flip the MOTOR toggle switch to OFF with the air purge valve open. Leave the air purge valve open for at least 15 seconds to purge the lines of residual ATF. 11. Disconnect the red and blue hoses from the ATF cooler lines. Connect the red and blue hoses to each other. 12. Disconnect the shop air from the air purge valve. Disconnect and stow the coupler if used. 13. Disconnect and stow the fittings from the ATF cooler inlet and outlet lines. 14. Unplug the cooler cleaner from the 110 V outlet. TOOL MAINTENANCE Follow these instructions to keep the ATF cooler cleaner working properly: *^ Replace the two magnetic nonbypass spin-on filters every 20 hours, based on hour meter reading. For more information on filter replacement, see the January 2008 Honda ServiceNews article, Hour Meter Tells You When to Replace ATF Cooler Cleaner Filters.* ^ Fill the tank so the ATF is 4.5 inches from the top of the filler hole; do not overfill. NOTE: If the fluid level is low, the red indicator above the HEAT toggle switch comes on and the tank heater will not work. ^ Replace the ATF in the tank when it looks dark or dirty. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3420 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3421 Transmission Cooler: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3422 Transmission Cooler: Technical Service Bulletins A/T - Leak From Cooler Line Banjo Bolt SOURCE: Honda Service News December 2003 TITLE: ATF Leaks From Cooler Line Banjo Bolt APPLIES TO: 1998-04 Accords, 2001-04 Civics, 1997-04 CR-Vs, 1999-04 Odysseys, 2003-04 Pilots SERVICE TIP: The banjo bolts and sealing washers on the ATF cooler lines are delicate and can be easily damaged if the line or the banjo bolt gets hit. Any movement of the line or the banjo bolt crushes the two sealing washers and lets ATF leak past the seals. Before you install an A/T or try finding an ATF leak, check the banjo bolt torque on the ATF cooler lines. If a banjo bolt is loose, remove the bolt along with the sealing washers. And if the cooler line has a bracket, remove that bolt too. Inspect the sealing surface on the A/T housing. If the surface is OK, reinstall the banjo bolt with new sealing washers, and torque the bolt to 28 Nm (21 lb-ft). Reinstall the bolt for the line bracket (if applicable), and torque the bolt to 9.8 Nm (7.2 lb-ft). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3431 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3432 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3438 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3439 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications Clutch Disc Rivet Head Depth Standard or New ................................................................................................................................................. 1.65 2.25 mm (0.065 - 0.089 inch) Service Limit ......................................................................................... ........................................................................................ 0.7 mm (0.03 inch) Thickness Standard or New ......................................................................................................................................................... 8.3 - 8.9 mm (0.33 - 0.35 inch) Service Limit ....................................................................................... .......................................................................................... 6.0 mm (0.24 inch) Clutch Friction Material Surface Area ............................................................................................................................................. 174 cm2 (26.97 sq inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal Clutch Disc: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment disc 07JAF-PM7011A ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Clutch alignment shaft 07ZAF-PR8A100 ^ Remover handle 07936-3710100 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tool and feeler gauge. If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 0.8 mm (0.03 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). 4. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3450 5. Inspect the pressure plate (A) surface for wear, cracks, and burning. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): 8.3 - 8.9 mm (0.33 - 0.35 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3451 Service Limit: 6.0 mm (0.24 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) Service Limit: 0.7 mm (0.03 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3452 Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Disc and Pressure Plate Installation 1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft. 2. Install the ring gear holder. 3. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 4. Install the pressure plate (A) and the mounting bolts (B) finger-tight. 5. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. PRESSURE PLATE MOUNTING BOLT TORQUE: 25 Nm (2.6 kgf-m, 19 ft. lbs.) 6. Remove the special tools. 7. Make sure the diaphragm spring fingers are all the same height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid type ................................................................................................................................................ Always use only Honda DOT 3 brake fluid Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel Clutch Master Cylinder: Customer Interest M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3465 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3466 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3467 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel Clutch Master Cylinder: All Technical Service Bulletins M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3473 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3474 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3475 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 3476 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C). 2. Remove the air cleaner housing cover and the air cleaner housing. 3. Remove the brake fluid from the clutch master cylinder reservoir with a syringe. 4. Remove the clutch line bracket from the frame rail, and remove the clutch line clip. 5. Remove the clutch master cylinder (A), and pull it toward the middle of the engine compartment. Remove the retaining clip (B). Disconnect the clutch line (C). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out. 6. Disconnect the reservoir hose (D) from the clutch master cylinder reservoir. Plug the end of the reservoir hose with a shop towel to prevent brake fluid from coming out. 7. Remove the O-ring (E) and the clutch master cylinder seal (F) from the master cylinder. 8. Install the clutch master cylinder in the reverse order of removal. Install a new O-ring. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 3477 9. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown. 10. To prevent the retaining clip (A) from coming off, pry open the tip of the retaining clip (B) with a screwdriver. 11. Tighten the master cylinder mounting nuts to 13 Nm (1.3 kgf-m, 9.4 ft. lbs.). 12. Bleed the clutch master hydraulic system. NOTE: The reservoir filling is covered in the bleeding procedure. 13. Install the air cleaner housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Slave Cylinder Replacement NOTE: ^ Use fender covers to avoid damaging painted surfaces. ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Write down the frequencies for the radio's preset buttons. Disconnect the negative (-) cable first, then the positive (+) cable from the battery. Remove the battery. 2. Remove the battery tray. 3. Remove the air cleaner housing cover and the air cleaner housing. 4. Remove the intake air duct. 5. Remove the clutch line bracket (A). 6. Remove the mounting bolts (A) and the slave cylinder (B). 7. Remove the roll pins (C). Disconnect the clutch line (D), and remove the O-ring (E). Plug the end of the clutch line with a shop towel to prevent brake fluid from coming out. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 3481 8. Install the slave cylinder in the reverse order of removal. Install a new O-ring (A). 9. Pull the boot (B) back, and apply brake assembly lube to the boot and slave cylinder rod (C). Reinstall the boot. 10. Apply super high temp urea grease (P/N 08798-9002) to the push rod of the slave cylinder. Tighten the slave cylinder mounting bolts to 22 Nm (2.2 kgf-m, 16 ft. lbs.). 11. Bleed the clutch hydraulic system. ^ Attach a hose to the bleeder screw (A), and suspend the hose in a container of brake fluid. ^ Make sure there is an adequate supply of fluid in the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose. ^ It may be necessary to limit the 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 Nm (0.8 kgf-m, 6 ft. lbs.); do not overtighten it. ^ Refill the clutch master cylinder with fluid when done. ^ Always use only Honda DOT 3 brake fluid. 12. Make sure the fluid level in the reservoir is at the MAX (upper) level line (A). 13. Install the intake air duct. 14. Install the air cleaner housing. 15. Install the battery tray. 16. Install the battery, connect the positive (+) cable first, then the negative (-) cable. 17. Reset the frequencies for the radio station preset buttons. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel Hydraulic Hose: Customer Interest M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3490 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3491 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3492 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel Hydraulic Hose: All Technical Service Bulletins M/T - Clutch Pedal Squeak/Twang or Notchy Feel 02-002 January 11, 2005 Applies To: See VEHICLES AFFECTED Squeak at the Clutch Pedal (Supersedes 02-002, dated September 21, 2004) SYMPTOM A squeak, a twang, or a notchy feel when the clutch pedal is pressed. PROBABLE CAUSE The clutch master cylinder spring is rubbing on the outer diameter of the piston when the pedal is pressed, or the master cylinder quick connect is moving. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3498 VEHICLES AFFECTED CORRECTIVE ACTION Replace the master cylinder, and apply a thin film of silicone grease to the clutch line fitting. REQUIRED MATERIALS Silicone Grease: P/N 08C30-B0234M, H/C 6110928 Brake Fluid: P/N 08798-9008, H/C 4423802 PARTS INFORMATION Civic/Civic Hybrid Master Cylinder: P/N 46920-S5A-G04, H/C 7569452 Accord/Civic Si/CR-V/Element Master Cylinder: P/N 46920-57A-A02, H/C 7604507 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 211101 Flat Rate Time: 0.6 hour (All Civics) 0.8 hour (Accord/CR-V/Element) Failed Part: Civic/Civic Hybrid: P/N 46920-55A-G01 H/C 6571103 Accord/Civic Si/CR-V/Element: P/N 46920-S7A-A01 H/C 6729031 Defect Code: 03214 Symptom Code: 04201 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3499 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Have an assistant press the clutch pedal while you grasp the clutch line at the clutch master cylinder, and then at the slave cylinder. If you feel a vibration through the clutch line when you hear the noise or the noise stops, go to REPAIR PROCEDURE. If you feel no vibration or the noise does not stop, look for other causes. REPAIR PROCEDURE NOTICE Do not spill brake fluid on the vehicle; it may damage the paint. If brake fluid does contact the paint, wash it off immediately with water. 1. Remove the clutch master cylinder. Refer to the appropriate service manual: 2003-04 Accord (L4): page 12-6 2003-04 Accord (V6): page 12-8 2001-04 Civic: page 12-5 2002-04 Civic Si: page 12-5 2003-04 Civic Hybrid: page 13-5 2002-04 CR-V: page 12-5 2003-04 Element: page 12-6 Enter keyword CLUTCH MASTER, and select Clutch Master Cylinder Replacement from the list. 2. Install the new clutch master cylinder, but do not attach the clutch line fitting. 3. Apply a thin coat of silicone grease to the clutch line fitting and to the opening in the clutch master cylinder. Do not use silicone spray; it could damage the 0-ring. 4. Connect the clutch line fitting to the clutch master cylinder. 5. Bleed the clutch hydraulic system, then top off the reservoir with brake fluid. 6. Check to see if the noise is gone when pressing the clutch pedal. ^ If the noise is gone, the repair is complete. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3500 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch Pedal: Height from the floor ............................................................................................................................ .............................................. 193 mm (7.60 inch) Stroke ................................................................... ............................................................................................................... 130 - 140 mm (5.1 - 5.5 inch) Play ............................................................................................................................................. ........................................ 10 - 16 mm (0.39 - 0.63 inch) Disengagement height from the floor .............................................................................................................................................. 115 mm (4.53 inch) min. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 3504 Clutch Pedal Assembly: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C). 2. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. To measure the pedal height to the floor, remove the driver's footrest, and measure to where it mounts to the floor. Clutch Pedal Stroke: 130 - 140 mm (5.12 - 5.51 inch) Clutch Pedal Free Play: 10 - 16 mm (0.39 - 0.63 inch) Clutch Pedal Height to floor: 193 mm (7.60 inch) to carpet: 155 mm (6.10 inch) Disengagement Height to floor: 115 mm (4.53 inch) to carpet: 77 mm (3.08 inch) 3. Tighten the clutch pushrod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C). 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten the clutch pedal position switch locknut (A). 7. Loosen locknut (J) and the clutch interlock switch (K). 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 10 - 16 mm (0.39 - 0.63 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 3508 Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 3509 27. Clutch Interlock Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 3510 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install the clutch interlock switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 3511 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C). 2. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. To measure the pedal height to the floor, remove the driver's footrest, and measure to where it mounts to the floor. Clutch Pedal Stroke: 130 - 140 mm (5.12 - 5.51 inch) Clutch Pedal Free Play: 10 - 16 mm (0.39 - 0.63 inch) Clutch Pedal Height to floor: 193 mm (7.60 inch) to carpet: 155 mm (6.10 inch) Disengagement Height to floor: 115 mm (4.53 inch) to carpet: 77 mm (3.08 inch) 3. Tighten the clutch pushrod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C). 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten the clutch pedal position switch locknut (A). 7. Loosen locknut (J) and the clutch interlock switch (K). 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 10 - 16 mm (0.39 - 0.63 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement 1. Remove the release fork boot (A) from the clutch housing (B). 2. Remove the release fork (C) from the clutch housing (B) by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E). 3. Check the release bearing for play and noise by spinning it by hand. If there is excessive play or noise, replace the release bearing with a new one. NOTE: The release bearing is packed with grease. Do not wash it in solvent. 4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas. 5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing. 6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely. Make sure the release fork set spring (F) is properly set. 7. Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Page 3515 8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Torque Specifications Pressure Plate: Specifications Torque Specifications Mounting Bolts ..................................................................................................................................... ........................................................ 25 Nm (19 lbft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Torque Specifications > Page 3520 Pressure Plate: Specifications Standards and Service Limits Pressure Plate Warpage Standard or New .................................................................................................................................. ............................. 0.03 mm (0.001 inch) max. Service Limit .............................................................. ............................................................................................................... 0.15 mm (0.001 inch) Height Of Diaphragm Spring Fingers Standard or New .................................................................................................................................. ................................. 0.6 mm (0.02 inch) max. Service Limit .............................................................. ................................................................................................................... 0.8 mm (0.03 inch) NOTE: Height of diaphragm spring fingers measured with special tool and feeler gauge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal Pressure Plate: Service and Repair Pressure Plate and Clutch Disc Removal Clutch Replacement Special Tools Required ^ Clutch alignment disc 07JAF-PM7011A ^ Ring gear holder 07LAB-PV00100 or 07924-PD20003 ^ Clutch alignment shaft 07ZAF-PR8A100 ^ Remover handle 07936-3710100 Pressure Plate and Clutch Disc Removal 1. Check the diaphragm spring fingers for height using the special tool and feeler gauge. If the height is more than the service limit, replace the pressure plate. Standard (New): 0.6 mm (0.02 inch) max. Service Limit: 0.8 mm (0.03 inch) 2. Install the special tools. 3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B). 4. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3523 5. Inspect the pressure plate (A) surface for wear, cracks, and burning. 6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch) 7. Remove the clutch disc and special tools. 8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it. 9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. Standard (New): 8.3 - 8.9 mm (0.33 - 0.35 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3524 Service Limit: 6.0 mm (0.24 inch) 10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) Service Limit: 0.7 mm (0.03 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Pressure Plate and Clutch Disc Removal > Page 3525 Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Installation Clutch Disc and Pressure Plate Installation 1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft. 2. Install the ring gear holder. 3. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools. 4. Install the pressure plate (A) and the mounting bolts (B) finger-tight. 5. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. PRESSURE PLATE MOUNTING BOLT TORQUE: 25 Nm (2.6 kgf-m, 19 ft. lbs.) 6. Remove the special tools. 7. Make sure the diaphragm spring fingers are all the same height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > A/T - Avoiding Fluid Contamination Fluid - CVT: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Line/Hose, CVT > Component Information > Technical Service Bulletins > A/T - Fixing Banjo Bolt Leaks Fluid Line/Hose: Technical Service Bulletins A/T - Fixing Banjo Bolt Leaks SOURCE: Honda Service News TITLE: Fixing A/T Banjo Bolt Leaks APPLIES TO: All models SERVICE TIP: Got ATF leaking from any of the A/T banjo bolts? The first thing you need to do is replace the sealing washers. Next, start threading the banjo and line bracket bolts in their holes. Finally, torque the banjo bolt to 31 Nm (22 lb-ft) and the line bracket bolt to 9.8 Nm (7.2 lb-ft.). NOTE: The banjo bolt torque spec we're recommending is slightly higher than what's listed in the S/M. This is intentional. If you torque just the banjo bolt, you won't really fix the leak. ATF leaks at the banjo bolt stem from the line bracket getting tightened before the banjo bolt. This can misalign the banjo joint, causing the banjo bolt sealing washers not to contact their mating surfaces evenly. Once the sealing washers have been used, you must replace them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3544 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3545 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3551 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3552 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Torque Converter, CVT > Component Information > Technical Service Bulletins > A/T - Do Not Remove Torque Converter From Mainshaft Torque Converter: Technical Service Bulletins A/T - Do Not Remove Torque Converter From Mainshaft SOURCE: Honda Service News TITLE: Keep Torque Converter on Mainshaft to Avoid Damage APPLIES TO: All models SERVICE TIP: We can't emphasize enough how important it is to keep the torque converter in place when you're handling or installing a reman A/T. If the torque converter slips off the mainshaft, and you don't put it back on the shaft exactly right, you could cut the O-ring. This could result in loss of lock-up control and ATF leakage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information Transmission Cooler: Technical Service Bulletins A/T - ATF Cooler Cleaner Information Use Worm-Style Clamps With the ATF Cooler Cleaner The spring-style clamps used on the ATF cooler lines are made to hold the cooler lines to the ATF cooler under normal operating conditions. The ATF Cooler Cleaner (P/N GHTTTCF6H) uses high pressure (100 psi) to do its job. With the pump motor running, the spring-style clamps can walk off or disconnect, and you'll wind up with a real mess to clean up in your shop. In March of this year, we sent each Honda dealership a pair of high-quality worm-style clamps to replace the original spring-style clamps. These clamps were part of a cooler cleaner update kit, and securely hold the cooler line in place. They've got a blue cap for easy identification. Need some more? Just call G-TFC, Inc. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Technical Service Bulletins > A/T - ATF Cooler Cleaner Information > Page 3565 Transmission Cooler: Technical Service Bulletins A/T - Avoiding Fluid Contamination SOURCE: Honda Service News TITLE: Avoiding Comebacks From A/T Contamination APPLIES TO: All models SERVICE TIP: Installing a reman A/T? Here are some important tips to keep in mind to ensure a first-time fix and to avoid any come-backs: - If the vehicle has an ATF cooler, make sure you clean the cooler with the ATF Cooler Cleaner (P/N GHTTTCF6H). See S/B 89-022, ATF Cooler Cleaner, for details. - If the reman A/T kit includes an in-line filter, don't forget to install it. If the vehicle already has an in-line filter from an earlier A/T replacement, then remove the existing filter, and install the new one. - Spray the driveshaft splines with solvent and compressed air before installing them in the reman A/T. If the failed A/T had a speed sensor, make sure it's clean before you install it. Debris from the failed A/T can catch in the driveshaft splines or on the speed sensor and contaminate the reman A/T. - If the reman A/T comes with a heater/cooler, make sure you install the reman A/T with that heater/cooler. Never install the heater/cooler from the failed A/T; you could contaminate the reman A/T. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3574 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3575 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3581 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3582 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Page 3591 Axle Shaft Assembly: Diagrams Driveshafts Reassembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Page 3592 Intermediate Shaft Reassembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection Axle Shaft Assembly: Service and Repair Driveshaft Inspection Driveshaft Inspection 1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking grease, and loose boot bands (D). If any damage is found, replace the boot and boot bands. 2. Turn the driveshaft by hand, and make sure the splines (E) and joint are not excessively loose. 3. Make sure the driveshaft is not twisted or cracked; if it is, replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3595 Axle Shaft Assembly: Service and Repair Driveshafts Removal Driveshafts Removal Special Tool Required ^ Ball 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. 3. Remove the wheel nuts and front wheels. 4. Lift up the locking tab (A) on the spindle nut (B), then remove the nut. 5. If the left driveshaft or the intermediate shaft is to be removed, drain the transmission fluid. Reinstall the drain plug using a new washer. 6. Hold the stabilizer ball joint pin (A) with a hex wrench (B), and remove the flange nut (C). Separate the front stabilizer link (D) from the lower arm. 7. Remove the lock pin (A) from the lower arm ball joint castle nut (B), and remove the nut. NOTE: ^ To avoid damaging the ball joint, install a hex nut on to the threads of the ball joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3596 ^ Be careful not to damage the ball joint boot when installing the remover. 8. Separate the ball joint from the lower arm (C) with the special tool. 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. 10. Left driveshaft: Pry the inboard joint (A) from the differential case with a prybar. Right driveshaft: Drive the inboard joint (A) off of the intermediate shaft with a drift and hammer. Remove the driveshaft as an assembly. Do not pull on the driveshaft (B), because the inboard joint may come apart. Draw the driveshaft straight out to avoid damaging the oil seal. Left driveshaft Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3597 Right driveshaft Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3598 Axle Shaft Assembly: Service and Repair Driveshafts Disassembly Driveshafts Disassembly Special Tools Required ^ Threaded adapter, 22 x 1.5 mm 07XAC-001010A ^ Slide hammer, commercially available ^ Boot band pincers, commercially available Inboard Joint Side: 1. Remove the set ring from the inboard joint. 2. Remove the boot bands. Be careful not to damage the boot and dynamic damper. ^ If the boot band is a welded type (A), cut the boot band (B). ^ If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E). ^ If the boot band is a low profile type (F), pinch the boot band using a commercially available boot band pincers (G). Welded Type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3599 Double Loop Type Low Profile Type 3. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3600 4. Make a mark (A) on the rollers (B) and spider (C) to identify the locations of rollers on the spider, then remove the rollers. 5. Remove the circlip (D). 6. Mark the spider (C) and driveshaft (E) to identify the position of the spider on the shaft. 7. Remove the spider (C). 8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 9. Remove the inboard boot. Be careful not to damage the boot. 10. Remove the vinyl tape. Outboard Joint Side: 1. Remove the boot bands. Be careful not to damage the boot and dynamic damper. ^ If the boot band is an ear clamp type (A), lift up the three tabs (B) with a screwdriver. Ear Clamp Type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3601 2. Slide the outboard boot (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 of the outboard joint end (C). 5. Carefully clamp the driveshaft in a vise. 6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B). 7. Remove the driveshaft from the vise. 8. Remove the stop ring from the driveshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3602 9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 10. Remove the outboard boot. Be careful not to damage the boot. 11. Remove the vinyl tape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3603 Axle Shaft Assembly: Service and Repair Dynamic Damper Replacement Dynamic Damper Replacement 1. Remove the inboard joint. 2. Remove the dynamic damper bands. Be careful not to damage the dynamic damper. ^ If the boot band is a welded type, cut the 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 band pincers. 3. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the dynamic damper. 4. Remove the dynamic damper. Be careful not to damage the dynamic damper. 5. Adjust the position of the new dynamic damper to the figure below. Left driveshaft (Directional): 296 - 300 mm (11.6 - 11.8 inch) Right driveshaft (Directional): 301 305 mm (11.9 - 12.0 inch) 6. Install the dynamic damper band. 7. Install the inboard joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3604 Axle Shaft Assembly: Service and Repair Driveshaft Inspection Driveshaft Inspection 1. Check the inboard boot (A) and the outboard boot (B) on the driveshaft (C) for cracks, damage, leaking grease, and loose boot bands (D). If any damage is found, replace the boot and boot bands. 2. Turn the driveshaft by hand, and make sure the splines (E) and joint are not excessively loose. 3. Make sure the driveshaft is not twisted or cracked; if it is, replace it. Driveshafts Removal Driveshafts Removal Special Tool Required ^ Ball 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. 3. Remove the wheel nuts and front wheels. 4. Lift up the locking tab (A) on the spindle nut (B), then remove the nut. 5. If the left driveshaft or the intermediate shaft is to be removed, drain the transmission fluid. Reinstall the drain plug using a new washer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3605 6. Hold the stabilizer ball joint pin (A) with a hex wrench (B), and remove the flange nut (C). Separate the front stabilizer link (D) from the lower arm. 7. Remove the lock pin (A) from the lower arm ball joint castle nut (B), and remove the nut. NOTE: ^ To avoid damaging the ball joint, install a hex nut on to the threads of the ball joint. ^ Be careful not to damage the ball joint boot when installing the remover. 8. Separate the ball joint from the lower arm (C) with the special tool. 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. 10. Left driveshaft: Pry the inboard joint (A) from the differential case with a prybar. Right driveshaft: Drive the inboard joint (A) off of the intermediate shaft with a drift and hammer. Remove the driveshaft as an assembly. Do not pull on the driveshaft (B), because the inboard joint may come apart. Draw the driveshaft straight out to avoid damaging the oil seal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3606 Left driveshaft Right driveshaft Driveshafts Disassembly Driveshafts Disassembly Special Tools Required ^ Threaded adapter, 22 x 1.5 mm 07XAC-001010A ^ Slide hammer, commercially available ^ Boot band pincers, commercially available Inboard Joint Side: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3607 1. Remove the set ring from the inboard joint. 2. Remove the boot bands. Be careful not to damage the boot and dynamic damper. ^ If the boot band is a welded type (A), cut the boot band (B). ^ If the boot band is a double loop type (C), lift up the band bend (D), and push it into the clip (E). ^ If the boot band is a low profile type (F), pinch the boot band using a commercially available boot band pincers (G). Welded Type Double Loop Type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3608 Low Profile Type 3. Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint. Then remove the inboard joint on the shop towel (D). Be careful not to drop the rollers when separating them from the inboard joint. 4. Make a mark (A) on the rollers (B) and spider (C) to identify the locations of rollers on the spider, then remove the rollers. 5. Remove the circlip (D). 6. Mark the spider (C) and driveshaft (E) to identify the position of the spider on the shaft. 7. Remove the spider (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3609 8. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 9. Remove the inboard boot. Be careful not to damage the boot. 10. Remove the vinyl tape. Outboard Joint Side: 1. Remove the boot bands. Be careful not to damage the boot and dynamic damper. ^ If the boot band is an ear clamp type (A), lift up the three tabs (B) with a screwdriver. Ear Clamp Type 2. Slide the outboard boot (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. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3610 4. Make a mark (A) on the driveshaft (B) at the same position of the outboard joint end (C). 5. Carefully clamp the driveshaft in a vise. 6. Remove the outboard joint (A) using the special tool and a commercially available 5/8" x 18 slide hammer (B). 7. Remove the driveshaft from the vise. 8. Remove the stop ring from the driveshaft. 9. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 10. Remove the outboard boot. Be careful not to damage the boot. 11. Remove the vinyl tape. Dynamic Damper Replacement Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3611 Dynamic Damper Replacement 1. Remove the inboard joint. 2. Remove the dynamic damper bands. Be careful not to damage the dynamic damper. ^ If the boot band is a welded type, cut the 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 band pincers. 3. Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the dynamic damper. 4. Remove the dynamic damper. Be careful not to damage the dynamic damper. 5. Adjust the position of the new dynamic damper to the figure below. Left driveshaft (Directional): 296 - 300 mm (11.6 - 11.8 inch) Right driveshaft (Directional): 301 305 mm (11.9 - 12.0 inch) 6. Install the dynamic damper band. 7. Install the inboard joint. Driveshafts Reassembly Driveshafts Reassembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3612 '02 model Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3613 '03-05 model Special Tools Required ^ Boot band tool, KD-3191 or equivalent, commercially available ^ Boot band pincers, Kent-Moore J-35910 or equivalent, commercially available ^ Boot band pincers,commercially available NOTE: Refer to the Exploded View as needed during this procedure. Inboard Joint Side: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3614 1. Wrap the splines with vinyl tape (A) to prevent damage to the inboard boot. 2. Install the inboard boot onto the driveshaft, then remove the vinyl tape. Be careful not to damage the inboard boot. 3. Install the spider (A) onto the driveshaft by aligning the marks (B) on the spider and the end of the driveshaft. 4. Fit the circlip (C) into the driveshaft groove. Always rotate the circlip in its groove to make sure it is fully seated. 5. Fit the rollers (A) onto the spider (B) with their high shoulders facing outward, and note these items: ^ Reinstall the rollers in their original positions on the spider by aligning the marks (C). ^ Hold the driveshaft pointed up to prevent the rollers from falling off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3615 6. Pack the inboard joint with the joint grease included in the new driveshaft set. Grease quantity Inboard joint: 130 - 140 g (4.6 - 4.9 oz) 7. Fit the inboard joint onto the driveshaft, and note these items: ^ Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the rollers. ^ Hold the driveshaft so the inboard joint is pointing up to prevent it from falling off. 8. Make sure the ends of the boot are seated in the grooves in the driveshaft and joint, then install the boot bands. ^ For the double loop type, go to step 12. (Replacement boot bands only) ^ For the low profile type, go to step 9. 9. Install the new low profile band (A) onto the boot (B), then hook the tab (C) of the band. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3616 10. Close the hook portion of the band (A) with a commercially available boot band pincers (B), then hook the tabs of the band. 11. Install the boot band on the other end of the boot, and repeat steps 9 and 10. 12. Fit the boot ends onto the driveshaft and the inboard joint, then install the new double loop band (A) onto the boot. 13. Pull up the slack in the band by hand. 14. Mark a position (A) on the band 10 - 14 mm (0.4 - 0.6 inch) from the clip (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3617 15. Thread the free end of the band 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). 16. Place a wrench on the winding mandrel of the boot band tool, and tighten the band until the marked spot (C) on the band meets the edge of the clip. 17. Lift up the boot band tool to bend the free end of the band 90 degrees to the clip. Center-punch the clip, then fold over the remaining tail onto the clip. 18. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5 - 10 mm (0.2 - 0.4 inch) tail protruding from the clip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3618 19. Bend the band end (A) 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 grease remaining on the surrounding surfaces 20. Repeat steps 12 through 19 for the band on the other end of the boot. 21. Install the new set ring. Outboard Joint Side: 1. Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot. 2. Install the new ear clamp bands (B) and outboard boot, then remove the vinyl tape. Be careful not to damage the outboard boot. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3619 3. Install the new stop ring into the driveshaft groove (A). 4. Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint. 5. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 cm (4 inch) onto a hard surface. Do not use a hammer as excessive force may damage the driveshaft. Be careful not to damage the threaded section (A) of the outboard joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3620 6. Check the alignment of the paint mark (A) with the outboard joint end (B). 7. Pack the outboard joint (A) with the joint grease included in the new joint boot set. Grease quantity Outboard joint: 105 - 115 g (3.7 - 4.1 oz) 8. Adjust the length of the driveshafts to the figure below, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the grooves of the driveshaft and joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3621 9. Fit the boot (A) ends onto the driveshaft (B) and outboard joint (C). 10. Close the ear portion (A) of the band with a commercially available boot band pincers Kent-Moore J-35910 or equivalent (B). 11. Check the clearance between the closed ear portion of the bands. If the clearance is not within the standard, close the ear portion of the bands farther. 12. Repeat steps 10 and 11 for the band on the other end of the boot. Driveshafts Installation Driveshafts Installation Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3622 1. Install a new set ring onto the set ring groove of the driveshaft (left driveshaft). 2. Apply 0.5 - 1.0 g (0.02 - 0.04 oz) of specified grease to the whole splined surface (A) of the right driveshaft. After applying grease, remove the grease from the splined grooves at intervals of 2 - 3 splines and from the set ring groove (B) so that air can bleed from the intermediate shaft. 3. Clean the areas where the driveshaft contacts the differential thoroughly with solvent, and dry with compressed air. Insert the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) until the set ring (D) locks in the groove (E). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3623 4. Install the outboard joint (A) into the front hub (B). 5. Wipe off the grease from the ball joint and lower arm tapered surfaces. Install the knuckle (A) onto the lower arm (B). Be careful not to damage the ball joint boot. Wipe off the grease before tightening the nut at the ball joint. Torque the new castle nut (C) to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the nut by loosening it. NOTE: Make sure the ball joint boot is not damage or cracks. 6. Install the new lock pin (D) into the ball joint pin hole from the inside to the outside of the vehicle. 7. Connect the front stabilizer link (A) to the lower arm. Hold the stabilizer link ball joint pin (B) with a hex wrench (C), and tighten the new flange nut (D). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3624 8. Install a new spindle nut (A), then tighten the nut. After tightening, use a drift to stake the spindle nut shoulder (B) against the driveshaft. 9. Clean the mating surfaces of the brake disc and the front wheel, 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 recommended transmission fluid. 12. Check the front wheel alignment, and adjust it if necessary. Intermediate Shaft Removal Intermediate Shaft Removal 1. Remove the right driveshaft. 2. Remove the heat shield. 3. Remove the flange bolt (A) and two dowel bolts (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3625 4. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential to prevent damage to the differential oil seal (B). Intermediate Shaft Disassembly Intermediate Shaft Disassembly Special Tools Required ^ Oil seal driver 07947-SB00100 ^ Half shaft base 07NAF-SR30101 1. Remove the set ring (A), outer seal (B), and external snap ring (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3626 2. Press the intermediate shaft (A) out of the intermediate shaft bearing (B) using a press. Be careful not to damage the metal rings (C) on the intermediate shaft during disassembly. 3. Remove the internal snap ring. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3627 4. Press the intermediate shaft bearing (A) out of the bearing support (B) using the special tools and a press. Intermediate Shaft Reassembly Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3628 Exploded View, '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3629 Exploded View, '04-05 models Intermediate Shaft Reassembly Special Tools Required ^ Driver 07749-0010000 ^ Attachment, 52 x 55 mm 07746-0010400 ^ Attachment, 35 mm I.D.07746-0030400 ^ Oil seal driver 07GAD-PW70201 NOTE: Refer to the Exploded View as needed during this procedure. 1. Clean the disassembled parts with solvent, and dry them with compressed air. Do not wash the rubber parts with solvent. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3630 2. Press the intermediate shaft bearing (A) into the bearing support (B) using the special tools and a press. 3. Install, then seat the internal snap ring into the groove of the bearing support. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3631 4. Press the intermediate shaft (A) into the shaft bearing (B) using the special tool and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3632 5. Install, then seat the external snap ring (A) into the groove of the intermediate shaft (B). 6. Install the outer seal (A) into the bearing support (B) using the special tool and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3633 7. Install the set ring. Intermediate Shaft Installation Intermediate Shaft Installation 1. Use solvent or brake cleaner to thoroughly clean the areas where the intermediate shaft (A) contacts the transmission (differential), and dry with compressed air. Insert the intermediate shaft assembly into the differential. Hold the intermediate shaft horizontal to prevent damage to the differential oil seal (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Driveshaft Inspection > Page 3634 2. Install the flange bolt (A) and two dowel bolts (B). 3. Install the heat shield, and tighten the three bolts. 4. Install the right driveshaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Page 3635 Axle Shaft Assembly: Tools and Equipment Driveline/Axle Special Tools Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing End Play Front .................................................................................................................................................... .................................. 0 - 0.05 mm (0 - 0.002 inch) Rear .................................................................... ................................................................................................................... 0 - 0.05 mm (0 - 0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Front > Page 3641 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Page 3642 Wheel Bearing: Testing and Inspection Wheel Bearing End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. Front Rear 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc inward and outward. Bearing end play: Standard: Front/rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard. replace the wheel bearing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3645 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3646 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3647 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3648 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3649 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3650 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and rear wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3651 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Release the parking brake lever. 5. Remove the brake hose mounting bolt (A). 6. Remove the caliper bracket mounting bolts (B), and hang the caliper (C) to one side. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage. 7. Remove the brake disc retaining screws (A). 8. Screw two 8 x 1.25 mm bolts (B) into the disc (C) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Remove the brake disc. 9. Remove the hub bearing unit (A) from the spindle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3652 10. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. - Use a new spindle nut on reassembly. - After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 3658 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3662 Flywheel: Testing and Inspection Flywheel Inspection 1. Inspect the ring gear teeth for wear and damage. 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning. 3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Resurfacing the flywheel is not recommended. Standard (New): 0.05 mm (0.002 inch) max. Service Limit: 0.15 mm (0.006 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3663 Flywheel: Service and Repair Flywheel Replacement 1. Install the special tool. 2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel. 3. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight. 4. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair Countershaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Carrier Assembly, M/T > Component Information > Specifications Differential Carrier Assembly: Specifications M/T Differential Carrier: Pinion shaft contact area Inside Diameter: Standard or New ...................................................................................................................................... 18.010 18.028 mm (0.7091 - 0.7098 inch) Carrier-To-Pinion Shaft Clearance Standard or New .......................................................................................................................................... 0.027 0.057 mm (0.0011 - 0.0022 inch) Service Limits ................................................................................. ............................................................................................. 0.1 mm (0.004 inch) Driveshaft contact area Inside Diameter: Standard or New ...................................................................................................................................... 28.025 28.045 mm (1.1033 - 1.1041 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Carrier Assembly, M/T > Component Information > Specifications > Page 3672 Differential Carrier Assembly: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Differential, Manual Transaxle; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Pinion Gear, M/T > Component Information > Specifications Pinion Gear: Specifications M/T Differential Pinion Gear: Backlash: Standard or New .................................................................................................................................................. 0.05 0.15 mm (0.002 - 0.006 inch) Inside Diameter: Standard or New ...................................................................................................................................... 18.042 18.066 mm (0.7103 - 0.7113 inch) Pinion Gear-To-Pinion Shaft Clearance: Standard or New .......................................................................................................................................... 0.059 0.095 mm (0.0023 - 0.0037 inch) Service Limit ................................................................................... .......................................................................................... 0.15 mm (0.006 inch) 80 mm Shim 80 mm shim-to-Bearing Outer Race Clearance In Transmission Housing: Standard or New ............................................................................................................................................................ 0 - 0.10 mm (0 - 0.0039 inch) Service Limit ......................................................................................... ............................................................................................................ Adjust Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Locations Drain Plug: Locations Drain plug (A) Filler plug (B) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Change ................................................................................................................................................ .............................................................. 1.5L (1.6 Qt) Overhaul .......................................................... .................................................................................................................................................. 1.7L (1.8 Qt) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3683 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ........................................................................................................................................ Honda Manual Transmission Fluid (MTF): P/N 08798-9016 If not available you may use 10W-30 or 10W-40 motor oil as a temporary replacement. An API Certification seal that says "For Gasoline Engines" should be used as a temporary replacement. Replace with Honda MTF as soon as it is convenient. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3684 Fluid - M/T: Service and Repair Transmission Fluid Inspection and Replacement 1. Park the vehicle on level ground, and turn the engine OFF. 2. Remove the oil filler plug (A) and washer (B), check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. If the transmission fluid is dirty, remove the drain plug (D) and drain the fluid. 4. Reinstall the drain plug with a new washer, and refill the transmission fluid to the proper level. Oil Capacity 1.5 L (1.6 US qt.) at fluid change 1.7 L (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 contain the proper additives. 5. Reinstall the oil filler plug with a new washer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Specifications Synchronizer Ring: Specifications Synchro Ring: Ring-To-Gear Clearance: Ring pushed against gear Standard or New ............................................................................................................................................ 0.70 1.49 mm (0.028 - 0.059 inch) Service Limits ....................................................................................... ................................................................................. 0.4 mm (0.016 inch) Triple Cone Synchro Ring: Outer Synchro Ring-To-Synchro Cone Clearance Ring pushed against gear Standard or New ............................................................................................................................................ 0.70 1.19 mm (0.028 - 0.047 inch) Service Limits ....................................................................................... ................................................................................. 0.3 mm (0.012 inch) Synchro Cone-To-Gear Clearance Ring pushed against gear Standard or New ............................................................................................................................................ 0.50 1.04 mm (0.020 - 0.041 inch) Service Limits ....................................................................................... ................................................................................. 0.3 mm (0.012 inch) Outer synchro ring-to-gear cone clearance Ring pushed against gear Standard or New ............................................................................................................................................ 0.95 1.68 mm (0.037 - 0.066 inch) Service Limits ....................................................................................... ................................................................................. 0.6 mm (0.024 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Technical Service Bulletins > M/T Mainshaft Reassembly Manual Revision Mainshaft: Technical Service Bulletins M/T Mainshaft Reassembly Manual Revision SOURCE: Honda Service News January 2004 TITLE: S/M Fix: M/T Mainshaft Reassembly APPLIES TO: 2001-04 Civic SERVICE TIP: The synchro ring order for 5th gear is wrong in the Exploded View on page 13-28. It shows the synchro ring with nine teeth per segment mating to 5th gear and the synchro ring with four teeth per segment mating to the tapered cone ring. If you install the synchro rings in this order, the M/T locks up in 5th gear. To ensure proper reassembly of 5th gear, refer to this exploded view. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Technical Service Bulletins > Page 3693 Mainshaft: Specifications Mainshaft End Play: Standard or New .................................................................................................................................................. 0.11 0.17 mm (0.004 - 0.007 inch) Service Limit ......................................................................................... ............................................................................................................ Adjust Diameter Of Bushing Surface: Standard or New .............................................................................................................................................. 20.80 20.85 mm (0.819 - 0.821 inch) Service Limit: ...................................................................................... .................................................................................... 20.75 mm (0.817 inch) Diameter Of Distance Collar: Standard or New ...................................................................................................................................... 31.984 32.000 mm (1.2594 - 1.2598 inch) Service Limit ................................................................................. .......................................................................................... 31.93 mm (1.257 inch) Diameter Of Ball Bearing Contact Area (Clutch Housing Side): Standard or New ...................................................................................................................................... 27.977 27.990 mm (1.1015 - 1.1020 inch) Service Limit ................................................................................. .......................................................................................... 27.92 mm (1.099 inch) Diameter Of Needle Bearing Contact Area: Standard or New ...................................................................................................................................... 38.984 39.000 mm (1.5348 - 1.5354 inch) Service Limit ................................................................................. .......................................................................................... 38.93 mm (1.533 inch) Diameter Of Ball Bearing Contact Area (Transmission Housing Side): Standard or New ...................................................................................................................................... 27.987 28.000 mm (1.1019 - 1.1024 inch) Service Limit ................................................................................. ......................................................................................... 27.93 m m (1.100 inch) Runout: Standard or New .................................................................................................................................. ............................. 0.02 mm (0.001 inch) max. Service Limit .............................................................. ............................................................................................................... 0.05 mm (0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Technical Service Bulletins > Page 3694 Mainshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse Idler Gear Inside Diameter: Standard or New ...................................................................................................................................... 20.016 20.043 mm (0.7880 - 0.7891 inch) Service Limit ................................................................................. .......................................................................................... 20.90 mm (0.832 inch) Gear-To-Shaft Clearance: Standard or New .......................................................................................................................................... 0.036 0.084 mm (0.0014 - 0.0033 inch) Service Limit ................................................................................... .......................................................................................... 0.16 mm (0.006 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Specifications Shift Fork: Specifications Shift Fork Finger Thickness Standard or New .......................................................................................................................................................... 7.4 - 7.6 mm (0.29 - 0.30 inch) Fork-To-Synchro Sleeve Clearance Standard or New .................................................................................................................................................. 0.35 0.65 mm (0.014 - 0.026 inch) Service Limit ......................................................................................... ...................................................................................... 1.0 mm (0.039 inch) Reverse Shift Fork Finger Thinkness Standard or New .............................................................................................................................................. 12.70 12.99 mm (0.500 - 0.511 inch) Fork-To-Reverse Idler Gear Clearance Standard or New ................................................................................................................................................. 0.20 0.59 mm (0.007 - 0.024 inch) Service Limit ......................................................................................... ...................................................................................... 1.3 mm (0.051 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Specifications > Page 3701 Shift Fork: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair Shifter M/T: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Shift Linkage, M/T; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Specifications Shift Linkage: Specifications Shift Arm: Inside Diameter: Standard or New ...................................................................................................................................... 13.973 14.000 mm (0.5501 - 0.5512 inch) Shift Fork Diameter At Contact Area: Standard or New .................................................................................................................................................. 16.9 17.0 mm (0.665 - 0.669 inch) Shift Arm-To-Shift Lever Clearance: Standard or New ...................................................................................................................................................... 0.2 - 0.5 mm (0.008 - 0.020 inch) Service Limit ......................................................................................... .................................................................................... 0.62 mm (0.024 inch) Select Lever: Finger Width: Standard or New .............................................................................................................................................. 14.85 14.95 mm (0.585 - 0.589 inch) Shift Lever: Shaft-To-Select Lever Clearance: Standard or New .................................................................................................................................................. 0.05 0.25 mm (0.002 - 0.010 inch) Service Limit ......................................................................................... .................................................................................... 0.50 mm (0.020 inch) Groove (To Select Lever): Standard or New .............................................................................................................................................. 15.00 15.10 mm (0.591 - 0.594 inch) Shaft-To-Shift Arm Clearance: Standard or New ............................................................................................................................................. 0.0 13 0.07 mm (0.0005 - 0.003 inch) Service Limit ....................................................................................... ........................................................................................ 0.1 mm (0.004 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Specifications > Page 3708 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Specifications > Page 3709 Shift Linkage: Service and Repair Gearshift Mechanism Replacement Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3720 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3721 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3727 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3728 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3742 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3743 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3749 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3750 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3766 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3767 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3773 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3774 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: Customer Interest A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3788 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3789 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3795 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3796 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Technical Service Bulletins > A/T - Vehicle Speed Sensor Installation Precautions Transmission Speed Sensor: Technical Service Bulletins A/T - Vehicle Speed Sensor Installation Precautions Install VSS Properly to Avoid Reman A/T Damage We can't emphasize enough how important it is to follow, to the letter, the installation instructions that come with a reman A/T. These instructions help ensure that you avoid damaging the A/T and score a successful repair. This is particularly true when it comes to installing the vehicle speed sensor (VSS). Step 6 of the instructions tells you to make sure its gear is fully engaged and the VSS is fully seated before you tighten the retaining bolt. If you don't install the VSS properly, the speed sensor gear will get stripped and the A/T will be seriously damaged. So don't take risks with your customer's vehicle. Always follow these instructions to the letter. You can rest assured you're doing the job right. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3806 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3807 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3808 199. Brake Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3809 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3810 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15 A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15 A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM (E22) and the No.7 HORN, STOP (15 A) fuse. Replace the No.7 HORN, STOP (15 A) fuse. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3811 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet and the insulator cutout (B). Measure the pedal height (C) from the middle of the left side of the pedal pad (D). Standard pedal height (with carpet removed): 184 mm (7 1/4 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the brake pedal by hand. 2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 3812 Brake Pedal Position Switch Clearance 1. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 - 0.118 inch) by locking the switch. Make sure the brake lights go off when the pedal is released. 2. Check the brake pedal free play. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations 27. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 3817 Electronic Brake Control Module: Connector Locations System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3818 190. ABS Modulator-Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3819 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel, and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem, and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the HDS. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the HDS. See the HDS help menu for specific operating instructions. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3820 Electronic Brake Control Module: Testing and Inspection System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 3821 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31P connector (B), then disconnect the connector. 3. Disconnect the six brake lines from the ABS modulator-control unit (C). 4. Remove the two 8 mm nuts. 5. Remove the ABS modulator-control unit. Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the HDS, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the HDS. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations 27. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 3825 190. ABS Modulator-Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 3826 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ABS Modulator The ABS modulator consists of the inlet solenoid valves, outlet solenoid valves, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four-channel type, one channel for each wheel. Pressure intensifying mode: Inlet valve open, outlet valve closed Master cylinder fluid is pumped out to the caliper. Pressure retaining mode: Inlet valve closed, outlet valve closed: Caliper fluid is retained by the inlet: valve and outlet valve. Pressure reducing mode: Inlet valve closed, outlet valve open: Caliper fluid flows through the outlet valve to the reservoir. Motor operation mode: When starting the pressure reducing mode, the pump motor is ON. When stopping ABS operation, the pump motor is OFF. The caliper fluid is pumped out by the pump, through the damping chamber, to the master cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 3827 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31P connector (B), then disconnect the connector. 3. Disconnect the six brake lines from the ABS modulator-control unit (C). 4. Remove the two 8 mm nuts. 5. Remove the ABS modulator-control unit. Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the HDS, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the HDS. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations 35. Lower Left Side of Engine Comp. (Right Sim.) 37. Under Left Rear of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3831 102. Right Side of Cargo Area Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3832 Wheel Speed Sensor: Diagrams 86. Wheel Speed Sensor, Left Front 87. Wheel Speed Sensor, Left Rear 88. Wheel Speed Sensor, Right Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3833 89. Wheel Speed Sensor, Right Rear Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3834 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contactless type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the inlet valve closes and if necessary, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, and the outlet valve closes, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3835 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 3836 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not allow dirt or other foreign matter to contaminate the brake fluid. ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleeder screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left-front, loosen the brake bleeder screw to allow air to escape from the system. Then tighten the bleeder screw securely. 5. Repeat the procedure for each wheel in the sequence shown following until air bubbles no longer appear in the fluid. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 3840 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Brake Pedal - Click Or Pop When Depressed Brake Pedal Assy: Technical Service Bulletins Brake Pedal - Click Or Pop When Depressed SOURCE: Honda Service News November 2004 TITLE: Click or Pop When Pressing the Brake Pedal APPLIES TO: 2003-04 Accord or 2001-05 Civic SERVICE TIP: Got a 2003-04 Accord or 2001-05 Civic in your shop that clicks or pops when you press the brake pedal? The culprit could be the brake pedal position switch. The switch plunger doesn't fit squarely into the switch casing. When you press the brake pedal, the plunger rubs the side of the casing and makes noise. There's a simple fix for this problem: Just turn the switch around so the connector lock now faces the 5 o'clock position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3845 Brake Pedal Assy: Specifications Brake Pedal Pedal Height (Carpet Removed) ...................................................................................................................................................... 184 mm (7 4/16 inch) Free Play ................................................................................................................. ...................................................... 0.4 - 3.0 mm (0.016 - 0.118 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3846 Brake Pedal Assy: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet and the insulator cutout (B). Measure the pedal height (C) from the middle of the left side of the pedal pad (D). Standard pedal height (with carpet removed): 184 mm (7 1/4 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the brake pedal by hand. 2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 3847 Brake Pedal Position Switch Clearance 1. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 - 0.118 inch) by locking the switch. Make sure the brake lights go off when the pedal is released. 2. Check the brake pedal free play. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 Brake Warning Indicator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Brake System Indicator Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Removal Front Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. For '04-05 models, remove the brake hose bracket mounting bolt (A). 2. Remove the flange bolt (B). 3. Pivot the caliper up out of the way, and remove the brake pads (A). 4. Remove the pad shim(s) (B). 5. Check the hose and pin boots for damage and deterioration. 6. Remove the pad retainers (A), and check the caliper pins for free movement. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 3889 7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 8. Check the brake disc for damage and cracks. 9. Install the pad retainers. 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to brake pad sides of the pad shims (A), the back of the brake pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the brake discs and brake pads. 11. Install the brake pads and pad shims correctly. Install the brake pads with the wear indicators (C) on the lower brake inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 12. Push in the piston (A) so the caliper will fit over the brake pads. Check the brake fluid level. The brake fluid may overflow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 13. Pivot the caliper (A) down into position. Be careful not to damage the pin boots, install the flange bolt (B), and tighten it to the specified torque. 14. For '04-05 models, install the brake hose bracket mounting bolt (C), and tighten it to the specified torque. 15. Press the brake pedal several times to make sure the brakes work, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Overhaul Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 3890 Front Brake Caliper Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ Make sure no grease or oil gets on the brake discs or pads. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not mix different brands of brake fluid as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones whenever disassembled. ^ After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 3891 Brake Caliper: Service and Repair Rear Removal Rear Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (A) and brake hose (B) from the mounting bracket. 2. Remove the caliper bolts (C), and remove the caliper (D) from the caliper bracket. 3. Remove the pad shims (A) and the brake pads (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 3892 4. Remove the pad retainers (A), and check the caliper pins for free movement. 5. Clean the caliper thoroughly;remove any rust, and check for grooves and cracks. 6. Check the brake disc for damage and cracks. 7. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainers on their mating surfaces against the caliper bracket. 8. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to both sides of the pad shims (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the discs and brake pads. 10. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the lower inside. If you are reusing the brake pads, always 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 (A) in the piston with the tab (B) on the inner pad by turning the piston back so the caliper can be installed. on the brake pad. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly. 12. Install the brake caliper (C) and caliper bolts (D), and tighten the bolts to the specified torque. 13. Install the brake hose (E). 14. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 15. Press the brake pedal several times to make sure the brake works, then test-drive the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 3893 NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. Check the parking brake adjustment. Overhaul Rear Brake Caliper Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ Make sure no grease or oil gets on the brake discs or pads. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not mix different brands of brake fluid as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. ^ Replace all rubber parts with new ones whenever disassembled. ^ After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake pads Thickness Front Standard or New .................................................................................................................................................. 9.5 10.5 mm (0.37 - 0.41 inch) Service Limit ............................................................................................. .............................................................................. 1.6 mm (0.06 inch) Rear Standard or New .................................................................................................................................................... 8.5 9.5 mm (0.33 - 0.37 inch) Service Limit ............................................................................................... ............................................................................ 1.6 mm (0.06 inch) Pad friction surface area Front .................................................................................................................................................... ........................................ 45 cm2 (7.0 sq inch) x 2 Rear .................................................................... ......................................................................................................................... 28 cm2 (4.3 sq inch) x 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection > Front Brake Pad: Testing and Inspection Front Front Brake Pad Inspection CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Check the thickness of the inner pad (A) and outer pad (B). Do not include the thickness of the brake pad backing plate. 3. If the brake pad thickness is less than the service limit, replace all the brake pads as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection > Front > Page 3899 Brake Pad: Testing and Inspection Rear Rear Brake Pad Inspection CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 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. 3. If the brake pad thickness is less than the service limit, replace all the pads as a set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Front Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. For '04-05 models, remove the brake hose bracket mounting bolt (A). 2. Remove the flange bolt (B). 3. Pivot the caliper up out of the way, and remove the brake pads (A). 4. Remove the pad shim(s) (B). 5. Check the hose and pin boots for damage and deterioration. 6. Remove the pad retainers (A), and check the caliper pins for free movement. 7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 8. Check the brake disc for damage and cracks. 9. Install the pad retainers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 3902 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to brake pad sides of the pad shims (A), the back of the brake pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the brake discs and brake pads. 11. Install the brake pads and pad shims correctly. Install the brake pads with the wear indicators (C) on the lower brake inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 12. Push in the piston (A) so the caliper will fit over the brake pads. Check the brake fluid level. The brake fluid may overflow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 13. Pivot the caliper (A) down into position. Be careful not to damage the pin boots, install the flange bolt (B), and tighten it to the specified torque. 14. For '04-05 models, install the brake hose bracket mounting bolt (C), and tighten it to the specified torque. 15. Press the brake pedal several times to make sure the brakes work, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 3903 Brake Pad: Service and Repair Rear Rear Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (A) and brake hose (B) from the mounting bracket. 2. Remove the caliper bolts (C), and remove the caliper (D) from the caliper bracket. 3. Remove the pad shims (A) and the brake pads (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 3904 4. Remove the pad retainers (A), and check the caliper pins for free movement. 5. Clean the caliper thoroughly;remove any rust, and check for grooves and cracks. 6. Check the brake disc for damage and cracks. 7. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainers on their mating surfaces against the caliper bracket. 8. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to both sides of the pad shims (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the discs and brake pads. 10. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the lower inside. If you are reusing the brake pads, always 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 (A) in the piston with the tab (B) on the inner pad by turning the piston back so the caliper can be installed. on the brake pad. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly. 12. Install the brake caliper (C) and caliper bolts (D), and tighten the bolts to the specified torque. 13. Install the brake hose (E). 14. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 15. Press the brake pedal several times to make sure the brake works, then test-drive the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 3905 NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. Check the parking brake adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information Brake Rotor/Disc: Technical Service Bulletins Brakes - Brake Disc Refinishing Information 00-088 July 14, 2010 Applies To: ALL Models Brake Disc Refinishing Guidelines (Supersedes 00-088, dated October 6, 2006, to revise the information marked with the black bars) *REVISION SUMMARY The requirement to refinish new brake discs was removed.* American Honda does not allow replacement of brake discs under warranty unless the brake disc is beyond its service limit for refinishing. If the brake disc is within its service limit, you must refinish it. Maximum refinishing limits may be found in the Conventional Brakes section of the appropriate service manual. *Refinish brake discs only when they are scored or out of specification for runout or parallelism. See the appropriate service manual for the specifications.* American Honda requires refinishing of the front brake discs with an on-car brake lathe that mounts to the steering knuckle. Use of an on-car, steering knuckle- mounted lathe is critical because it corrects runout of the hub and disc as an assembly. Experience has shown that very small amounts of runout, not felt as brake pulsation initially, will grow and become noticeable as the discs are subjected to heat and wear over time and mileage. Two on-car brake lathes are recommended. The Kwik-Lathe, model number KWY-108000501, is supported with automatic shipments of adapters for new models, when required. The Accu-turn On-car Brake Lathe, model ACCHONOCLPKG, is also recommended. A power driver is required for the 82000 and is highly recommended for all other models. The Kwik-Lathe power driver model number is KWY-108012005; the Accu-turn lathe includes a power driver. Here are some advantages of using power drivers: ^ The disc is rotated at the optimum speed for a smooth and consistent cut. ^ There is no need to climb in and out of the vehicle to start and stop the engine or to shift the transmission. ^ Securing the opposite wheel with a tie-down strap is not required. ^ There is no waiting for the engine to return to idle and no concern about engine speed changes that can adversely affect brake disc cut and finish. ^ The Traction Control System (TCS) is not involved. ^ Consistent cutting speed increases cutting tool life. ORDERING INFORMATION Order brake lathes and power drivers through the Honda Tool and Equipment Program. To place an order, call or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday thru Friday from 7:30 a.m. to 7:00 p.m. Central Time. You can also order online through the Interactive Network (iN). Click on Service, Tool and Equipment, and then Online Catalog. Click on Alignment, Wheel, and Brake Equipment, and then On-Car Brake Lathes. WARRANTY CLAIM INFORMATION None, this bulletin is for information only. FRONT BRAKE DISCS The following guidelines show the Kwik-Way lathe setup, the Accu-turn lathe setup is similar. Setting Up the Vehicle Put the transmission in Neutral. If you are not using the power drive system, start the engine, and let it warm up to its normal operating temperature so the idle speed will stabilize to its lowest rpm. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 3910 Raise the vehicle on a lift. Check for loose wheel bearings. You must replace loose wheel bearings before you refinish the brake discs. If you do not, the brake lathe will not correct for brake disc runout, resulting in an uneven finish and brake pulsation. Remove the front wheels, then reinstall the wheel nuts with flat washers to compensate for the removed wheel. Torque the wheel nuts to the required specification (see the appropriate service manual). Remove the caliper assembly. Use a wire or a S-hook to hold the caliper to the spring or damper tower. Do not kink the brake hose or use it to support the caliper. If you are not using the power drive system and the vehicle has ICS or VSA, make sure you install a brake pad spreader between the pads on the hanging caliper. Also, make sure the ICS or VSA is turned off anytime the engine is started. If the system is not turned off, the brakes could activate, causing the brake pads on the hanging caliper to hit each other or the caliper pistons to fall out. Install the vibration damper on the brake disc. If you are not using the power drive system, make sure you install the protective band around the wheel nuts. If you are not using the power drive system, use a fabric tie-down strap to secure the brake disc that is opposite to the one you are refinishing. If you are working on a Prelude with ATTS, do not use a tie-down strap; let both wheels turn freely. Mounting the Brake Lathe Remove the tool bed from the brake lathe, then mount the brake lathe to the steering knuckle with a Honda 1-piece speed mount. These mounts provide quicker, more accurate mounting, and can be ordered through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 3911 Honda 1-Piece Speed Mounts P/N KWY-108006000 (for most models), P/N KWY-108007500 (Odysseys, Pilots, and Ridgelines with two-piston calipers) Attaching the Power Drive System 1. Make sure the drive motor assembly on the power drive system is level with the brake disc. 2. Attach the mounting yoke to the brake disc, and secure it with one of the wheel nuts. Torque the wheel nut to the required specification (see the appropriate service manual). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 3912 3. Attach the driveshaft on the drive motor assembly to the mounting yoke, making sure the center line of the driveshaft is level with the spindle nut on the wheel hub. 4. Set the lower toggle switch on the drive motor assembly to FWD (counterclockwise rotation) or REV (clockwise rotation). Setting Up and Adjusting the Brake Lathe Use Kwik-Way cutting bits, P/N KWY-109109223, and the holding screws that come with them. These bits are stamped KW and are available through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Before you use the brake lathe, inspect the tips of the cutting bits with a magnifying glass to make sure the tips are not worn out. Each bit has three tips. If a tip is worn, rotate the bit, and use a new tip. A worn tip produces a poor finish and may cause chattering. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 3913 Reinstall the tool bed on the brake lathe with the top of the cutting bits facing up and the feed knobs facing down. Adjust the tool bed until the brake disc is centered between the cutting bits. For proper refinishing, the brake disc must turn toward the top of the cutting bits. Do not set the cutting depth on the brake lathe to more than 0.2 mm (0.008 in.). This is two divisions on the cutting knob. Make sure you start your cut at least 3 mm (0.12 in.) beyond the worn area on the brake disc. If you are cutting larger diameter brake discs, make sure you use the 150 cutting bit holders. These bit holders, available through the Honda Tool and Equipment Program (see ORDERING INFORMATION), supersede the original bit holders and provide better cutting coverage for larger diameter brake discs. Each bit holder is clearly marked for proper installation on the tool holder. Cutting the Brake Disc To get the smoothest cut and the best brake disc finish, always use the slowest feed speed on the tool bed feed motor. Place the drive belt on the smallest pulley of the feed motor and on the largest pulley of the hand wheel. Make sure the lower toggle switch on the power drive system drive motor assembly is set to the proper rotation to turn the brake disc toward the top of the cutting bits. Plug the tool bed feed motor into the power outlet on the drive motor assembly, then turn on the drive motor with the upper toggle switch on the assembly. If you are not using the power drive system, make sure the transmission is in 1st gear (2nd gear on Preludes with ATTS) or Reverse and the engine is idling, but not at a fast idle. If the transmission and engine are at higher gears and speeds, you will damage the cutting bits. Turn on the tool bed feed motor, and snap it into place; there should be tension on the feed belt. Cut the brake disc until the cutting bits clear the outer edge of the disc. The cutting bits should produce a smooth, consistent finish with no chatter marks or grooves. If the disc did not clean up entirely on the first pass, reset the brake lathe and make a second pass. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes - Brake Disc Refinishing Information > Page 3914 Finishing the Job Remove the vibration damper and the protective band (if used). Use a micrometer to measure the thickness of the brake disc. Make sure the thickness is within the service manual specifications. Clean the brake disc with soapy water or brake cleaner, then wipe it dry. Use a vacuum cleaner to remove any dust or chips, but do not use compressed air. Unplug the tool bed feed motor from the drive motor assembly, and remove the mounting yoke from the brake disc. Remove the speed mount from the steering knuckle. Apply a small amount of Molykote 77 grease to the brake pad shims. Reinstall the caliper assembly. (If you did not use the power drive system, use the brake pad spreader to push the pistons back into the caliper.) Torque the nuts and bolts to the required specification (see the appropriate service manual). Refinish the other front brake disc using the same guidelines. Check the brake fluid level, then test-drive the vehicle to make sure the brake pedal is firm and does not pulsate. Lightly apply the brakes about 20 times during the test-drive to seat the brake pads. REAR BRAKE DISCS It is possible to use an on-car lathe on some models if the rear caliper mounts are low enough to clear the vehicle body. A power driver is needed for front drive models. Refinish rear brake discs on bench-mounted equipment if necessary. Follow the same guidelines you used for refinishing front brake discs, noting these differences: ^ Mount the brake lathe to the rear knuckle with the Honda 2-Piece Adapter (P/N KWY-1 08102504). You can order the 2-piece adapter through the Honda Tool and Equipment Program (see ORDERING INFORMATION). Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 3915 Brake Rotor/Disc: Specifications Brake disc Thickness Front Standard or New ................................................................................................................................................ 20.9 21.8 mm (0.82 - 0.86 inch) Service Limit ............................................................................................. .......................................................................... 19.00 mm (0.75 inch) Rear Standard or New .............................................................................................................................................. 9.9 10.1 mm (0.389 - 0.397 inch) Service Limit ......................................................................................... .................................................................................. 9.0 mm (0.35 inch) Runout Front .................................................................................................................................................... ...................................... 0.10 mm (0.004 inch) Rear ........................................................................... ................................................................................................................ 0.10 mm (0.004 inch) Parallelism Front and rear ...................................................................................................................................... .................................. 0.015 mm (0.0006 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front Brake Rotor/Disc: Testing and Inspection Front Front Brake Disc Inspection Runout 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the brake pads. 3. Inspect the brake disc surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 4. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. 5. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (3/8 inch) from the outer edge of the brake disc. NOTE: When measuring the brake disc runout, turn the other side of the brake disc slowly by hand. Brake disc runout: Service limit: 0.10 mm (0.004 inch) 6. If the brake disc is beyond the service limit, refinish the brake disc. Max. refinish limit: 19.0 mm (0.75 inch) NOTE: ^ If the brake disc is beyond the service limit for refinishing, replace it. ^ A new brake disc should be refinished if its runout is greater then 0.10 mm (0.004 inch). Thickness and Parallelism 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. Remove the front wheels. 2. Remove the brake pads. 3. Using a micrometer, measure the brake disc thickness at eight points, approximately 45° apart and 10 mm (3/8 inch) in from the outer edge of the brake disc. Brake disc thickness: Standard: 20.9 - 21.8 mm (0.82 - 0.86 inch) Max. refinishing limit: 19.0 mm (0.75 inch) Brake disc parallelism: 0.015 mm (0.0006 inch) max. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front > Page 3918 NOTE: This is the maximum allowable difference between the thickness measurements. 4. If the smallest measurement is less than the max. refinishing limit, replace the brake disc. 5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Kwik-way Manufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front > Page 3919 Brake Rotor/Disc: Testing and Inspection Rear Rear Brake Disc Inspection Runout 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. 2. Remove the brake pads. 3. Inspect the brake disc surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 4. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. 5. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (3/8 inch) from the outer edge of the brake disc. Brake disc runout: Service limit: 0.10 mm (0.004 inch) 6. If the brake disc is beyond the service limit, refinish the brake disc. Max. refinish limit: 8.0 mm (0.31 inch) NOTE: ^ If the brake disc is beyond the service limit for refinishing, replace it. ^ A new disc should be refinished if its runout is greater than 0.10 mm (0.004 inch). Thickness and Parallelism 1. Raise the rear of the vehicle, and support with safety stands in the proper locations. Remove the rear wheels. 2. Remove the brake pads. 3. Using a micrometer, measure the brake disc thickness at eight points, approximately 45° apart and 10 mm (3/8 inch) in from the outer edge of the brake disc. Brake disc thickness: Standard: 9.9 - 10.1 mm (0.389 - 0.397 inch) Max. refinishing limit: 8.0 mm (0.31 inch) Brake disc parallelism: 0.016 mm (0.0006 inch) max. NOTE: This is the maximum allowable difference between the thickness measurements. 4. If the smallest measurement is less than the max. refinishing limit, replace the brake disc. 5. If the brake disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe. The Kwik-Lathe produced by Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front > Page 3920 Kwik-way Manufacturing Co. and the "Rear Brake Disc Lathe" offered by Snap-on Tools Co. are approved for this operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Brake System Bleeding NOTE: ^ Do not reuse the drained fluid. ^ Always use Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not allow dirt or other foreign matter to contaminate the brake fluid. ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. ^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleeder screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Starting at the left-front, loosen the brake bleeder screw to allow air to escape from the system. Then tighten the bleeder screw securely. 5. Repeat the procedure for each wheel in the sequence shown following until air bubbles no longer appear in the fluid. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 3925 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Removal Front Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. For '04-05 models, remove the brake hose bracket mounting bolt (A). 2. Remove the flange bolt (B). 3. Pivot the caliper up out of the way, and remove the brake pads (A). 4. Remove the pad shim(s) (B). 5. Check the hose and pin boots for damage and deterioration. 6. Remove the pad retainers (A), and check the caliper pins for free movement. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 3930 7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 8. Check the brake disc for damage and cracks. 9. Install the pad retainers. 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to brake pad sides of the pad shims (A), the back of the brake pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the brake discs and brake pads. 11. Install the brake pads and pad shims correctly. Install the brake pads with the wear indicators (C) on the lower brake inside. If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 12. Push in the piston (A) so the caliper will fit over the brake pads. Check the brake fluid level. The brake fluid may overflow if the reservoir is too full. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down. 13. Pivot the caliper (A) down into position. Be careful not to damage the pin boots, install the flange bolt (B), and tighten it to the specified torque. 14. For '04-05 models, install the brake hose bracket mounting bolt (C), and tighten it to the specified torque. 15. Press the brake pedal several times to make sure the brakes work, then test-drive. NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Overhaul Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 3931 Front Brake Caliper Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ Make sure no grease or oil gets on the brake discs or pads. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not mix different brands of brake fluid as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. Replace all rubber parts with new ones whenever disassembled. ^ After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 3932 Brake Caliper: Service and Repair Rear Removal Rear Brake Pad Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the bolt (A) and brake hose (B) from the mounting bracket. 2. Remove the caliper bolts (C), and remove the caliper (D) from the caliper bracket. 3. Remove the pad shims (A) and the brake pads (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 3933 4. Remove the pad retainers (A), and check the caliper pins for free movement. 5. Clean the caliper thoroughly;remove any rust, and check for grooves and cracks. 6. Check the brake disc for damage and cracks. 7. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainers on their mating surfaces against the caliper bracket. 8. Install the pad retainers. Wipe excess grease off the retainers. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 9. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to both sides of the pad shims (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess assembly paste off the shim. Contaminated brake discs and brake pads reduce stopping ability. Keep grease and paste off the discs and brake pads. 10. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the lower inside. If you are reusing the brake pads, always 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 (A) in the piston with the tab (B) on the inner pad by turning the piston back so the caliper can be installed. on the brake pad. Lubricate the boot with rubber grease to avoid twisting the piston boot. If the piston boot is twisted, back it out so it is positioned properly. 12. Install the brake caliper (C) and caliper bolts (D), and tighten the bolts to the specified torque. 13. Install the brake hose (E). 14. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 15. Press the brake pedal several times to make sure the brake works, then test-drive the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 3934 NOTE: Engagement of the brake may require a greater pedal stroke immediately after the brake pads has been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 16. Check the parking brake adjustment. Overhaul Rear Brake Caliper Overhaul CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. ^ Avoid breathing dust particles. ^ Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Remove, disassemble, inspect, reassemble, and install the caliper, and note these items: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected hose joints with rags or shop towels. ^ Clean all parts in brake fluid and air dry; blow out all passages with compressed air. ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones as specified in the illustration. ^ Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. ^ Make sure no grease or oil gets on the brake discs or pads. ^ When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. ^ Do not reuse drained brake fluid. Use only clean Honda DOT 3 Brake Fluid from an unopened container. Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. ^ Do not mix different brands of brake fluid as they may not be compatible. ^ Coat the piston, piston seal groove, and caliper bore with clean brake fluid. ^ Replace all rubber parts with new ones whenever disassembled. ^ After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid ...................................................................................................................................... Genuine Honda DOT 3 Brake Fluid (P/N 08798-9008) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 3938 Brake Fluid: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 3943 22. Left Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 3944 24. Brake Fluid Level Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 3945 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection Brake Hose/Line: Testing and Inspection Brake Hose and Line Inspection 1. Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. 3. Check for leaks at hose and line joints or connections, and retighten if necessary. 4. Check the master cylinder and ABS modulator unit for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Page 3949 Brake Hose/Line: Service and Repair Brake Hose Replacement NOTE: ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Replace parts with new ones whenever specified to do so. ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ To prevent dripping, cover disconnected line joints with rags or shop towels. 1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks. 2. Disconnect the brake hose from the brake line (B) using a 10 mm flare nut wrench (C). 3. Remove the flange bolt (A), and remove the brake hose brackets from the damper. 4. Remove and discard the hose clip (B). 5. Remove the banjo bolt (C), and remove the brake hose (D) from the caliper. 6. Install the brake hose bracket (A) on the damper with the flange bolt (B) first, then connect the brake hose (C) to the caliper with the banjo bolt (D) and new sealing washers (E). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Page 3950 7. Install the brake hose onto the hose bracket on the body with a new hose clip (A). 8. Connect the brake line to the brake hose. 9. After installing the brake hose, bleed the brake system. 10. Do the following checks: ^ Check the brake hose and line joint for leaks, and tighten if necessary. ^ Check the brake hoses for interference and twisting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations 27. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 3954 190. ABS Modulator-Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 3955 Hydraulic Control Assembly - Antilock Brakes: Description and Operation ABS Modulator The ABS modulator consists of the inlet solenoid valves, outlet solenoid valves, reservoir, pump, pump motor, and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir, and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining, and pressure reducing. The hydraulic circuit is an independent four-channel type, one channel for each wheel. Pressure intensifying mode: Inlet valve open, outlet valve closed Master cylinder fluid is pumped out to the caliper. Pressure retaining mode: Inlet valve closed, outlet valve closed: Caliper fluid is retained by the inlet: valve and outlet valve. Pressure reducing mode: Inlet valve closed, outlet valve open: Caliper fluid flows through the outlet valve to the reservoir. Motor operation mode: When starting the pressure reducing mode, the pump motor is ON. When stopping ABS operation, the pump motor is OFF. The caliper fluid is pumped out by the pump, through the damping chamber, to the master cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 3956 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31P connector (B), then disconnect the connector. 3. Disconnect the six brake lines from the ABS modulator-control unit (C). 4. Remove the two 8 mm nuts. 5. Remove the ABS modulator-control unit. Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the HDS, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the HDS. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection Brake Master Cylinder: Testing and Inspection Master Cylinder Inspection NOTE: ^ Before reassembling, check that all parts are free of dust and other foreign particles. ^ Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new part if necessary. ^ Do not allow dirt or foreign matter to contaminate the brake fluid. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 3960 Brake Master Cylinder: Adjustments Brake Booster Pushrod Clearance Adjustment Special Tools Required Pushrod adjustment gauge 07JAG-SD40100 NOTE: Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). 2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. 3. Install the master cylinder nuts (B), and tighten them to the specified torque. 4. Connect the booster in-line with a vacuum gauge (C) 0 - 101 kPa (0 - 760 mmHg, 0 - 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 inch Hg) vacuum. 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore, it must be adjusted and rechecked. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 3961 6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. ^ Adjust the clearance while the specified vacuum is applied to the booster. ^ Hold the yoke (C) while adjusting. 7. Tighten the star locknut securely. 8. Remove the special tool (D). 9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the yoke (C) in or out to adjust. 10. Install the master cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 3962 Brake Master Cylinder: Service and Repair Master Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Remove the air cleaner assembly (A). 2. Disconnect the brake fluid level sensor connector (A). 3. Remove the clutch reservoir (B) and engine wire harness clip (C) from the master cylinder mounting base (D). 4. Remove the reservoir cap and brake fluid from the reservoir. 5. Remove the reservoir (E) on the master cylinder mounting base. 6. Disconnect the brake lines (F) from the master cylinder (G). TO prevent spills, cover the hose joints with rags or shop towels. 7. Remove the master cylinder mounting nuts (H) and washers. 8. Remove the master cylinder from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder. 9. Remove the rod seal (I) from the master cylinder. 10. install the master cylinder in the reverse order of removal, and note these steps: ^ Replace all the rubber parts with new ones whenever the master cylinder is removed. ^ Check the pushrod clearance before installing the master coriander, airy adjust it if necessary. ^ Use a new rod seal on reassembly. ^ Coat the inner bore lip and outer circumference of the new rod seal (A) with the recommended seal grease in the Master cylinder set. ^ Install the rod steal onto the master cylinder with its grooved side (B) toward the master cylinder. ^ Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 3963 ^ Bleed the brake system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3968 Parking Brake Cable: Adjustments Parking Brake Check and Adjustment Check 1. Pull the parking brake lever (A) with 196 N (20 kgf, 44 ft. lbs.) of force to fully apply the parking brake. The parking brake [ever should be locked within the specified number of clicks (B). 2. Adjust the parking brake if the lever clicks are not within the specification. Adjustment 1. Release the parking brake lever fully. 2. Loosen the parking brake adjusting nut, start the engine, and press the brake pedal several times to set the self-adjusting brake before adjusting the parking brake. 3. Block the front wheels, then raise the rear of the vehicle, and support it with safety stands in the proper locations. 4. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B). NOTE: The parking brake arm will only contact the brake caliper pin when the parking brake adjusting nut is loosened. 5. Remove the rear console. 6. Pull the parking brake lever up one click. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3969 7. Tighten the adjusting nut (A) until the parking brake drags slightly when the rear wheels are turned. 8. Release the parking brake lever fully, and check that the parking brake does not drag when the rear wheels are turned. Readjust if necessary. 9. Make sure the parking brake is fully applied when the parking brake lever is pulled up fully. 10. Reinstall the rear console, Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3970 Parking Brake Cable: Service and Repair Parking Brake Cable Replacement Exploded View NOTE: ^ The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure. ^ Refer to the Exploded View as needed during this procedure. 1. Release the parking brake lever fully. 2. Remove the rear console. 3. Loosen the parking brake cable adjusting nut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3971 4. Remove the parking brake cable clip (A) from the brake cable (B). 5. Disconnect the parking brake cable from the lever (C). 6. Remove the parking brake cable mounting hardware, then remove the cable. 7. Install the new cable in the reverse order of removal, and note these items: ^ Be careful not to bend or distort the cable. ^ Make sure the parking brake cable clip is fully seated on the cable housing. ^ Do the parking brake cable adjustment. 8. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 3975 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 3976 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 3977 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection Vacuum Brake Booster: Testing and Inspection Brake Booster Test Functional Test 1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the brake pedal hard, and hold it for 15 seconds. If the brake pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, or calipers) is leaking. 2. Start the engine with the brake pedal pressed. If the brake pedal sinks slightly, the vacuum booster is working properly. If the brake pedal height does not vary, the booster or check valve is faulty. 3. With the engine running, press the brake pedal lightly. If the brake pedal sinks more than 10 mm (3/8 inch) in 3 minutes, the master cylinder is faulty. A slight change in brake pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the booster.) Leak Test 1. Press the brake pedal with the engine running, then stop the engine. If the brake pedal height does not vary while pressed 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 brake pedal is first pressed, it should be low. On consecutive applications, the brake pedal height should gradually rise. If the brake pedal position does not vary, check the booster check valve. 3. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster side. 4. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. 5. Reconnect the brake booster vacuum hose. Start the engine, and then pinch the brake booster vacuum hose between the check valve and the booster. 6. Turn the ignition switch OFF, and wait 30 seconds. Press the brake pedal several times using normal pressure. When the brake pedal is first pressed, it should be low. On consecutive applications, the brake pedal height should gradually rise. ^ If the pedal position does not vary, replace the brake booster. ^ If the pedal position varies, replace the brake booster vacuum hose/check valve assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 3982 Vacuum Brake Booster: Adjustments Brake Booster Pushrod Clearance Adjustment Special Tools Required Pushrod adjustment gauge 07JAG-SD40100 NOTE: Brake booster pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. 1. Set the special tool (A) on the master cylinder body (B), push in the center shaft (C) until the top of it contacts the end of the secondary piston (D) by turning the adjusting nut (E). 2. Without disturbing the center shaft's position, install the special tool (A) backwards on the booster. 3. Install the master cylinder nuts (B), and tighten them to the specified torque. 4. Connect the booster in-line with a vacuum gauge (C) 0 - 101 kPa (0 - 760 mmHg, 0 - 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mmHg, 20 inch Hg) vacuum. 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore, it must be adjusted and rechecked. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 3983 6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. ^ Adjust the clearance while the specified vacuum is applied to the booster. ^ Hold the yoke (C) while adjusting. 7. Tighten the star locknut securely. 8. Remove the special tool (D). 9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the yoke (C) in or out to adjust. 10. Install the master cylinder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 3984 Vacuum Brake Booster: Service and Repair Brake Booster Replacement 1. Remove the master cylinder. 2. Remove the master cylinder brake lines (A) from the brake line clip. 3. Remove the vacuum hose mounting bracket (B). 4. Disconnect the vacuum hose (C) from the brake booster. 5. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke from the brake pedal. 6. Remove the brake booster mounting nuts (C). 7. Remove the brake booster (A) from the engine compartment. NOTICE: ^ Be careful not to damage the booster surfaces and threads of the booster stud bolts. ^ Be careful not to bend or damage the brake lines. 8. Install the brake booster in the reverse order of removal, and note these items: ^ Adjust the pushrod clearance before installing the brake booster. ^ Use a new lock pin whenever installing. ^ After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Booster Check Valve Test 1. Disconnect the brake booster vacuum hose (check valve built-in) (A) at the booster side. 2. Start the engine, and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve, and retest. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations 27. Right Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Component Locations > Page 3993 Electronic Brake Control Module: Connector Locations System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3994 190. ABS Modulator-Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3995 Electronic Brake Control Module: Description and Operation ABS Control Unit Main Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration. The ABS control unit calculates the slip rate of each wheel, and transmits the control signal to the modulator unit solenoid valve when the slip rate is high. The pressure reduction control has three modes: pressure reducing, pressure retaining, and pressure intensifying. Self-diagnosis Function 1. The ABS control unit is equipped with a main CPU and a sub-CPU. Each CPU checks the other for problems. 2. The CPUs check the circuit of the system. 3. The ABS control unit turns on the ABS indicator when the unit detects a problem, and the unit stops the system. 4. The self-diagnosis can be classified into these two categories: ^ Initial diagnosis ^ Regular diagnosis On-board Diagnosis Function The ABS can be diagnosed with the HDS. The ALB Checker cannot be used with this system. For air bleeding and checking wheel sensor signals, use the HDS. See the HDS help menu for specific operating instructions. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3996 Electronic Brake Control Module: Testing and Inspection System Description Part 1 Part 2 ABS Control Unit Inputs and Outputs for 31P Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 3997 Electronic Brake Control Module: Service and Repair ABS Modulator-Control Unit Removal and Installation NOTE: ^ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. ^ Be careful not to damage or deform the brake lines during removal and installation. ^ To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material. Removal 1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 31P connector (B), then disconnect the connector. 3. Disconnect the six brake lines from the ABS modulator-control unit (C). 4. Remove the two 8 mm nuts. 5. Remove the ABS modulator-control unit. Installation 1. Install the ABS modulator-control unit, then tighten the two 8 mm nuts. 2. Align the connecting surface of the ABS control unit 31P connector. 3. Push in the lock of the ABS control unit 31P connector until you hear it click into place, then connect the connector. 4. Connect the six brake lines. 5. Bleed the brake system, starting with the front wheels. 6. Connect the HDS, and do the solenoid function test for each wheel. 7. Bleed the brake system again, starting with the front wheels. 8. Start the engine, and check that the ABS indicator and brake system indicator go off. 9. Disconnect the HDS. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Component Locations > Page 4003 22. Left Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4004 24. Brake Fluid Level Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4005 Brake Fluid Level Sensor/Switch: Testing and Inspection Brake Fluid Level Switch Test Check for continuity between the terminals (A) with the float in the down position and the up position. ^ Remove the brake fluid completely from the reservoir. With the float down, there should be continuity. ^ Fill the reservoir with brake fluid to MAX (upper) level (B). With the float up, there should be no continuity. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations Braking Sensor/Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4009 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4010 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4011 199. Brake Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4012 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4013 Braking Sensor/Switch: Testing and Inspection Brake Pedal Position Switch Signal Circuit Troubleshooting 1. Check the brake lights. Are the brake lights on without pressing the brake pedal? YES - Inspect the brake pedal position switch. NO - Go to step 2. 2. Press the brake pedal. Do the brake lights come on? YES - Go to step 3. NO - Go to step 4. 3. Measure voltage between ECM connector terminals A24 and E22 with the brake pedal pressed. Is there battery voltage? YES - The brake pedal position switch signal is OK. NO - Repair open in the wire between the ECM (E22) and the brake pedal position switch. 4. Inspect the No.7 HORN, STOP (15 A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the brake pedal position switch and the No.7 HORN, STOP (15 A) fuse. Inspect the brake pedal position switch. NO - Repair short in the wire between the ECM (E22) and the No.7 HORN, STOP (15 A) fuse. Replace the No.7 HORN, STOP (15 A) fuse. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4014 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. Disconnect the brake pedal position switch connector, turn the brake pedal position switch (A) counterclockwise, and pull it back until it is no longer touching the brake pedal. 2. Lift up the carpet and the insulator cutout (B). Measure the pedal height (C) from the middle of the left side of the pedal pad (D). Standard pedal height (with carpet removed): 184 mm (7 1/4 inch) 3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod pressed. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the brake pedal by hand. 2. If the pedal free play is out of specification, adjust the brake pedal position switch (C). If the pedal free play is insufficient, it may result in brake drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4015 Brake Pedal Position Switch Clearance 1. Push in the brake pedal position switch until its plunger is fully pressed (threaded end (A) touching the pad (B) on the pedal arm). Then, turn the brake pedal position switch 45° clockwise to lock it. The gap between the brake pedal position switch and the pad is automatically adjusted to 0.4 to 3.0 mm (0.016 - 0.118 inch) by locking the switch. Make sure the brake lights go off when the pedal is released. 2. Check the brake pedal free play. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4019 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4020 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4021 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations 35. Lower Left Side of Engine Comp. (Right Sim.) 37. Under Left Rear of Vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4025 102. Right Side of Cargo Area Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4026 Wheel Speed Sensor: Diagrams 86. Wheel Speed Sensor, Left Front 87. Wheel Speed Sensor, Left Rear 88. Wheel Speed Sensor, Right Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4027 89. Wheel Speed Sensor, Right Rear Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4028 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contactless type. As the gear purser teeth rotate past the wheel sensor's magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the inlet valve closes and if necessary, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, and the outlet valve closes, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4029 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Inspect the front and rear pursers for chipped or damaged teeth. 2. Measure the air gap between the wheel sensor and the purser all the way around while rotating the purser. Remove the rear brake disc to measure the gap on the rear wheel sensor. If the gap exceeds 1.0 mm (0.04 inch), check for a bent suspension arm. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 4030 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4036 Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4037 27. Clutch Interlock Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4038 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install the clutch interlock switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4039 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C). 2. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. To measure the pedal height to the floor, remove the driver's footrest, and measure to where it mounts to the floor. Clutch Pedal Stroke: 130 - 140 mm (5.12 - 5.51 inch) Clutch Pedal Free Play: 10 - 16 mm (0.39 - 0.63 inch) Clutch Pedal Height to floor: 193 mm (7.60 inch) to carpet: 155 mm (6.10 inch) Disengagement Height to floor: 115 mm (4.53 inch) to carpet: 77 mm (3.08 inch) 3. Tighten the clutch pushrod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C). 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten the clutch pedal position switch locknut (A). 7. Loosen locknut (J) and the clutch interlock switch (K). 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 10 - 16 mm (0.39 - 0.63 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4045 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4046 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4047 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4048 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4049 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4050 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4051 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4052 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4053 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4054 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4059 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4060 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4061 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Electrical - Battery Replacement Precautions Battery Cable: Technical Service Bulletins Electrical - Battery Replacement Precautions Replacing a Battery? Don't Disconnect the Cables With the Engine Running When replacing a battery, many service techs disconnect the battery cables with the engine running to keep the data alive in volatile memory. This practice worked fine back in the day when vehicles were pretty much a box on wheels, but with so many of today's vehicles sporting a impressive array of cool, high tech hardware, it's not recommended. Here's why: ^ The battery works as a capacitor to prevent sudden swings in voltage. With the battery cables disconnected, the alternator voltage regulator tries to stabilize the system voltage, but it can only do so by turning the alternator on and off. ^ When solenoids or relays are turned on and of{ they produce a very high voltage spike that travels through the 12-volt system. This voltage spike can fry sensitive solid state components or corrupt the data that's stored in volatile memory for such components as the gauge control module, the radio, and the various control units. The best way to keep data alive in volatile memory when replacing a battery is to hook up a Honda Computer Memory Saver to the 16P data link connector (DLC). This portable tool works as a secondary 12-volt source. It saves you the hassle of writing down your customer's audio presets, resetting the clock, or even doing the idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Electrical - Battery Replacement Precautions > Page 4067 The Honda Computer Memory Saver is indeed a real time saver, but here's a word of caution: Don't let the positive battery cable touch any body ground. It will cause a short that will either blow the fuse in the tool or cause a drop in system voltage resulting in the loss of any data that 5 in volatile memory. The Honda Computer Memory Saver is available through the Honda Tool and Equipment Program. To order one, just call and ask for FZRMS4000H. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Engine Won't Start - Check Alternator Bolts Alternator: Technical Service Bulletins Engine Won't Start - Check Alternator Bolts SOURCE: Honda Service News August 2004 TITLE: Engine Won't Start? Check for Loose Alternator Bolts APPLIES TO: 2001-04 Civic SERVICE TIP: Got a 2001-04 Civic in your shop with any or all of these symptoms? - The engine cranks but it won't start. - The MIL comes on. - The immobilizer indicator blinks while the engine cranks. - The HDS can't communicate with the ECM/PCM. Check for loose alternator bolts. If these bolts are loose for any reason such as the alternator was R&R;'ed or an accessory A/C was installed on a DX model at the dealership, the alternator can overcharge and fry the ECM/PCM. If the alternator bolts are loose, tighten them, and try restarting the engine. If the engine still won't start, then check the ECM/PCM connector for battery voltage and ground. If you're reading battery voltage and ground at the connector, then replace the ECM/PCM. Keep in mind, though, any ECM/PCM damage that's caused by loose alternator bolts from A/C installation or body repair isn't covered by warranty. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Page 4073 Alternator: Specifications Alternator Output At 13.5 V and normal engine temperature ............................................................................................................................................................ 80 A Coil (rotor) resistance AT 68°F (20°C) .................................................................................................................................... ................................................ 2.2 - 3.0 Ohms Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Page 4074 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views 117. Alternator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator FR Signal Circuit Troubleshooting Alternator: Testing and Inspection Alternator FR Signal Circuit Troubleshooting Alternator FR Signal Circuit Troubleshooting 1. Disconnect the alternator 4P connector from the alternator. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM connector terminals A24 and B13. Is there about 5 V? YES - Go to step 4. NO - Go to step 13. 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in neutral) until the radiator 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 alternator FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM connector B (24P). 10. Disconnect the alternator 4P connector. 11. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator FR Signal Circuit Troubleshooting > Page 4079 12. Check for continuity between body ground and ECM connector terminal B13. Is there continuity? YES - Test the alternator. NO - Repair open in the wire between the ECM (B13) and the alternator. 13. Turn the ignition switch OFF. 14. Disconnect ECM connector B (24P). 15. Check for continuity between body ground and ECM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM (B13) and the alternator. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement Alternator: Service and Repair Replacement Alternator Replacement 1. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets. Make sure the ignition switch is OFF. 2. Disconnect the negative cable from the battery first, then disconnect the positive cable. 3. Remove the front bumper. 4. Remove the right side headlight. 5. Remove the reserve tank from the bracket. 6. Remove the drive belt. 7. Remove the three bolts securing the alternator. 8. Disconnect the alternator connector (A) and BLK wire (B) from the alternator. 9. Remove the alternator. 10. Install the alternator and drive belt in the reverse order of removal. 11. Connect the positive cable to the battery, then connect the negative cable. 12. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 13. Set the clock. 14. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4082 Alternator: Service and Repair Overhaul Alternator Overhaul Exploded View Special Tools Required - Driver 07749-0010000 - Attachment, 42 x 47 mm 07746-0010300 NOTE: Refer to the Exploded View as needed during this procedure. Alternator Disassembly 1. Test the alternator and regulator before you remove them. 2. Remove the alternator. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4083 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. 4. Remove the harness bracket (A), insulator (B), three flange nuts (C), and the screw (D), then remove the plate terminal (E). 5. Remove the end cover (A) and dust seal (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4084 6. Remove the brush holder (A), voltage regulator (B), and the rubber seal (C). 7. Remove the four screws, then remove the rectifier (A) and four insulators (B). 8. Remove the four flange nuts, then remove the rear housing (A) and washer (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4085 9. If you are not replacing 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 stator housing for seizure marks. - If either the rotor or stator housing is damaged, replace the alternator. - If both the rotor and the stator housing are OK, go to step 11. 11. Remove the rear bearing using a puller as shown. 12. With a hammer and commercially available tools shown, install a new rear bearing on the rotor shaft. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4086 13. Remove the front bearing retainer plate. 14. Support the stator housing in a vise, and drive out the front bearing with a brass drift and hammer. 15. With a hammer and the special tools, install a new front bearing in the stator housing. Rectifier Test Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4087 16. Check for continuity in each direction, between the B terminal and P terminals, and between the E terminal and P terminals of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of eight diodes (four pairs), you must test each diode in both directions for continuity with an Ohmmeter that has diode checking capability: a total of 16 checks. If any diode is faulty, replace the rectifier assembly. (Diodes are not available separately.) - If all the diodes are OK, go to step 17. Alternator Brush Inspection 17. Measure the length of both brushes (A) with a vernier caliper (B). - If either brush is shorter than the service limit, replace the brush assembly. - If brush length is OK, go to step 18. Rotor Slip Ring Test Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Replacement > Page 4088 18. Check for continuity between the slip rings (A), - If there is continuity, go to step 19. - If there is no continuity, replace the alternator. 19. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C). - If there is no continuity, then go to step 20. - If there is continuity, replace the alternator. Stator Test 20. Check for continuity between each pair of leads (A). - If there is continuity, go to step 21. - If there is no continuity, replace the alternator. 21. Check for continuity between each lead and the coil core(B). - If there is no continuity, go to step 22. - If there is continuity, replace the alternator. 22. Assemble the alternator in the reverse order of disassembly, and note these items: - Be careful not to get any grease or oil on the slip rings. - If you removed the pulley, tighten its locknut to 111 N.m (11.3 kgf.m, 81.7 lbf.ft) when you install it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4093 Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4094 27. Clutch Interlock Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4095 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector. 2. Remove the clutch interlock switch (A). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install the clutch interlock switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4096 Clutch Switch: Adjustments Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment NOTE: To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and pushrod, the release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems. 1. Loosen the clutch pedal position switch locknut (A), and back off the clutch pedal position switch (B) until it no longer touches the clutch pedal (C). 2. Loosen the clutch pushrod locknut (D), and turn the pushrod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. To measure the pedal height to the floor, remove the driver's footrest, and measure to where it mounts to the floor. Clutch Pedal Stroke: 130 - 140 mm (5.12 - 5.51 inch) Clutch Pedal Free Play: 10 - 16 mm (0.39 - 0.63 inch) Clutch Pedal Height to floor: 193 mm (7.60 inch) to carpet: 155 mm (6.10 inch) Disengagement Height to floor: 115 mm (4.53 inch) to carpet: 77 mm (3.08 inch) 3. Tighten the clutch pushrod locknut (D). 4. With the clutch pedal released, turn the clutch pedal position switch (B) in until it contacts the clutch pedal (C). 5. Turn the clutch pedal position switch (B) in an additional 3/4 to 1 turn. 6. Tighten the clutch pedal position switch locknut (A). 7. Loosen locknut (J) and the clutch interlock switch (K). 8. Press the clutch pedal to the floor. 9. Release the clutch pedal 10 - 16 mm (0.39 - 0.63 inch) from the fully depressed position, and hold it there. Adjust the position of the clutch interlock switch (K) so that the engine will start with the clutch pedal in this position. 10. Tighten the clutch interlock switch locknut (J). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Lock: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Ignition Switch Lock Cylinder: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4106 Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4107 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4108 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4109 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4110 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4111 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4112 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4113 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4114 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch > Page 4115 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Cable: Customer Interest Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4128 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4129 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4130 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4131 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Cable: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4137 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4138 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4139 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4140 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Motor: Customer Interest Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4149 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4150 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4151 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4152 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Motor: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4158 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4159 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4160 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 4161 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 4162 Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 4163 Starter Motor: Testing and Inspection Starter Performance Test 1. Disconnect the wires from the S terminal and the M terminal. 2. Make a connection as shown using as heavy a wire as possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, never leave the battery connected for more than 10 seconds. 3. Connect the battery as shown. Make sure you disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly. 4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly. 5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly. 6. Clamp the starter firmly in a vise. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 4164 7. Connect the starter to the battery as shown in the diagram, and check that the motor turns and keeps rotating. 8. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement Starter Motor: Service and Repair Replacement Starter Replacement 1. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets. Make sure the ignition switch is OFF. 2. Disconnect the negative cable from the battery first, then disconnect the positive cable. 3. Disconnect the knock sensor connector. 4. Remove the bolt (A) securing the harness bracket, then remove the intake manifold bracket (B). 5. Disconnect the starter cable (A) from the B terminal on the solenoid, then disconnect the BLK/WHT wire (B) from the S terminal. 6. Remove the two bolts holding the starter, then remove the starter. 7. Install the starter in the reverse order of removal. Make sure the crimped side of the ring terminal (A) is facing out. 8. Connect the positive cable to the battery first, then connect the negative cable. 9. Start the engine to make sure the starter operates properly. 10. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 11. Set the clock. 12. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4167 Starter Motor: Service and Repair Overhaul Starter Overhaul Exploded View Armature Inspection and Test 1. Remove the starter. 2. Disassemble the starter as shown at the beginning of this procedure. 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4168 4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the specifications in step 5, or recondition with #500 or #600 sandpaper (B). 5. Check the commutator diameter. If the diameter is out of the service limit, replace the armature. 6. Measure the commutator (A) runout. - If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. - If the commutator runout is not within the service limit, replace the armature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4169 7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D). 8. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature. 9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4170 10. Check with an Ohmmeter for continuity between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If there is continuity, replace the armature. Starter Brush Inspection 11. Measure the brush length. If it is not within the service limit, replace the brush holder assembly. Starter Field Winding Test 12. Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B). 13. Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing. Starter Brush Holder Test Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4171 14. Check for continuity between the (+) brush holder (A) and (-) brush holder (B). If there is continuity, replace the brush holder assembly. Brush Spring Inspection 15. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. If the spring tension is not to specification, replace the spring. Planetary Gear Inspection 16. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged. Overrunning Clutch Inspection 17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Replacement > Page 4172 18. Rotate the overrunning clutch (A) both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it. 19. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel ring gear. Replace the flywheel if the ring gear teeth are damaged. Starter Reassembly 20. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side out, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator. 21. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush. 22. Install the starter end cover to retain the brush holder. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4176 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4177 Starter Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4178 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations 1. Front Of Engine (Intake Manifold Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 4182 11. Starter Solenoid Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 4183 Starter Solenoid: Testing and Inspection Starter Solenoid Test 1. Disconnect the S and M connectors from the starter solenoid. 2. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity. - If there is continuity, go to step 3. - If there is no continuity, replace the solenoid. 3. Check the pull-in coil for continuity between the S terminal and M terminal. There should be continuity. - If there is continuity, the solenoid is OK. - If there is no continuity, replace the solenoid. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 Auxiliary Power Outlet: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4216 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 19. Acessory Power Socket Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Auxiliary Power Outlet: Electrical Diagrams Accessory Power Sockets - Circuit Diagram Wiring Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Diagram 155-0 Diagram 155-1 (Honda Accessory) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4223 Auxiliary Power Outlet: Testing and Inspection Accessory Power Socket Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No. 1 and No. 2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: Poor ground (G502). - An open in the wire. - Blown No. 18 (15 A) fuse in the under-dash fuse/relay box. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4224 Auxiliary Power Outlet: Service and Repair Accessory Power Socket Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No. 1 and No. 2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: Poor ground (G502). - An open in the wire. - Blown No. 18 (15 A) fuse in the under-dash fuse/relay box. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Electronic Noise Suppressor: Diagrams 51. Noise Condenser, Rear Window Defogger 52. Noise Condenser, Rear Window Wiper Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations Fuse: Component Locations Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4232 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4233 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4234 Fuse: Connector Locations Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4235 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4240 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4241 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4246 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4247 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4248 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4249 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4250 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4251 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4252 Fuse Block: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4253 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4254 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4255 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4258 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4259 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4260 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4261 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4262 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4263 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4264 Fuse Block: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Application and ID Ground To Components Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams 189. C104 (Junction Connector) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals Multiple Junction Connector: Service and Repair How To Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4273 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4274 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. 2. Remove the terminal from the female half. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4275 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4276 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4277 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4278 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4279 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4280 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4281 Multiple Junction Connector: Service and Repair How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4282 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4283 Multiple Junction Connector: Service and Repair How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4284 to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4285 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4286 Multiple Junction Connector: Service and Repair Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4287 Multiple Junction Connector: Service and Repair Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4293 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4294 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4295 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4296 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4297 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4298 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4299 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4300 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4301 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4302 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4303 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4304 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4305 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4306 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4307 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4308 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4309 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4312 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4313 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4318 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4319 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4320 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4321 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4322 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4323 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4324 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4325 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4326 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4327 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4328 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4329 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4330 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4331 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4332 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4333 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4334 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4337 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4338 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4349 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4350 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4353 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Auxiliary Power Outlet: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 19. Acessory Power Socket Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 Auxiliary Power Outlet: Electrical Diagrams Accessory Power Sockets - Circuit Diagram Wiring Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Diagram 155-0 Diagram 155-1 (Honda Accessory) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4378 Auxiliary Power Outlet: Testing and Inspection Accessory Power Socket Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No. 1 and No. 2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: Poor ground (G502). - An open in the wire. - Blown No. 18 (15 A) fuse in the under-dash fuse/relay box. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4379 Auxiliary Power Outlet: Service and Repair Accessory Power Socket Test/Replacement 1. Carefully pry the accessory power socket (A) out from the center lower cover. 2. Disconnect the 2P connector (B) from the socket. 3. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Turn the ignition switch ACC (I), and check for voltage between the No. 1 and No. 2 terminals. - There should be battery voltage. - If there is no battery voltage, check for: Poor ground (G502). - An open in the wire. - Blown No. 18 (15 A) fuse in the under-dash fuse/relay box. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Electronic Noise Suppressor: Diagrams 51. Noise Condenser, Rear Window Defogger 52. Noise Condenser, Rear Window Wiper Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations Fuse: Component Locations Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4387 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4388 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4389 Fuse: Connector Locations Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Component Locations > Page 4390 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box Fuse: Application and ID Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4395 Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4396 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4401 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4402 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4403 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4404 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4405 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4406 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4407 Fuse Block: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4408 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4409 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 4410 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4413 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4414 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4415 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4416 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4417 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4418 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4419 Fuse Block: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Application and ID Ground To Components Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams 189. C104 (Junction Connector) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals Multiple Junction Connector: Service and Repair How To Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4428 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4429 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. 2. Remove the terminal from the female half. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4430 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4431 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4432 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4433 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4434 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4435 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4436 Multiple Junction Connector: Service and Repair How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4437 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4438 Multiple Junction Connector: Service and Repair How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4439 to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4440 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4441 Multiple Junction Connector: Service and Repair Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 4442 Multiple Junction Connector: Service and Repair Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4448 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4449 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4450 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4451 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4452 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4453 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4454 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4455 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4456 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4457 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4458 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4459 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4460 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4461 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4462 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4463 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4464 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4467 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4468 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations Starting System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4473 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4474 63. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4475 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4476 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4477 Charging System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4478 20. Left Side of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4479 Relay Box: Connector Locations Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4480 Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4481 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 4482 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4483 Relay Box: Diagrams 199. Under-dash Fuse/Relay Box Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4484 199. Under-dash Fuse/Relay Box Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4485 199. Under-dash Fuse/Relay Box Part 3 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4486 199. Under-dash Fuse/Relay Box Part 4 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4487 199. Under-dash Fuse/Relay Box Part 5 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4488 199. Under-dash Fuse/Relay Box Part 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4489 200. Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 4492 Under-hood Fuse/Relay Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4493 Relay Box: Service and Repair Under-Dash Fuse/Relay Box Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the driver's dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt, and slide the under-dash fuse/relay box (A) down from the bracket (B). 6. Disconnect the back side from connectors from the back of the under-dash fuse/relay box, and remove the fuse/relay box. NOTE: The SRS connector is a spring-loaded lock type. Installation 1. Install the under-dash fuse/relay box in the reverse order of removal and connect all connectors to the under-dash fuse/relay box. 2. Install the driver's dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. On '04-05 models, reset the power window control unit. 6. Confirm that all systems work properly. 7. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: Customer Interest Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4503 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4504 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4505 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4506 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4507 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4508 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4509 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4510 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4511 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right Alignment: All Technical Service Bulletins Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4517 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4518 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4519 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4520 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4521 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4522 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4523 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4524 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 4525 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN041115 > Nov > 04 > Alignment - Specifications For Sport Suspension Kit Alignment: All Technical Service Bulletins Alignment - Specifications For Sport Suspension Kit SOURCE: Honda Service News November 2004 TITLE: Sport Suspension Kit Alignment Specifications APPLIES TO: 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension SERVICE TIP: Doing an alignment on a 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension Kit? Keep in mind the alignment specs aren't entirely the same as the standard specs in the S/M. Refer to this chart for the proper specs on these vehicles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds > Page 4534 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN041115 > Nov > 04 > Alignment - Specifications For Sport Suspension Kit Alignment: All Technical Service Bulletins Alignment - Specifications For Sport Suspension Kit SOURCE: Honda Service News November 2004 TITLE: Sport Suspension Kit Alignment Specifications APPLIES TO: 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension SERVICE TIP: Doing an alignment on a 2004 Accord V6 or a 2004 Civic 2-door or 3-door equipped with the Sport Suspension Kit? Keep in mind the alignment specs aren't entirely the same as the standard specs in the S/M. Refer to this chart for the proper specs on these vehicles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds Alignment: All Technical Service Bulletins Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > SN030915 > Sep > 03 > Suspension - Drifting & Pulling At Highway Speeds > Page 4544 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4545 Alignment: By Symptom Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4546 Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4547 The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4548 The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4549 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4550 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4551 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4552 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4553 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4554 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Technical Service Bulletin # SN030915 Date: 030901 Suspension - Drifting & Pulling At Highway Speeds SOURCE: Honda Service News September 2003 TITLE: Drifting and Pulling at Highway Speeds APPLIES TO: All Models SERVICE TIP: Got a customer complaining that the vehicle drifts or pulls when driving at highway speeds? Use this handy procedure to diagnose and repair the problem. NOTE: Before doing the procedure in this article, check ISIS for related S/Bs and other S/N articles for the model you're working on. 1. Check if your customer has original equipment wheels and tires and that the ride height hasn't been modified. - If the wheels, tires, and ride height are OK, go to step 2. - If the wheels or tires aren't original equipment or the ride height was modified, stop here. Aftermarket wheels or tires or a ride height that's been modified pose challenges that this article doesn't cover. Resolve these issues with your customer before going further. 2. Set the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. 3. Find a straight stretch of 4-lane road where you can safely (and legally) go 60 mph for several minutes. Ideally, you want a road that's perfectly flat, but most roads have a crown that¡C■s anywhere from 1.5° to 1.75° so they can drain. Flat Road - While driving at 60 mph, use a stopwatch to time how long it takes to drift one full lane from center to center. Record the time. Repeat this, driving in the opposite direction to cancel the effects of wind, then average the two times you recorded. If the vehicle drifts one full lane from center to center in less than 6 seconds, go to step 4. If not, return the vehicle to your customer. Crowned Road - While driving at 60 mph, check if the vehicle climbs the crown. Do this for both a left- and right-crowned road. A drift to the right on a right-crowned road and a drift to the left on left-crowned road are considered normal. If the vehicle climbs the crown or it drifts to the right on a left crowned road, go to step 4. 4. Record the original toe, camber, and caster readings. On Passports, set the ride height to spec if needed. Refer to Ride Height Adjustment in S/B 99-043, Steering Wheel Shimmy or Chassis Vibration. 5. Loosen the subframe mounting bolts, and move the rear beam (it¡C■s the entire front subframe on some models) to get the maximum amount of caster and equal side-to-side camber. (As little as 0.4° of camber stagger can cause the vehicle to pull.) 6. Make sure the steering wheel is centered, then set the front and rear toe to the maximum toe-in spec. (Toe-in improves vehicle stability and reduces the tendency to drift or pull.) 7. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, return the vehicle to your customer. - If the drift is still out of spec, go to step 8. 8. Swap the front and rear tires on each side of the vehicle, then adjust the tire pressures to the recommended cold inflation values listed on the doorjamb sticker. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4555 9. Test-drive the vehicle on the same road you used earlier. - If the drift is now within spec, swap each rear tire back to the front, one at a time, and test-drive the vehicle on the same road you used earlier. Replace the bad tire, then return the vehicle to your customer. - If the drift is still out of spec after swapping the front and rear tires, go to step 10. 10. Test-drive a known-good donor vehicle on the same road you used earlier, and check its pull. 11. Swap all four tires from the donor vehicle with the tires on your customer¡C■s vehicle. 12. Test-drive your customer¡C■s vehicle on the same road you used earlier. - If the drift is now within spec, swap the tires back to the donor vehicle one at a time, and test-drive your customer¡C■s vehicle on the same road you used earlier. Do this until the drift comes back. Replace the bad tire(s), then return the vehicle to your customer. - If the drift is still out of spec using the donor vehicle tires, contact Tech Line for further action. Technical Service Bulletin # 06-068 Date: 090502 Steering/Suspension - Vehicle Pulls Left/Right 06-068 May 2, 2009 Applies To: ALL *Vehicle Pulls or Drifts, and/or Steering Wheel Is Off-Center (Supersedes 06-068, Vehicle Pulling or Drifting, dated October 4, 2007, to revise the information marked by asterisks) (Replaces 90-011, Steering Wheel Off-Center Adjustment at PDI)* *REVISION SUMMARY The title description was revised.* SYMPTOM While driving on a straight road, the vehicle pulls or drifts to the right or left. BACKGROUND New tools were developed to help you diagnose and correct a pulling and/or steering wheel off-center issue. There is a diagnosis worksheet included to take on your test-drive and record your findings. These values are used to build the 15-digit DTC (diagnostic trouble code) that is required for your warranty claim. The last step in each repair procedure helps you create the correct code. In the rare case that you have to repair a vehicle that pulls and has the steering wheel off-center, use REPAIR PROCEDURE B to file your warranty claim. For more information, refer to Training Module SSC 44 - Steering Drift or Pull Interactive Service Bulletin. PROBABLE CAUSES Several conditions can cause the vehicle to pull or drift: ^ Wheel alignment ^ Tires ^ Off-center steering wheel (no pulling or drifting, but a customer may believe this is the case) CORRECTIVE ACTION Diagnose the problem using the special tools and the worksheet on page 4 that guides you to one of four repair procedures. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4556 TOOL INFORMATION Centering Tape (enough to diagnose 240 vehicles): T/N O7AAJ-001A300 Steering Drift Set Level: T/N 07AAJ-00100 Steering Drift Set: T/N O7MJ-001A140 Replacement Weight for Steering Drift Set: T/N 07AAJ-001A400 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 53560-SDA-AO1 H/C 7139652 Defect Code: 07406 Symptom Code: 03602 Skill Level: Repair Technician Diagnostic Trouble Code: To create the 15-digit DTC, see the applicable repair procedure. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. TOOL DESCRIPTIONS The holding force gauge measures the amount of pull on the vehicle. It is a bracket that counts as one weight, plus five removable weights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4557 During the test-drive, attach the bracket and the weights to the steering wheel on the side opposite the pulling direction. For example, if the vehicle pulls to the right, attach the bracket and weights to the left side of the steering wheel. Start with the maximum amount of weight on the steering wheel, and remove the weights until the vehicle drives in a straight line. When recording the pull on the worksheet, write down the direction of the pull (lefi or right) and the number of weights required to balance the pull (one through six). For example, if you have the bracket and two weights on the steering wheel, then record this as three weights. NOTE: The bracket counts as one weight. The road crown gauge measures the amount of road crown. Almost all roads have a crown to help drain water during rainstorms. Use the suction cup to attach the road crown gauge bracket to the vehicle in a vertical position. If necessary, bend the bracket until the gauge is vertical. Once you attach and align the road crown gauge, calibrate the gauge to zero. There are two ways to calibrate the gauge: ^ Park the vehicle on a level surface, such as an alignment rack, and calibrate the gauge by moving the gauge until the ball is on the zero mark. ^ If you do not have a perfectly flat surface, park the vehicle on a reasonably flat surface and note the gauge reading. Turn the vehicle 1800 and, with the tires in the same spot, note the new gauge reading. Then move the gauge half of the difference. For example, if your first reading is +3 and, after moving the vehicle, the gauge reads -1, then the difference is 4 degrees. Position the gauge to read +1. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4558 NOTE: You must calibrate the gauge with the same weight in the vehicle that you will use for the test-drive. If you plan to have an assistant help you during the test-drive, calibrate the gauge while both of you are sitting in the vehicle. The steering wheel offset gauge is a sticker that attaches to the steering wheel and the steering column cover. Place the sticker on the steering wheel when the steering wheel is straight. When you test-drive the vehicle, you can read how many millimeters the steering wheel is off-center. NOTE: If the vehicle is pulling, repairing the pull may correct the steering wheel offset. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4559 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4560 NOTE: Do this repair procedure if, after doing step 10 of the test-drive, the vehicle pulled in the opposite direction after you swapped the front tires. 1. Swap wheels 2 and 4 on the passenger's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 2, then go to step 3. ^ If the pull does not go away, put wheels 2 and 4 back to their original positions, and go to step 2. 2. Swap wheels 1 and 3 on the driver's side of the vehicle, and test-drive again. ^ If the pull goes away, replace the tire on wheel 1, then go to step 3. ^ If the pull does not go away, use a known-good tire in position 1 and continue diagnosis. 3. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. REPAIR PROCEDURE B Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4561 1. Place the vehicle on a commercially available, computerized, four-wheel alignment rack, and record the following measurements. Follow the equipment manufacturer's instructions. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. 2. If any measurement is out of specification, inspect the front suspension for any damage. Repair any damaged parts before continuing your diagnosis. 3. Determine how the front wheel camber is affecting the pull. Pick the combination of left- and right-front camber that best matches the vehicle you are repairing, then note the camber thrust direction for that combination: NOTE: ^ If the camber of both front wheels is negative, but one wheel is grossly more negative than the other, the camber thrust direction will be opposite the wheel with more negative camber (for example, if the left-front wheel is more negative, the camber thrust direction is right). ^ If the camber of both front wheels is positive, but one wheel is grossly more positive than the other, the camber thrust direction will be the same as the wheel with more positive camber (for example, if the left-front wheel is more positive, the camber thrust direction is left). 4. Determine how the camber needs to be adjusted. 5. Adjust the camber as needed. Front Camber Adjustment, Double Wishbone Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4562 ^ Loosen the front subframe bolts. See the applicable service manual for more information. NOTE: The front wheels are being viewed from the rear of the vehicle. ^ Depending which way you need to shift the subframe, insert a pry bar between the subframe and body at both the front and rear positions of the subframe. NOTE: Be careful not to damage the vehicle. You could bend and damage the frame and/or body if you apply too much pressure. ^ Press on both pry bars to shift the subframe. It will move only a few millimeters. This should adjust the camber about 0.2-0.5°. ^ While holding the subframe in place, have an assistant torque the subframe bolts to their proper torque. Front Camber Adjustment, Strut Suspension ^ Raise the vehicle, and remove the front tires. ^ Loosen the damper pinch bolts and the flange nuts. ^ Adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. NOTE: Some vehicles have special pinch bolts that allow more adjustment. For more information, refer to the parts catalog. ^ Tighten the damper pinch bolts to the specified torque. ^ Reinstall the front wheels and lower the vehicle. Bounce the front of the vehicle several times to stabilize the suspension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4563 6. Test-drive the vehicle to make sure it no longer pulls. If the steering wheel is now off-center by more than 2 mm, go to REPAIR PROCEDURE C. 7. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. NOTE: Enter each reading in decimal degrees. Example 30' = 0.50. REPAIR PROCEDURE C 1. Make sure the steering wheel is centered. ^ Turn the steering wheel all the way to the right until it stops. ^ Turn the steering wheel all the way to the left, and count the number of revolutions until it stops. ^ Divide the number of revolutions in half, and turn the steering wheel until it is centered. For example, if it takes four revolutions of the steering wheel to go from lock to lock, then two turns is centered. ^ If the steering wheel is off-center by a large amount (20 mm or more), it may not be centered on the steering column shaft. Reinstall the steering wheel before going to step 2. 2. Place the vehicle on a lift, turn the steering wheel until it is centered, and then raise the vehicle. 3. Adjust the tie-rods. Use your measurements from question 13 of the test-drive to make your adjustment. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4564 ^ If the wheels are pointed to the right, shorten the driver's side tie-rod, and lengthen the passenger's side. ^ If the wheels are pointed to the left, shorten the passenger's side tie-rod, and lengthen the driver's side. ^ Each 360° turn of the tie-rod equals about 8 mm of steering wheel adjustment. For example, a steering wheel is off-center by 4 mm with the front wheels pointed right (when the steering wheel is centered). To correct the off-center, shorten the driver's side tie-rod by a half-turn, and lengthen the passenger's side tie-rod by a half-turn. 4. Use your diagnosis worksheet to fill in the following table and build your 15-digit DTC. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment > Page 4567 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment > Page 4568 Alignment: Specifications Sport Suspension NOTE: This article has been updated as per TSB SN0411155. With Sport Suspension Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4569 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust the toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust the camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: '02-03 Front/rear: 195/60R15 88V Tire size: '04-05 Front/rear: 205/55R16 89V Tire pressure: '02-03 models Front: 230 kPa (2.3 kgf/cm2, 33 psi) Rear: 210 kPa (2.1 kgf/cm2, 30 psi) Tire pressure: '04-05 models Front/Rear: 210 kPa (2.1 kgf/cm2, 30 psi) 4. Check the runout of the wheels and tires. 5. Check the suspension ball joints. (Hold a wheel with your hands, and move it up and down and right and left to check for wobbling). 6. Bounce the vehicle up and down several times to stabilize the suspension. Front Caster Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: '02-03 models 1°40' ± 1° Front caster angle: '04-05 models 1°35' ± 1° Front Camber Inspection Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, adjust the camber. Front camber angle: '02-03 models - 0°30' ± 45' Front camber angle: '04-05 models - 0°10' ± 45' Front Camber Adjustment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4570 The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 2. Loosen the damper pinch nuts and bolts (A), and adjust the camber by moving the bottom of the damper within the range of the damper pinch bolt free play. 3. Tighten the bolts to the specified torque. 4. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 5. Check the camber angle. If it is within the specification, check the front toe. If it is not within the specification, go to step 6. 6. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 7. Replace the damper pinch bolts with the adjusting bolts (A), and adjust the camber angle. NOTE: The camber angle can be adjusted up to ± 15' (center of tolerance) by replacing one damper pinch bolt with the adjusting bolt. The camber angle can be adjusted up to ± 30' by replacing both upper and lower damper pinch bolts with the adjusting bolts. 8. Tighten the bolts to the specified torque. 9. Reinstall the front wheels. Lower the front of the vehicle to the ground, and bounce the vehicle several times to stabilize the suspension. 10. Check the camber angle. If it is within the specification, check the front toe, and adjust it if necessary. If it is not within the specification, readjust, and recheck. If the camber angle cannot be adjusted to the specification, check for bent or damaged suspension components. Rear Camber Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. Check the camber angle. If the camber angle is not within the specification, check for bent or damaged suspension components. Rear camber angle: '02-03 models - 0°55' ± 45' Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4571 Rear camber angle: '04-05 models - 0°50' ± 45' NOTICE; Do not loosen the special bolts on the trailing arm. Front Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Center the steering wheel spokes. 2. Check the toe. If it is not within the specification, go to step 3. Front toe-in: 0 ± 3 mm (0 ± 0.12 inch) 3. Loosen the locknut (A) while holding the tie-rod end (B). 4. Turn the tie-rod (C) until the toe is correct. 5. After adjusting, tighten the locknut while holding the tie-rod end. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in (inspection): '02-03 models 1 ± 3 mm (0.04 ± 0.12 inch) Rear toe-in (inspection): '04-05 models 2 ± 3 mm (0.08 ± 0.12 inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the lower arm to adjust the alignment. 4. Replace the self-locking nut with a new one, and lightly tighten. NOTE: Always use a new self-locking nut whenever it has been loosened. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4572 5. Turn the adjusting bolt until the toe is correct. Rear toe-in (adjustment): 2 [2/1] mm (0.08 [0.08/0.04] inch) 6. Tighten the self-locking nut to the specified torque while holding the adjusting bolt. Turning Angle Inspection Use commercially-available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions. 1. Turn the steering wheel fully to the right and left while applying the brake, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. Turning angle: '02-03 Inward: 34°00' ± 2° Outward: 28°00' (reference) Turning angle: '04-05 Inward: 34°40' ± 2° Outward: 28°10' (reference) 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4578 49. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4579 Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4580 195. EPS Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4581 Steering Control Module: Service and Repair EPS Control Unit Removal/Installation 1. Remove the passenger's dashboard lower cover. 2. Turn up the floor carpet, and remove the EPS control unit. 3. Disconnect the EPS control unit connectors. 4. Install the EPS control unit in the reverse order of removal. 5. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 4590 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 4591 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 4596 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 4597 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4602 Front Steering Knuckle: Service and Repair Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4603 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4604 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4605 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4606 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Diagrams > Page 4607 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Locations > Component Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Locations > Component Locations > Page 4613 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Locations > Page 4614 32. EPS Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Locations > Page 4615 Power Steering Motor: Service and Repair Motor Removal and Installation Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait 3 minutes before beginning work. 3. Remove the air cleaner assembly (A). 4. Remove the connector bracket (A) on the gearbox housing, and disconnect the motor 2P connector (B). 5. Remove the motor (A) from the gearbox housing. 6. Remove the O-ring (B) and discard it. Installation Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Locations > Page 4616 7. Clean the mating surface of the motor (A) and gearbox. 8. Apply a thin coat of silicone grease (P/N 08733-B070E) to the new O-ring (B), and carefully fit it on the motor. 9. Apply grease (Nippon Grease WR-S or equivalent steering gear grease) into the motor shaft (C). 10. Install the motor on the gearbox by engaging the motor shaft and worm shaft (D). Note the motor installation position (direction of motor wires). 11. Before tightening the bolts, turn the motor two or three times right 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 order of removal, and note these items: ^ Make sure the motor 2P connector is properly connected. ^ Make sure the motor and EPS wires are not caught or pinched by any parts. ^ Reconnect the negative cable to the battery. ^ Do the engine control module (ECM) idle learn procedure. ^ Enter the anti-theft code for the radio station presets. Reset the clock. 13. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4620 49. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4621 Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4622 195. EPS Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 4623 Steering Control Module: Service and Repair EPS Control Unit Removal/Installation 1. Remove the passenger's dashboard lower cover. 2. Turn up the floor carpet, and remove the EPS control unit. 3. Disconnect the EPS control unit connectors. 4. Install the EPS control unit in the reverse order of removal. 5. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4628 49. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4629 Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4630 195. EPS Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 4631 Steering Control Module: Service and Repair EPS Control Unit Removal/Installation 1. Remove the passenger's dashboard lower cover. 2. Turn up the floor carpet, and remove the EPS control unit. 3. Disconnect the EPS control unit connectors. 4. Install the EPS control unit in the reverse order of removal. 5. After installation, start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 4639 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 4640 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 4644 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 4645 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 4651 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 4652 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations 72. In Steering Column Cover Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 4656 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 4657 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations > Page 4658 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch, the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the multiplex control unit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed from the ignition switch. 4. If the continuity is not as specified, replace the ignition switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair Steering Column Lock: Service and Repair Steering Lock Replacement NOTE: Do not try to re-key a replacement steering lock. If necessary, re-key the other locks. 1. Remove the steering column. 2. Center punch each of the two shear bolts (A), and drill their heads off with a 5 mm (3/16 inch) drill bit. Be careful not to damage the switch body when removing the shear bolts. 3. Remove the shear bolts from the switch body. 4. Install the switch body without the key inserted. 5. Loosely tighten the new shear bolts. 6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns freely. 7. Tighten the shear bolts (A) until the hex heads (B) twist off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Adjustments Tilt Wheel Handle: Adjustments Steering Column/Tilt Lever Inspection/Adjustment On Vehicles Manufactured In Suzuka Plant: - Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing noisy or has excessive play, replace the steering column as an assembly. - Check the sliding capsules (C) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly. On Vehicles Manufactured In Other Plants: - Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly. - Check the absorbing plates (C), absorbing plate guides (D), stop (E), and coating plates (F) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly. 1. Move the tilt lever (A) from the loose position to the lock position 3 to 5 times; then measure the tilt lever preload 10 mm (0.4 inch) from the end of the tilt lever. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Adjustments > Page 4665 2. If the measurement is out of the specification, adjust the preload using the following procedures. - Loosen the tilt lever, and set the steering column in the neutral position. - Remove the 6 mm lock bolt (B), and remove the stop (C). Be careful not to loosen the tilt lever when installing the stop or tightening the 6 mm lock bolt. - Adjust the preload by turning the tilt lock bolt (D) left or right. - Pull up the tilt lever to the uppermost position, and install the stop. Check the preload again. If the measurement is still out of specification, repeat the above procedures to adjust. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Service and Repair Steering Gear Mount: Service and Repair Steering Gearbox Mount Bushing Replacement Special Tools Required ^ Bushing glider 07041F-SAA0111 ^ Cap 070AF-SAA0121 ^ Bolt/Nut/Collar/Plain washer 070AF-SAA0130 ^ Spacer 070AF-SAA0140 Removal 1. Remove the steering gearbox. 2. To ensure special tools move smoothly, apply a small amount of the new engine oil to the threaded part of the bolt (A) and nut (B) of the special tools. 3. Assemble the special tool bolt, collar (C) plain washer (D), washer (E), and install it through the gearbox mount bushing (F). 4. Position the special tool bushing slider (G) and cap (H) on the bolt and secure it with the nut hand tightened. NOTE: ^ The gearbox mount bushing can be removed in either direction. ^ Do not loosen the bolt once it is tightened. 5. Holding the nut with a wrench, tighten the bolt with another wrench, and remove the gearbox mount bushing. Do not reuse the removed gearbox mount bushing. Installation 6. Clean the inside of the gearbox bushing mounting hole and surrounding area thoroughly. All of the removed, mount bushing and any other foreign materials must be off the bushing installation surface. 7. Apply assembly oil to the interior of the bushing slider (A), interior of the gearbox bushing installation hole, and to the outer surface of the new gearbox mount bushing (B). NOTE: Use only assembly oil. Using anything else can cause abnormal slippage or deflection to the bushing and adversely affect the steering stability. 8. Keep any dust, dirt, and other foreign materials off the oiled gearbox mount bushing) Push the new gearbox mount into the special tool (bushing slider) lightly with your finger. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Service and Repair > Page 4670 9. Set the gearbox mount bushing (A) in the special tool bushing slider (B). 10. Pass the special tool bolt (C), collar (D), plain washer (E), and washer (F) through the gearbox mount bushing assembly. 11. Position the cap (G) on the bolt and secure it with the nut (H). 12. Holding the nut with a wrench, tighten the bolt with another wrench securely until the end of the gearbox mount bushing comes in contact with the interior of the cap. NOTE: ^ To install the gearbox mount bushing, pull it into the hole beyond the specified installation position, then return the bushing to the specified position. ^ Do not loosen the bolt once it is tightened. 13. Remove the special tools. 14. Make sure that the bushing collar (A) is set in the gearbox installation hole securely. The bushing end (B) of the pull-in side must be protruding. NOTE: If the bushing collar is not set in the hole securely, reassemble the special tools and push the gearbox mount bushing in. 15. Install the bolt (A), and collar (B) and plain washer (C) of the special tools on the protruding gearbox mount bushing side. 16. Position the spacer (D) and cap (E) on the bolt as shown, and secure them with the nut (F). 17. Holding the nut with a wrench, tighten the bolt with another wrench until the collar (G) at the end of the gearbox mount bushing contacts the flange. There must not be a gap between the collar and flange. 18. Remove the special tools. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Service and Repair > Page 4671 19. Measure the dimension of the collar (A) at both ends of the gearbox mount bushing (B). 20. If the measurements are not within specification, reinstall the special tools and adjust to the specifications. The collars must be equal at both ends of the gearbox mount bushing. 21. Install the steering gearbox. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Removal Steering Wheel: Service and Repair Steering Wheel Removal Steering Wheel Removal SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. 1. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel. 2. Disconnect the cruise control set/resume switch connector (A), and loosen the steering wheel nut (B). 3. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller. Note these items when removing the steering wheel: ^ Do not tap on the steering wheel or the steering column shaft when removing the. steering wheel. ^ If you thread the puller bolts (D) into the wheel hub more than 5 threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts 5 threads up on each puller bolt. 4. Remove the steering wheel puller, then remove the steering wheel nut and steering wheel from the steering column. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Removal > Page 4677 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Removal > Page 4678 Steering Wheel: Service and Repair Steering Wheel Installation Steering Wheel Installation 1. Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about two and a half turns. The arrow mark (B) on the cable reel label should point straight up. 2. Position the two tabs (A) of the turn signal canceling sleeve (B) as shown. Install the steering wheel onto the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel. 3. Install the steering wheel nut (A), and tighten it to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Removal > Page 4679 4. Connect the cruise control set/resume switch connector (B). Make sure the wire harness is routed and fastened properly. 5. Install the driver's airbag, and confirm that the system is operating properly. 6. Check the horn, turn signal canceling and cruise control switches for proper operation. 7. Reconnect the battery and do the following: ^ Do the engine control module (ECM) idle learn procedure. ^ Enter the anti-theft code for the radio, then enter the customer's radio station presets. ^ Set the clock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair Tie-rod Ball Joint Boot Replacement Special Tools Required Attachment, 42 mm 07QAD-P0A0100 1. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. 2. Pack the lower area of the ball pin (A) with fresh multipurpose grease. 3. Pack the interior of the new boot (B) and lip (C) with fresh multipurpose grease. Note these items when applying new grease: ^ Keep grease off the boot installation section (D) and the tapered section (E) of the ball pin. ^ Do not allow dust, dirt, or other foreign materials to enter the boot. 4. Install the new boot (A) using the special tool. The boot must not have a gap at the boot installation sections (B). After installing the boot, check the ball pin tapered section for grease contamination, and wipe it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications TORQUE SPECIFICATIONS Castle Nut Lower ................................................................................................................................. .................................. 59 - 69 Nm (43 - 51 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Removal Ball Joint: Service and Repair Ball Joint Removal Removal Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 NOTICE: Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it. 1. Install a hex nut (A) onto the threads of the ball joint (B). Make sure the nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint pin. 2. Apply grease to the special tool on the areas shown (A). This will ease installation of the tool and prevent damage to the pressure bolt (B) threads. 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). 4. After adjusting the adjusting bolt, make sure the head (C) of the adjusting bolt is in the position shown to allow the jaw to pivot. 5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the steering arm or knuckle. If necessary, apply penetrating type lubricant to loosen the ball joint pin. NOTE: Do not use pneumatic or electric tools on the pressure bolt. 6. Remove the tool, then remove the nut from the end of the ball joint pin, and pull the ball joint out of the steering arm or knuckle. Inspect the ball Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Removal > Page 4690 joint boot, and replace it if damaged. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Removal > Page 4691 Ball Joint: Service and Repair Ball Joint Boot Replacement Replacement Special Tools Required Front hub dis/assembly tool 07965-SA50500 1. Remove the boot. 2. Pack the interior and lip (A) of a new boot with fresh grease. Keep the grease off of the boot-to-knuckle mating surfaces (B). 3. Wipe the grease off the tapered section of the pin (C), and pack fresh grease onto the base (D). 4. Install the boot onto the ball joint pin, then squeeze it gently to force out any air. Do not let dirt or other foreign materials get into the boot. 5. Press the boot with the special tool until the bottom seats on the knuckle (A) evenly around. 6. After installing a boot, wipe any grease off the exposed portion of the ball joint pin. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension Control Arm: Service and Repair Front Suspension Lower Arm Removal/Installation Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 2. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 3. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 4. Disconnect the lower arm from the knuckle using the special tool. 5. Remove the flange bolts (A), and remove the lower arm (B). 6. Install the lower arm in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when connecting the lower arm to the knuckle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4696 - Tighten all mounting hardware to the specified torque values. - First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening it to the specified torques. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new lock pin on the castle nut after torquing. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 4697 Control Arm: Service and Repair Rear Suspension Upper Arm Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. 2. Place a floor jack under the trailing arm, and support the suspension. 3. Remove the flange bolt (A) and wheel sensor harness bracket (B). 4. Remove the flange bolts (A), and remove the upper arm (B). 5. Install the upper arm in the reverse order of removal, and note these items: - First install all the suspension components and lightly tighten the bolts and nuts, then place a jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the specified torque values. - Tighten all the mounting hardware to the specified torque values. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4701 Front Steering Knuckle: Service and Repair Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4702 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4703 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4704 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4705 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Diagrams > Page 4706 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Knuckle Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. 2. Remove the brake disc and hub bearing unit. 3. Remove the flange bolts (A) and splash guard (B) from the knuckle. 4. Remove the wheel sensor (A), brake hose mounting bracket (B), and parking cable mounting bracket (C) from the knuckle. Do not disconnect the wheel sensor connector. 5. Place the floor jack under the trailing arm (A), to support it. NOTICE: Do not place the jack against the plate section of the lower arm. Be careful not to damage any suspension components. 6. Remove the flange bolt (B), and disconnect the upper arm (C) from the knuckle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 4710 7. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), the remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 8. Remove the flange bolt (D), and remove the knuckle (E). 9. Install the knuckle in the reverse order of removal, and note these items: - First install all the suspension components, and lightly tighten the bolts and nuts, 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 positions of the adjusting bolt (A) and adjusting cam (B) with the marked positions when tightening. - Use a new self-locking nut on reassembly. - Tighten all the mounting hardware to the specified torque values. - Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. - 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. - Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations 24. Rear of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 4715 150. EPS Torque Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 4716 Steering Angle Sensor: Description and Operation Electrical Power Steering (EPS) Sensor The EPS sensor signals the ECM when the power steering load is high. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front Removal/Installation 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), and remove the stabilizer link (E). 3. Install the stabilizer link (A) on the stabilizer bar (B) and lower arm (C) with the joint pins (D) set at the center of their range of movement. 4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly. 5. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the lower arm ball joint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 4722 6. Tighten the self-locking nut (A) and flange nut (B) to the specified torque values while holding the respective joint pins (C) with a hex wrench (D). 7. After 5 minutes of driving, re-tighten the self-locking nut again to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 4723 Stabilizer Link: Service and Repair Rear Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), and remove the stabilizer link (E). 3. Install the stabilizer link (A) on the stabilizer bar (B) and trailing arm (C) with the joint pins (D) set at the center of each moving range. 4. Install the self-locking nut and flange nut, and lightly tighten them. NOTE: Use a new self-locking nut on reassembly. 5. Place a jack under the trailing arm at the knuckle side end, and raise the suspension to load it with the vehicle's weight. 6. Tighten the self-locking nut (A) and flange nut (B) to the specified torque values while holding the respective joint pins (C) with a hex wrench (D). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 4724 7. After 5 minutes of driving, re-tighten the self-locking nut again to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair Removal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 4728 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse, and leave the transmission mount bracket attached to the front side frame. - Check the wheelhouse upper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and wheelhouse upper extension as an assembly. If possible. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 4729 - Replace the wheelhouse upper extension, damper housing and damper housing extension as an assembly. - Check the transmission mount bracket position, and check for damage. If necessary, replace it. Installation 1. Set the new damper housing assembly, front wheelhouse and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front subframe, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for differences in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 4730 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, damper housing extension and wheelhouse upper extension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 4731 - From the dashboard upper side, plug weld the holes in the damper housing. - Weld the front wheelhouse, damper housing, and front side frame. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 4732 - Weld the wheelhouse upper member. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter Subframe: Technical Service Bulletins Body/Frame - Universal Subframe Removal Adapter 05-066 November 24, 2005 Applies To: See VEHICLES AFFECTED Universal Front Subframe Removal Adapter (Replaces 01-043, Civic Front Sub frame Removal Adapter, dated September 11, 2001) The universal front subframe removal adapter is a required tool. When properly fitted to a transmission jack and the vehicle's front subframe, the adapter provides a convenient way to remove the subframe. Front subframe removal is required for transmission or engine removal. NOTE: The adapter will only support the subframe it will not support the entire powertrain assembly. Refer to the WARNING label on the adapter. VEHICLES AFFECTED 2003-06 Accord - ALL 2005-06 Accord Hybrid - ALL 2001-06 Civic - ALL 2001-06 Civic GX - ALL 2003-06 Civic Hybrid - ALL 2002-06 Civic Si - ALL 2002-06 CRV - ALL 2003-06 Element - ALL ORDERING INFORMATION The universal front subframe removal adapter is TIN VSB02C000016. To order additional adapters, call the Honda Tool and Equipment Program. USING THE ADAPTER NOTE: The adapter is designed to be used with the transmission jack, (new model number NRI-72500D), available through the Honda Tool and Equipment Program. (The old model number LSL-W93714 can still be used.). The adapter also works with many commercially available transmission jacks. 1. Loosen the four bolts that hold the adapter's adjustable arms to its center plate. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter > Page 4737 2. Line up the slots in the arms with the bolt holes on the corners of the jack base, then attach the adapter to the jack base with the bolts that came with the jack. Tighten all of the bolts securely. 3. Raise the jack to vehicle height. 4. With the rear bar of the adapter spanning the sides of the subframe, route the adapter's strap around the front of the subframe. Pull the strap as tightly as possible, insert the pin through the appropriate loop, then tighten the wing nut. 5. With all of the vehicle parts properly supported or removed (see Engine or Transmission Removal in the appropriate service manual), carefully lower the subframe using the controls on the jack. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Page 4738 Subframe Torque Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Diagrams > Front > Page 4743 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Spring ( Coil / Leaf ): Service and Repair Front Damper/Spring Replacement Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4746 2. Remove the cotter pin (A) from the tie-rod end ball joint, and remove the nut (B). 3. Disconnect the tie-rod end from the steering arm on the damper using the special tool. 4. Remove the bolts, and remove the wheel sensor harness bracket (A) and brake hose bracket (B) from the damper. Do not disconnect the wheel sensor connector. 5. Remove the damper pinch bolts (A) while holding the nuts (B). 6. Remove the flange nuts (A) from the top of the damper. 7. Lower the lower arm, and remove the damper assembly (B). Disassembly/Inspection Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4747 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the upper spring seat and spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, and binding during these tests. Reassembly NOTE: Refer to the Exploded View as needed. 1. Install the upper spring mounting cushion (A) on the upper spring seat (B) by aligning the tab portion (C) on the cushion with the cutout (D) in the seat. 2. Install the spring (E) in the groove of the cushion securely. 3. Install the damper mounting bearing and damper mounting base on the upper spring seat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4748 4. 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 (B) up through the compressed spring. 6. Align the bottom of the spring (C) and the stepped part (D) of the lower spring seat. 7. Check that the cutout (A) in the side of the upper spring seat (B) is in position shown. If the cutout is out of position, remove all of the components from the spring compressor. Go to step 2, and reassemble the spring and upper spring seat accordingly. Left side Right side 8. Hold the bottom of the damper with your hand, and compress the spring. Do not compress the spring excessively. 9. Install the 12 mm nut (A) on the damper shaft (B). Hold the damper shaft with a hex wrench (C), and tighten the 12 mm nut to the specified torque. 10. Remove the damper assembly from the strut spring compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4749 Installation 1. Lower the lower arm, and position the damper assembly in the body. Turn the damper mounting base so the "[triangle]L" or "[triangle]R" mark (A) faces toward the outside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. 3. Position the damper on the knuckle, and install the new damper pinch bolts (A) and nuts (B), and lightly tighten the nuts. 4. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the lower arm ball joint. 5. Tighten the flange nuts on the top of the damper to the specified torque. 6. Tighten the damper pinch nuts to the specified torque. 7. Install the brake hose bracket (A) and the wheel sensor harness bracket (B) onto the damper, and tighten the bolt to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4750 8. Connect the tie-rod end to the steering arm, and tighten the nut (A) to the specified torque. Install the cotter pin (B) after tightening, and bend its end as shown. 9. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 10. Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4751 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Damper/Spring Replacement Removal 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4752 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the rear bulkhead cover. 4. Remove the flange nuts (A) from the top of the damper in the trunk. 5. Remove the damper assembly from the body. Disassembly/Inspection 1. Compress the damper spring with a commercially available strut compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4753 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the spring compressor. 4. Install the new self-locking nut (A) on the damper shaft. 5. Hold the damper shaft (B) with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 4754 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole dot on it is toward the front and inside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. 3. Loosely install the flange bolt (A) on the bottom of the damper. 4. Raise the suspension with a floor jack to load the vehicle weight, and tighten the nuts and bolt to the specified torque values. 5. Clean the mating surface of the brake disc and the inside of the wheel, then install the rear wheel. 6. Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Front TIGHTENING SPECIFICATIONS Damper Shaft Nut ................................................................................................................................ ............................... 44 N.m (4.5 kgf-m, 33 lbf-ft) Upper Flange Nut ............................................................................................................................................................ 44 N.m ((4.5 kgf-m, 33 ft. lbs.) Damper Pinch Bolt ......................................................................................................................................................... 157 N.m (16.0 kgf-m, 116 ft-lb) Brake Hose Bracket Bolt ..................................................................................................................................................... 22 N.m (2.2 kgf-m, 16 lbf-ft) Wheel Sensor Bracket ....................................................................................................................................................... 9.8 N.m (1.0 kgf-m, 7.2 lbf-ft) Tie-rod End to Steer Arm ................................................................................................................................................ 43 N.m (4.4 kgf-m, 32 lbf-ft) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 4759 Suspension Strut / Shock Absorber: Specifications Rear TIGHTENING SPECIFICATIONS Damper Shaft Nut ................................................................................................................................ ................................ 29 N.m (3.0 kgf-m, 22 lbf-ft) Upper Flange Nut .................................................. .............................................................................................................................. 59 N.m (43 ft. lbs.) Rear Lower Bolt ................................................................................................................................... ............................................... 61 N.m (45 ft. lbs.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Diagrams > Front > Page 4762 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front Damper/Spring Replacement Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper location. Remove the front wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4765 2. Remove the cotter pin (A) from the tie-rod end ball joint, and remove the nut (B). 3. Disconnect the tie-rod end from the steering arm on the damper using the special tool. 4. Remove the bolts, and remove the wheel sensor harness bracket (A) and brake hose bracket (B) from the damper. Do not disconnect the wheel sensor connector. 5. Remove the damper pinch bolts (A) while holding the nuts (B). 6. Remove the flange nuts (A) from the top of the damper. 7. Lower the lower arm, and remove the damper assembly (B). Disassembly/Inspection Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4766 1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the upper spring seat and spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, and binding during these tests. Reassembly NOTE: Refer to the Exploded View as needed. 1. Install the upper spring mounting cushion (A) on the upper spring seat (B) by aligning the tab portion (C) on the cushion with the cutout (D) in the seat. 2. Install the spring (E) in the groove of the cushion securely. 3. Install the damper mounting bearing and damper mounting base on the upper spring seat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4767 4. 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 (B) up through the compressed spring. 6. Align the bottom of the spring (C) and the stepped part (D) of the lower spring seat. 7. Check that the cutout (A) in the side of the upper spring seat (B) is in position shown. If the cutout is out of position, remove all of the components from the spring compressor. Go to step 2, and reassemble the spring and upper spring seat accordingly. Left side Right side 8. Hold the bottom of the damper with your hand, and compress the spring. Do not compress the spring excessively. 9. Install the 12 mm nut (A) on the damper shaft (B). Hold the damper shaft with a hex wrench (C), and tighten the 12 mm nut to the specified torque. 10. Remove the damper assembly from the strut spring compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4768 Installation 1. Lower the lower arm, and position the damper assembly in the body. Turn the damper mounting base so the "[triangle]L" or "[triangle]R" mark (A) faces toward the outside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. 3. Position the damper on the knuckle, and install the new damper pinch bolts (A) and nuts (B), and lightly tighten the nuts. 4. Place the floor jack under the lower arm ball joint, and raise the suspension to load it with the vehicle's weight. NOTICE: Do not place the jack against the lower arm ball joint. 5. Tighten the flange nuts on the top of the damper to the specified torque. 6. Tighten the damper pinch nuts to the specified torque. 7. Install the brake hose bracket (A) and the wheel sensor harness bracket (B) onto the damper, and tighten the bolt to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4769 8. Connect the tie-rod end to the steering arm, and tighten the nut (A) to the specified torque. Install the cotter pin (B) after tightening, and bend its end as shown. 9. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels. 10. Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4770 Suspension Strut / Shock Absorber: Service and Repair Rear Damper/Spring Replacement Removal 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4771 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the rear bulkhead cover. 4. Remove the flange nuts (A) from the top of the damper in the trunk. 5. Remove the damper assembly from the body. Disassembly/Inspection 1. Compress the damper spring with a commercially available strut compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut. 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4772 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the spring compressor. 4. Install the new self-locking nut (A) on the damper shaft. 5. Hold the damper shaft (B) with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 4773 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole dot on it is toward the front and inside of the vehicle. 2. Loosely install the flange nuts (A) onto the top of the damper. 3. Loosely install the flange bolt (A) on the bottom of the damper. 4. Raise the suspension with a floor jack to load the vehicle weight, and tighten the nuts and bolt to the specified torque values. 5. Clean the mating surface of the brake disc and the inside of the wheel, then install the rear wheel. 6. Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Removal/Installation 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. Remove the rear wheels. 2. Remove the knuckle. 3. Place the floor jack under the trailing arm (A) to support it. 4. Remove the flange nut (B), and disconnect the stabilizer link (C) from the trailing arm. 5. Remove the flange bolt (D), and disconnect the damper (E) from the trailing arm. 6. Remove the trailing arm front mounting bolts (A). 7. Remove the trailing arm rear mounting bolt (A). NOTICE: Do not loosen the special bolts (B) on the trailing arm. 8. Lower the jack, and remove the trailing arm. 9. Install the trailing arm in the reverse order of removal, and note these items: - First install all the suspension components and lightly tighten the bolts and nuts, then place a jack under the trailing arm, and raise the suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the specified torque values. - Tighten all the mounting hardware to the specified torque values. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing End Play Front .................................................................................................................................................... .................................. 0 - 0.05 mm (0 - 0.002 inch) Rear .................................................................... ................................................................................................................... 0 - 0.05 mm (0 - 0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Front > Page 4782 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Page 4783 Wheel Bearing: Testing and Inspection Wheel Bearing End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. Front Rear 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc inward and outward. Bearing end play: Standard: Front/rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard. replace the wheel bearing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4786 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4787 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4788 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4789 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4790 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4791 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and rear wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4792 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Release the parking brake lever. 5. Remove the brake hose mounting bolt (A). 6. Remove the caliper bracket mounting bolts (B), and hang the caliper (C) to one side. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage. 7. Remove the brake disc retaining screws (A). 8. Screw two 8 x 1.25 mm bolts (B) into the disc (C) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Remove the brake disc. 9. Remove the hub bearing unit (A) from the spindle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 4793 10. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. - Use a new spindle nut on reassembly. - After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 4799 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lift and Support Points NOTE: If you are going to remove heavy components such as the suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), on safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B). Center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Size Of Spare Tire ............................................................................................................................... ..................................................... T125/70 D15 95M Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Aluminum Wheel Runout Standard or New: Axial ..................................................................................................................................................... ......................... 0 - 0.7 mm (0 - 0.03 inch) Radial ............................................................................... ............................................................................................. 0 - 0.7 mm (0 - 0.03 inch) Service Limit: Axial ..................................................................................................................................................... ................................... 2.0 mm (0.08 inch) Radial ............................................................................... ........................................................................................................ 1.5 mm (0.06 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Specifications > Page 4811 Wheels: Testing and Inspection Wheel Runout Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. 2. Check for a bent or deformed wheel. 3. Set up the dial gauge as shown, and measure the axial runout by turning the wheel. Front and rear wheel axial runout: Standard: Aluminum wheel: 0 - 0.7 mm (0 - 0.03 inch) Service limit: 2.0 mm (0.08 inch) 4. Reset the dial gauge to the position shown, and measure the radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0 - 0.7 mm (0 - 0.03 inch) Service limit: 1.5 mm (0.06 inch) 5. If the wheel runout is not within the specification, check the wheel bearing end play, and make sure the mating surfaces on the brake disc and the inside of the wheel are clean. 6. If the bearing end play is within the specification but the wheel runout is more than the service limit, replace the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing End Play Front .................................................................................................................................................... .................................. 0 - 0.05 mm (0 - 0.002 inch) Rear .................................................................... ................................................................................................................... 0 - 0.05 mm (0 - 0.002 inch) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front > Page 4817 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Page 4818 Wheel Bearing: Testing and Inspection Wheel Bearing End Play Inspection 1. Raise the vehicle, and support it with safety stands in the proper location. Remove the wheels. 2. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. Front Rear 3. Set up the dial gauge against the hub flange as shown, and measure the bearing end play moving the brake disc inward and outward. Bearing end play: Standard: Front/rear: 0 - 0.05 mm (0 - 0.002 inch) 4. If the bearing end play is more than the standard. replace the wheel bearing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Knuckle/Hub/Wheel Bearing Replacement Special Tools Required Hub dis/assembly tool 07GAF-SE00100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 1. Raise the front of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and front wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4821 3. Remove the brake hose bracket mounting bolt (A). 4. Remove the caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Raise the stake (A), and remove the spindle nut (B). 6. Remove the brake disc retaining flat screws (A). 7. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4822 8. Remove the flange bolt (A) and wheel sensor (B) from the knuckle. Do not disconnect the wheel sensor connector. 9. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). 10. Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the lock pin into the ball joint pin from the inside to the outside of the vehicle. The closed end of the lock pin must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4823 12. Loosen the damper pinch bolts (A) while holding the nuts (B), and remove the bolts and nuts. 13. Remove the driveshaft outboard joint (C) from the knuckle (D) by tapping the driveshaft end (E) with a plastic hammer while drawing the knuckle outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The driveshaft joint may come off. 14. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 15. Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4824 16. Remove the snap ring (A) and the splash guard (B} from the knuckle (C). 17. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 18. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 19. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press. Place the wheel bearing on the knuckle with the pack seal side facing (metal color) toward the inside. Be careful not to damage the sleeve of the pack seal. 20. Install the snap ring (A) securely in the knuckle (B). 21. Install the splash guard (C), and tighten the screws (D) to the specified torque. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4825 22. Press a new hub bearing unit (A) onto the hub (B) using the special tools and a press. 23. Install the knuckle/hub/hub bearing unit in the reverse order of removal, and note these items: - Be careful not to damage the ball joint boot when installing the knuckle. - Tighten all mounting hardware to the specified torque values. - Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. - Install a new look pin on the castle nut after torquing. Use a new spindle nut on reassembly. - Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft. - Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. - Check the front wheel alignment, and adjust it if necessary. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4826 Wheel Bearing: Service and Repair Rear Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper location. 2. Remove the wheel cap, wheel nuts, and rear wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4827 3. Remove the hub cap (A), raise the stake (B), and remove the spindle nut (C). 4. Release the parking brake lever. 5. Remove the brake hose mounting bolt (A). 6. Remove the caliper bracket mounting bolts (B), and hang the caliper (C) to one side. To prevent damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage. 7. Remove the brake disc retaining screws (A). 8. Screw two 8 x 1.25 mm bolts (B) into the disc (C) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Remove the brake disc. 9. Remove the hub bearing unit (A) from the spindle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 4828 10. Install the hub bearing unit in the reverse order of removal, and note these items: - Tighten all mounting hardware to the specified torque values. - Before installing the brake disc, clean the mating surface of the hub and the inside of the brake disc. - Use a new spindle nut on reassembly. - After tightening, use a drift to stake the spindle nut shoulder against the spindle. - Use a new hub cap on reassembly. - Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 4834 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations > Page 4842 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations > Page 4843 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it work properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations 46. Under Right Side of Dash 55. Behind Glove Box Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 4848 69. Under Left Side of Dash Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 4849 Air Door Actuator / Motor: Diagrams 135. Air Mix Control Motor 147. Recirculation Cntrol Motor 164. Mode Control Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Air Mix Control Motor Test Air Door Actuator / Motor: Testing and Inspection Air Mix Control Motor Test Air Mix Control Motor Test 1. Disconnect the 5P connector from the air mix control motor. NOTE: Incorrectly applying power and ground to the air mix control motor will damage it. Follow the instructions carefully. 2. Connect battery power to the No. 1 terminal of the air mix control motor, and ground the No. 2 terminal; the air mix control motor should run, and stop at Max Cool. If it doesn't, reverse the connections; the air mix control motor should run, and stop at Max Hot. 3. If the air mix control motor did not run in step 2, remove it, then check the air mix control linkage and door for smooth movement. - If the linkage and door move smoothly, replace the air mix control motor. - If the linkage or door stick or bind, repair them as needed. - If the air mix control motor runs smoothly, go to step 4. 4. Measure the resistance between the No. 4 and No. 5 terminals. It should be between 2.1 to 3.9 kOhm. 5. Reconnect the air mix control motor 5P connector, then turn the ignition switch ON (II). 6. Using the Backprobe Set, measure the voltage between the No. 3 and No. 4 terminals. Max Cool - about 1 V Max Hot - about 4 V 7. If either the resistance or voltage readings are not as specified, replace the air mix control motor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Air Mix Control Motor Test > Page 4852 Air Door Actuator / Motor: Testing and Inspection Mode Control Motor Test Mode Control Motor Test 1. Disconnect the 10P connector from the mode control motor. NOTE: Incorrectly applying power and ground to the mode control motor will damage it. follow the instructions carefully. 2. Connect battery power to the No. 1 terminal of the mode control motor, and ground the No. 2 terminal; the mode control motor should run smoothly and stop at Defrost. If it doesn't, reverse the connections; the mode control motor should run smoothly and stop at Vent. When the mode control motor stops running, disconnect battery power immediately. 3. If the mode control motor did not run in step 2, remove it, then check the mode control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the mode control motor. - If the linkage or doors stick or bind, repair them as needed. - If the mode control motor runs smoothly, go to step 4. 4. Use a digital multimeter with an output of 1 mA or less at the 20 kOhms range. With the mode control motor running as in step 2, check for continuity between the No. 4, 5, 6, 7, 8, and 9 terminals and the No. 10 terminal individually. There should be continuity for a moment at each terminal as the motor moves past each mode position. 5. If there is no continuity for a moment at each terminal, replace the mode control motor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Air Mix Control Motor Test > Page 4853 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Circuit Troubleshooting Recirculation Control Motor Circuit Troubleshooting 1. Check the No. 14 (10 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck. 2. Disconnect the recirculation control motor 5P connector. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No. 5 terminal of the recirculation control motor 5P connector and body ground. Is there battery voltage? YES - Go to step 5. NO - Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the recirculation control motor. 5. Turn the ignition switch OFF. 6. Test the recirculation control motor. Is the recirculation control motor OK? YES - Go to step 7. NO - Go to step 12. 7. Disconnect heater control panel connector A (14P). 8. Check for continuity between the No. 5 and No. 6 terminals of heater control panel connector A (14P) and body ground individually. Is there continuity? YES - Repair any short to body ground in the wire(s) between the heater control panel and the recirculation control motor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Air Mix Control Motor Test > Page 4854 NO - Go to step 9. 9. Turn the ignition switch ON (II), and check the same wires for voltage. Is there any voltage? YES - Repair any short to power in the wire(s) between the heater control panel and the recirculation control motor. This short may also damage the heater control panel. Repair the short to power before replacing the heater control panel. NO - Go to step 10. 10. Turn the ignition switch OFF. 11. Check for continuity between the following terminals of heater control panel connector A (14P) and the recirculation control motor 5P connector. 14P: 5P: No. 5 No. 1 No. 6 No. 2 Is there continuity? YES - Check for loose wires or poor connections at heater control panel connector A (14P) and at the recirculation control motor 5P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Repair any open in the wire(s) between the heater control panel and the recirculation control motor. 12. Remove the recirculation control motor. 13. Check the recirculation control linkage and doors for smooth movement. Do the recirculation control linkage and doors move smoothly? YES - Replace the recirculation control motor. NO - Repair the recirculation control linkage or doors. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Air Mix Control Motor Test > Page 4855 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Test Recirculation Control Motor Test 1. Disconnect the 5P connector from the recirculation control motor. NOTE: Incorrectly applying power and ground to the recirculation control motor will damage it. Follow the instructions carefully. 2. Connect battery power to the No. 5 terminal of the recirculation control motor, and ground the No. 1 and No. 2 terminals; the recirculation control motor should run smoothly. To avoid damaging the recirculation control motor, do not reverse power and ground. Disconnect the No. 1 or No. 2 terminals from ground; the recirculation control motor should stop at Fresh (when the No. 1 terminal is disconnected) or Recirculate (when the No. 2 terminal is disconnected). Don't cycle the recirculation control motor for a long time. 3. If the recirculation control motor did not run in step 2, remove it, then check the recirculation control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the recirculation control motor. - If the linkage or doors stick or bind, repair them as needed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Mix Control Motor Air Door Actuator / Motor: Service and Repair Air Mix Control Motor Air Mix Control Motor Replacement 1. Remove the under-dash fuse/relay box. 2. Disconnect the 5P connector (A) from the air mix control motor (B). Remove the self-tapping screws and the air mix control motor from the heater unit. Remove the rod (C) from the arm (D) of the air mix control motor. 3. Install the motor in the reverse order of removal After installation, make sure the motor runs smoothly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Mix Control Motor > Page 4858 Air Door Actuator / Motor: Service and Repair Mode Control Motor Mode Control Motor Replacement 1. Remove the ECM. 2. Remove the relay mount bracket bolt, and move the relays out of the way. 3. Disconnect the 10P connector (A) from the mode control motor (B). Remove the self-tapping screws and the mode control motor from the heater unit. 4. Install the motor in the reverse order of removal, and note these items: - Make sure the pin on the linkage is properly engaged with the motor. - After installation, make sure the motor runs smoothly. - Do the ECM idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Mix Control Motor > Page 4859 Air Door Actuator / Motor: Service and Repair Recirculation Control Motor Recirculation Control Motor Replacement 1. Remove the ECM. 2. Remove the relay mount bracket bolt, and move the relays out of the way. 3. Disconnect the 5P connector (A) from the recirculation control motor (B). Remove the self-tapping screws and the recirculation control motor from the blower unit. 4. Install the motor in the reverse order of removal and note these items: - Make sure the pin on the motor is properly engaged with the linkage. - After installation, make sure the motor runs smoothly. - Do the ECM idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Blower (Heater) Motor Gets Hot and Blows A Fuse Blower Motor: Technical Service Bulletins Blower (Heater) Motor Gets Hot and Blows A Fuse SOURCE: Honda Service News November 2003 TITLE: Heater Blower Motor Gets Hot or Blows a Fuse APPLIES TO: 1990-04 Accords, 1992-04 Civics, 1997-04 CR-Vs, 2003 Elements, 2000-04 Insights, 1995-04 Odysseys, 1996-02 Passports, 2003-04 Pilots, 1997-01 Preludes, and 2000-04 S2000s SERVICE TIP: A blocked cooling hose for the heater blower motor can cause the motor to overheat, draw more current, blow a fuse, or even melt its plastic impeller. Before you order a replacement blower motor, make sure the cooling hose isn't blocked. On some models, you'll find the cooling hose molded into the blower motor housing; on other models, it's a separate piece. Check the S/M for the vehicle you're working on to determine the actual location of the cooling hose. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 4867 Blower Motor: Locations 52. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 4868 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views 23. Blower Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal and Installation Blower Motor: Service and Repair Removal and Installation Blower Unit Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the battery negative cable, and wait 3 minutes before beginning work. 3. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 4. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown. Remove and discard the plastic cross brace. 5. Remove the steering hanger beam bracket cover from the right side of the glove box opening, then remove the bolts and the glove box frame. 6. Remove the ECM. 7. Remove the EPS control unit. 8. Disconnect and remove the PGM-FI main relays and bracket assembly, then remove the ECM bracket. 9. Disconnect the connectors (A) from the blower motor and the power transistor, then remove the wire harness clips (B) and the connectors (C). Remove the self-tapping screws and the bracket (D). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal and Installation > Page 4873 10. Disconnect the connector (A) from the recirculation control motor, then remove the wire harness clip (B). Remove the mounting bolts, the mounting nuts and the blower unit (C). 11. Install the unit in the reverse order of removal. Make sure that there is no air leakage. 12. Reconnect the negative battery terminal. 13. Do the engine control module (ECM) idle learn procedure. 14. Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal and Installation > Page 4874 Blower Motor: Service and Repair Components Replacement Blower Unit Component Replacement Note these items when overhauling the blower unit: - The recirculation control motor (A), the power transistor (B), the blower motor (C), and the dust and pollen filters (D) can be replaced without removing the blower unit. - Before reassembly, make sure that the recirculation control linkage and doors move smoothly. - After reassembly, make sure the recirculation control motor runs smoothly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 4878 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 4879 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 4880 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 4884 Cabin Air Filter: Service and Repair Dust and Pollen Filter Replacement The dust and pollen filters should be replaced every 30,000 miles (48,000 km) or 24 months whichever comes first Replace the filters more often if the air flow is less than usual, or if the vehicle is driven in areas that have high concentrations of soot from industry or diesel powered vehicles. 1. Open the glove box. Remove both glove box stops, then let the glove box hang down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlets (B) Take care not to scratch the body. 3. Install the air outlets by pushing on the hook portions until the hooks snap into place. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor Clutch Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > A/C Compressor Clutch Circuit Troubleshooting Compressor Clutch: Testing and Inspection A/C Compressor Clutch Circuit Troubleshooting A/C Compressor Clutch Circuit Troubleshooting NOTE: - Do not use this troubleshooting procedure if the fans are also inoperative with the A/C on. Refer to the symptom troubleshooting index. - Before performing symptom troubleshooting, check for powertrain DTCs. 1. Check the No. 1 (20 A) fuse in the under-hood fuse/relay box, and the No. 14 (10 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 2. NO - Replace the fuse(s), and recheck. 2. Check the engine coolant temperature, the throttle position sensor, and the idle speed (use the HDS PGM-FI data list if possible). Is the coolant temperature, throttle position, and idle speed OK? YES - Go to step 3. NO - Troubleshoot and repair the cause of the high engine coolant temperature, low idle, or excessively high throttle position sensor reading. 3. Remove the A/C compressor clutch relay from the under-hood fuse/relay box, and test it. Is the relay OK? YES - Go to step 4. NO - Replace the A/C compressor clutch relay. 4. Measure the voltage between the No. 2 terminal of the A/C compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 5. NO - Replace the under-hood fuse/relay box. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > A/C Compressor Clutch Circuit Troubleshooting > Page 4894 5. Connect the No. 1 and No. 2 terminals of the A/C compressor clutch relay 4P socket with a jumper wire. Does the A/C compressor clutch click? YES - Go to step 6. NO - Go to step 14. 6. Disconnect the jumper wire. 7. Turn the ignition switch ON (II). 8. Measure the voltage between the No. 3 terminal of the A/C compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 9. NO - Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the A/C compressor clutch relay. 9. Turn the ignition switch OFF. 10. Reinstall the A/C compressor clutch relay. 11. Make sure the A/C switch is OFF. 12. Turn the ignition switch ON (II). 13. Using the Backprobe Set, measure the voltage between the No. 18 terminal of ECM connector E (31P) and body ground with the ECM connectors connected. Is there battery voltage? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > A/C Compressor Clutch Circuit Troubleshooting > Page 4895 away with a known-good ECM, replace the original ECM. NO - Repair open in the wire between the A/C compressor clutch relay and the ECM. 14. Disconnect the jumper wire. 15. Disconnect the A/C compressor clutch 1P connector. 16. Check for continuity between the No. 1 terminal of the A/C compressor clutch relay 4P socket and the No. 1 terminal of the A/C compressor clutch 1P connector. Is there continuity? YES - Check the A/C compressor clutch clearance, the thermal protector, and the A/C compressor clutch field coil. NO - Repair open in the wire between the A/C compressor clutch relay and the A/C compressor clutch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > A/C Compressor Clutch Circuit Troubleshooting > Page 4896 Compressor Clutch: Testing and Inspection A/C Compressor Clutch Check A/C Compressor Clutch Check 1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set. 2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag. 3. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance. Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in.) NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. 4. Release the field coil connector from the holder, then disconnect it. Check the thermal protector for continuity. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above 252 to 270 °F (122 to 32 °C). When the temperature drops below 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > A/C Compressor Clutch Circuit Troubleshooting > Page 4897 5. Check resistance of the field coil. If resistance is not within specifications, replace the field coil. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 4898 Compressor Clutch: Service and Repair A/C Compressor Clutch Overhaul Special Tools Required A/C clutch holder, Robinair 10204 or, Kent-Moore J37872.or Honda Tool and Equipment KMT-J33939, commercially available 1. Remove the center nut (A) while holding the armature plate with a commercially available A/C clutch holder (B). 2. Remove the armature plate (A) and shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and recheck its clearance. NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. 3. If you are replacing the field coil, remove the snap ring (A) with snap ring pliers, then remove the rotor pulley (B). Be careful not to damage the rotor pulley or the A/C compressor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 4899 4. Remove the bolt and holder (A), then disconnect the field coil connector (B). Loosen the clamp screw (C) to free the field coil wire. Remove the snap ring (D) with snap ring pliers, then remove the field coil (E). Be careful not to damage the field coil or the A/C compressor. 5. Reassemble the clutch in the reverse order of disassembly, and note these items: - Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the A/C compressor. - Clean the rotor pulley and A/C compressor sliding surfaces with contact cleaner or other non-petroleum solvent. - Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. - Make sure that the rotor pulley turns smoothly after it's reassembled. - Route and clamp the wires properly or they can be damaged by the rotor pulley. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4903 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4904 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4905 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4906 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair A/C Condenser Replacement 1. Recover the refrigerant with a recovery/recycling/charging station 2. Remove the front bumper. 3. Remove the bolts, then disconnect the discharge line (A) and the A/C condenser line (B) from the A/C condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. 4. Remove the mounting bolts, then remove the A/C condenser by lifting it up. Be careful not to damage the radiator or the A/C condenser fins when removing the A/C condenser. 5. Install the A/C condenser in the reverse order of removal, and note these items: - If you're installing a new A/C condenser, add refrigerant oil (KEIHIN SP-10). - Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately - Be careful not to damage the radiator or the A/C condenser fins when installing the A/C condenser. - Charge the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations 29. Right Front of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 4914 17. A/C Condenser Fan Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 4918 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 4919 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 4920 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views 196. Heater Control Panel Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4925 Control Assembly: Testing and Inspection Heater Control Power and Ground Circuit Troubleshooting 1. Check the No.14 (10 A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck. 2. Disconnect heater control panel connector A (14P). 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No. 14 terminal of heater control panel connector A (14P) and body ground. Is there battery voltage? YES - Go to step 5. NO - Repair open in the wire between the No. 14 fuse in the under-dash fuse/relay box and the heater control panel. 5. Turn the ignition switch OFF. 6. Check for continuity between the No. 13 terminal of heater control panel connector A (14P) and body ground. Is there continuity? YES - Check for loose wires or poor connections at heater control panel connector A (14P). If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Check for an open in the wire between the heater control panel and body ground. If the wire is OK, check for poor ground at G501. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4926 Control Assembly: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel 2. Remove the dials (A), then remove the self tapping screws and the heater control panel (B) from the center panel (C) Remove the self tapping screws and the push switch assembly (D) from the center panel 3. Install the control panel and push switch assembly in the reverse order of removal After installation, operate the control panel controls to see whether it work properly 4. Run the self diagnosis function to confirm that there are no problems in the system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair Evaporator Core: Service and Repair Evaporator Core Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the bolt, then disconnect the suction line (A) and the receiver line (B) from the evaporator core. 3. Remove the blower unit. 4. Remove the self-tapping screws and the expansion valve cover. 5. Carefully pull out the evaporator core (A) without bending the pipes. 6. Remove the evaporator expansion valve (B) from the evaporator core. 7. Install the core in the reverse order of removal, and note these items: - If you're installing a new evaporator core, add refrigerant oil (KEIHIN SP-10). - Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If the refrigerant oil contacts the paint, wash it off immediately - Charge the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations 70. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4933 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4934 36. Evaporator Temperature Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4935 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour warm water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown, in the graph; the resistance should be within the specifications. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 4936 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Remove the driver's dashboard lower cover and the under cover. 2. Remove the under-dash fuse/relay box. 3. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Remove the self-tapping screw, and carefully pull out the evaporator temperature. 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air/A/C Blows Hot Air Heater Blows Cold Air; A/C Blows Warm Air NOTE: This article applies to all A/C-equipped Honda models that use a heater valve cable. Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose (P/N 95005-35008-10M, H/C 2325058), and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > A/C - Heater Blows Cold Air/A/C Blows Hot Air > Page 4942 Heater Control Valve Cable: Technical Service Bulletins A/C - Heater Blows Cold Air, A/C Blows Warm Air SOURCE: Honda Service News TITLE: Heater Blows Cold Air, A/C Blows Warm Air APPLIES TO: all A/C-equipped Honda models that use a heater valve cable. SERVICE TIP: Got a vehicle in your shop that blows cold air from the heater or warm air from the A/C ? The problem could just be the heater valve cable has slipped off the heater valve arm. There's a real easy fix for this problem. Slip the heater valve cable back onto the heater valve arm. Then cut yourself a 10 mm length of 3.5 mm vacuum hose and slide it onto the arm. This holds the cable on the arm nice and snug so it won't slip off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 4943 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 4944 Heater Control Valve Cable: Adjustments Heater Valve Cable Adjustment 1. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C) 2. From under the dash, disconnect the heater valve cable housing from the cable clamp (A), and disconnect the heater valve cable (B) from the air mix control linkage (C). 3. Set the temperature control dial on Max Cool with the ignition switch ON (II). 4. Attach the heater valve cable (B) to the air mix control linkage (C) as shown, then snap the heater valve cable housing into the cable clamp (A). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and the precautions and procedures before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the bolt and the heater valve, then remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 8. Remove the dashboard. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 4948 9. Disconnect the connectors (A) from the blower motor, the recirculation control motor, the mode control motor, and the power transistor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screws and the bracket (D). 10. Disconnect the connectors (A) from the evaporator temperature sensor and the air mix control motor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screw and the cover (D). Disconnect the heater valve cable (E). 11. Remove the mounting bolts, the mounting nuts, and the heater unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 4949 12. Remove the self-tapping screws and the expansion valve cover (A). Carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the grommet (C), then remove the self-tapping screws and the flange cover (D). Remove the self-tapping screws and the pipe cover (E), then carefully pull out the heater core (F) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. - Refill the cooling system with engine coolant. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Refer to evaporator core replacement. - Do the engine control module (ECM) idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 4953 Heater Core Case: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations, and the precautions and procedures before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the bolt and the heater valve, then remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines and the brake lines, etc. 8. Remove the dashboard. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 4954 9. Disconnect the connectors (A) from the blower motor, the recirculation control motor, the mode control motor, and the power transistor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screws and the bracket (D). 10. Disconnect the connectors (A) from the evaporator temperature sensor and the air mix control motor, then remove the wire harness clips (B) and the connector (C). Remove the self-tapping screw and the cover (D). Disconnect the heater valve cable (E). 11. Remove the mounting bolts, the mounting nuts, and the heater unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 4955 12. Remove the self-tapping screws and the expansion valve cover (A). Carefully pull out the evaporator core (B) so you don't bend the inlet and outlet pipes. Remove the grommet (C), then remove the self-tapping screws and the flange cover (D). Remove the self-tapping screws and the pipe cover (E), then carefully pull out the heater core (F) so you don't bend the inlet and outlet pipes. 13. Install the heater core and the evaporator core in the reverse order of removal. 14. Install the heater unit in the reverse order of removal, and note these items: - Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. - Refill the cooling system with engine coolant. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Refer to evaporator core replacement. - Do the engine control module (ECM) idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair High Pressure Safety Valve HVAC: Service and Repair A/C Compressor Relief Valve Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the relief valve (A) and the O-ring (B). Plug the opening to keep foreign matter from entering the system and the A/C compressor oil from running out. 3. Clean the mating surfaces. 4. Install a new O-ring on the relief valve, and apply a thin coat of refrigerant oil to the O-ring. 5. Remove the plug, and install and tighten the relief valve. 6. Charge the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations 48. Under Right Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations > Page 4965 118. Blower Power Transistor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations > Page 4966 Power Transistor HVAC: Testing and Inspection Power Transistor Test 1. Disconnect the 4P connector from the power transistor 2. Measure the resistance between the No 1 and No 2 terminals of the power transistor It should be about 1.4 - 1.5 kOhm - If the resistance is within the specifications, go to step 3 - If the resistance is not within the specifications replace the power transistor 3. Carefully release the lock tab on the No 4 terminal (BLU/YEL) (A) in the 4P connector, then remove the terminal and insulate it from body ground 4. Reconnect the 4P connector to the power transistor 5. Supply 12 volts to the No 4 cavity with a jumper wire 6. Turn the ignition switch ON (II), and check that the blower motor runs - If the blower motor does not run, replace the power transistor - If the blower motor runs, the power transistor is OK Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection Refrigerant: Technical Service Bulletins A/C - Refrigerant Leak Detection 07-030 October 12, 2007 Applies To: ALL Vehicles With Conventional A/C Compressors A/C Leak Detection (Supersedes 07-030, dated June 15, 2007, to update the information marked by asterisks) The OPTIMAX Jr. (TM)A/C Leak Detection Kit for Honda vehicles, P/N TRP124893, is a new required tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find. When searching for leaks, always begin by using an electronic leak detector. Refer to Service Bulletin 97-027, Denso HLD-100 Halogen Leak Detector; for tips on using this tool, then follow up with the OPTIMAX Jr. This new detection kit complements but does not replace the electronic detector. The kit contains: ^ TRP8640CS, OPTIMAX Jr. (TM) cordless, fluorescent leak detection flashlight lamp (includes 3 standard AA batteries) ^ TRP38600601, (6) 0.06 oz. (1.7 g) Tracer-Stick(R) R134a/PAG A/C dye capsules with ID labels ^ TRP3887, R-134a Universal Connect Set(TM) ^ TRP120884, GLO-AWAY(TM) dye cleaner ^ TRP9940, fluorescence-enhancing glasses ^ TRP1143, (1) empty Tracer-Stick dye capsule ORDERING INFO *One OPTIMAX Jr. A/C Leak Detection Kit was shipped to each current dealer as a required special tool. Additional kits and replacement capsules may be ordered through the Honda Tool and Equipment Program. On the iN, click on Service, Service Bay, Tool and Equipment Program, Online Catalog tab, and Air Conditioning Equipment, or call.* NOTICE ^ Do not use leak-trace dye in any Honda hybrid vehicle equipped with a dual-scroll compressor This can increase the chance of electric shock. The compressor is easily identified by the orange high-voltage cable that is connected to the compressor body. ^ Only Tracer-Stick single-dose fluorescent dye capsules from Tracer Products (Tracerline(R)) are approved for use in Honda vehicles. Other dyes contain solvents that may contaminate the system's refrigerant oil, leading to component failure. ^ Adding excessive amounts of dye can lead to compressor damage and failure. USING THE OPTIMAX JR. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 4971 1. Before adding any leak-detection dye, check to see if there is dye in the system now. ^ Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system. ^ Dye may have been added even though no label is present. To confirm this: - Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap. - Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system. ^ If there is no dye in the system, go to step 2. ^ If there is dye in the system, go to step 5. Do not add more dye. 2. Add the dye. NOTE: Air and moisture must be evacuated from the universal connect set if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise do the following: (a) Attach the empty dye capsule (provided in the dye kit) to the control valve fitting. (b) Attach the service valve fitting (provided in the kit) to the empty dye capsule. (c) Attach the low-side hose of the A/C recovery and charging station, and open the quick coupler's hand-wheel valve. Then open the control valve (black knob) on the universal connect set. (d) Following the manufacturer's instructions for your recovery and charging station, evacuate the universal connect set for approximately 3 minutes. (e) When evacuation is complete, be sure the set's control valve is closed (finger tight), and disconnect the NC recovery and charging station. (f) Remove the service valve fitting and the empty dye capsule from the set, and store them for future use. NOTE: ^ Check the refrigerant charge level. There must be enough refrigerant in the system to operate the A/C compressor and to circulate refrigerant oil. ^ If the refrigerant charge is too low, recover the remaining amount and recharge the system before adding any dye. (g) Start the vehicle and operate the A/C system. Follow your A/C refrigerant recovery and charging station's operating instructions for low-side charging to install the dye. * NOTE: Only 0.05 lb (0.02 kg) of refrigerant is needed to push the dye into the A/C system.* (h) Once the refrigerant charge is programmed, open the control valve on the set to allow the dye to enter the system. (i) After the dye capsule clears, allow the low-side of the A/C system to reach its lowest operating pressure, then quickly close both the service equipment's low-side coupler valve and the control valve on the set. (j) Remove the set from the vehicle by releasing its quick coupler. Remove the empty dye capsule from the service valve fitting. Return the hose, control valve, and service-valve fitting to the storage case. * NOTE: Store the hose with the control valve closed. This will retain a small amount of refrigerant in the hose so it does not have to be evacuated the next time you use it.* (k) Fill out an identification label (provided in the kit), and attach it to a location near the A/C charge label. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 4972 3. Connect the universal connect set and the Tracer- Stick dye capsule: (a) Be sure the quick coupler and control valves on the set are closed. (b) Remove the low-side service port sealing cap, and connect the set to the low-side service port using the quick coupler. (c) Hold a new dye capsule so that the embossed arrow is pointing up. Remove the black end cap, and carefully attach the capsule to the control valve fitting. NOTE: The capsule must be held with the embossed arrow pointing up or the dye will leak out of the capsule. (d) Turn the capsule so the embossed arrow is pointing down. Remove the orange end cap, and carefully attach the service valve fitting provided in the kit (finger tight). NOTE: The capsule must be held with the embossed arrow pointing down or the dye will leak out. 4. Connect the NC service equipment: With the universal connect set and dye capsule attached to the vehicle's low-side service port, connect the A/C refrigerant recovery and charging station's low-side hose quick coupler to the service valve fitting. Open the blue hand-wheel valves on both quick couplers. Leave the control valve (black knob) on the universal connect set closed. NOTE: * ^ If you have recovered refrigerant to weigh it as part of your diagnostics, or if there is a low charge, it is more efficient to recharge the system using normal procedures before installing the universal connect set. Dye can then be added using approximately 0.05 lb (0.02 kg) of refrigerant.* ^ You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding. ^ Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system. 5. Inspect the A/C system for leaks: (a) Run the A/C system for at least 15 minutes to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow. Smaller leaks may require at least 24 hours of vehicle operation before they become visible. Operate the A/C system as much as possible during this time to keep the dye circulating. (b) Stop the vehicle's engine and inspect the system for leaks using the ultraviolet (UV) lamp and fluorescence-enhancing glasses from the kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 4973 Low ambient light conditions (a dark work area) will aid in locating the leak. NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks. (c) Inspect the entire system. Be sure to check these locations: ^ damaged and corroded areas ^ fittings ^ hose-to-line couplings ^ refrigerant controls ^ service ports ^ brazed or welded areas ^ areas near attachment points (d) Check for evaporator leaks by illuminating the evaporator drain tube area with the UV lamp and glasses. (e) After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water (follow the instructions on the bottle). Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity or system .............................................................................................................................. ................................... 500 - 550 g (17.6 - 19.4 oz) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 4976 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant oil Capacity of components Condenser ........................................................................................................................................... ............................................... 25 ml (5/6 fl oz) Evaporator ................................................................. .................................................................................................................... 45 ml (1 1/2 fl oz) Each line and hose ....................................................................................................................................... .................................... 10 ml (1/3 fl oz) Compressor .......................................................................... .......................................................................................... 130 - 150 ml (4 1/3 - 5 fl oz) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 4981 Refrigerant Oil: Fluid Type Specifications Use only ............................................................................................................................................... ................................................. SP-10 refrigerant oil Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 4982 Refrigerant Oil: Service and Repair Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 4983 A/C Refrigerant Oil Replacement Recommended PAG oil: KEIHIN SP-10: - P/N 38897-P13-A01AH: 120 mL (4 fl.oz) - P/N38899-P13-A01: 40 mL(1 1/3 fl.oz) Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint. If it gets on the paint, wash it off immediately. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4987 21. Left Front of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4988 18. A/C Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4989 Refrigerant Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch Circuit Troubleshooting NOTE: - Do not use this troubleshooting procedure if any of the following items are operative; A/C condenser fan, radiator fan, A/C compressor, or if the heater is inoperative. Refer to the symptom troubleshooting index. - Before performing symptom troubleshooting, check for powertrain DTCs. 1. Turn the ignition switch ON (II). 2. Turn the blower switch on, and check for blower motor operation. Does the blower motor run on all speeds? YES - Go to step 3. NO - Troubleshoot the blower motor circuit. 3. Turn the ignition switch OFF. 4. Disconnect heater control panel connector A (14P). 5. Turn the ignition switch ON (II). 6. Measure the voltage between the No. 4 terminal of heater control panel connector A (14P) and body ground. Is there battery voltage? YES - Go to step 7. NO - Go to step 12. 7. Start the engine. 8. Connect the No. 4 terminal of heater control panel connector A (14P) to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 9. NO - Refer to the multiplex control system. 9. Turn the ignition switch OFF. 10. Disconnect heater control panel connector B (22P). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4990 11. Measure the resistance between the No. 2 terminal of the heater control panel connector A (14P) and the No. 7 terminal of the heater control panel connector B (22P). Is there resistance less than 24 kOhms? YES - Check for loose wires or poor connections at heater control panel connector A (14P) and B (22P) and at the A/C pressure switch 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Test the evaporator temperature sensor. 12. Using the Backprobe Set, connect the No. 9 terminal of under-dash fuse/relay box connector F (12P)to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 13. NO - Refer to the multiplex control system. NOTE: Check for multiplex codes in mode 1. Follow the troubleshooting for any codes found. If no codes are found, substitute known-good multiplex control unit and a ECM one at a time. 13. Disconnect the A/C pressure switch 2P connector and under-dash fuse/relay box connector F (12P). 14. Check for continuity between the No. 2 terminal of the A/C pressure switch 2P connector and the No. 9 terminal of under-dash fuse relay box connector F (12P). Is there continuity? Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 4991 YES - Go to step 15. NO - Repair open in the wire between the under-dash fuse/relay box and the A/C pressure switch. 15. Check for continuity between the No. 1 and No. 2 terminals of the A/C pressure switch. Is there continuity? YES - Repair open in the wire between the heater control panel and the A/C pressure switch. NO - Go to step 16. 16. Check for proper A/C system pressure. Is the pressure within specifications? YES - Replace the A/C pressure switch. NO - Repair the A/C pressure problem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 4996 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 4997 Blower Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 4998 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5002 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5003 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5004 Compressor Clutch Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5005 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5009 Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5010 Condenser Fan Motor Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5011 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 5016 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 5017 Air Conditioning Switch: Service and Repair Heater Control Panel and Push Switch Assembly Removal and Installation 1. Remove the center panel. 2. Remove the dials (A), then remove the self-tapping screws and the heater control panel (B) from the center panel (C). Remove the self-tapping screws and the push switch assembly (D) from the center panel. 3. Install the control panel and push switch assembly in the reverse order of removal. After installation, operate the control panel controls to see whether it work properly. 4. Run the self-diagnosis function to confirm that there are no problems in the system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations 70. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5024 Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5025 36. Evaporator Temperature Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5026 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour warm water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown, in the graph; the resistance should be within the specifications. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5027 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Remove the driver's dashboard lower cover and the under cover. 2. Remove the under-dash fuse/relay box. 3. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Remove the self-tapping screw, and carefully pull out the evaporator temperature. 4. Install the sensor in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5031 21. Left Front of Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5032 18. A/C Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5033 Refrigerant Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch Circuit Troubleshooting NOTE: - Do not use this troubleshooting procedure if any of the following items are operative; A/C condenser fan, radiator fan, A/C compressor, or if the heater is inoperative. Refer to the symptom troubleshooting index. - Before performing symptom troubleshooting, check for powertrain DTCs. 1. Turn the ignition switch ON (II). 2. Turn the blower switch on, and check for blower motor operation. Does the blower motor run on all speeds? YES - Go to step 3. NO - Troubleshoot the blower motor circuit. 3. Turn the ignition switch OFF. 4. Disconnect heater control panel connector A (14P). 5. Turn the ignition switch ON (II). 6. Measure the voltage between the No. 4 terminal of heater control panel connector A (14P) and body ground. Is there battery voltage? YES - Go to step 7. NO - Go to step 12. 7. Start the engine. 8. Connect the No. 4 terminal of heater control panel connector A (14P) to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 9. NO - Refer to the multiplex control system. 9. Turn the ignition switch OFF. 10. Disconnect heater control panel connector B (22P). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5034 11. Measure the resistance between the No. 2 terminal of the heater control panel connector A (14P) and the No. 7 terminal of the heater control panel connector B (22P). Is there resistance less than 24 kOhms? YES - Check for loose wires or poor connections at heater control panel connector A (14P) and B (22P) and at the A/C pressure switch 2P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Test the evaporator temperature sensor. 12. Using the Backprobe Set, connect the No. 9 terminal of under-dash fuse/relay box connector F (12P)to body ground with a jumper wire. Does the A/C system come on? YES - Go to step 13. NO - Refer to the multiplex control system. NOTE: Check for multiplex codes in mode 1. Follow the troubleshooting for any codes found. If no codes are found, substitute known-good multiplex control unit and a ECM one at a time. 13. Disconnect the A/C pressure switch 2P connector and under-dash fuse/relay box connector F (12P). 14. Check for continuity between the No. 2 terminal of the A/C pressure switch 2P connector and the No. 9 terminal of under-dash fuse relay box connector F (12P). Is there continuity? Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5035 YES - Go to step 15. NO - Repair open in the wire between the under-dash fuse/relay box and the A/C pressure switch. 15. Check for continuity between the No. 1 and No. 2 terminals of the A/C pressure switch. Is there continuity? YES - Repair open in the wire between the heater control panel and the A/C pressure switch. NO - Go to step 16. 16. Check for proper A/C system pressure. Is the pressure within specifications? YES - Replace the A/C pressure switch. NO - Repair the A/C pressure problem. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Service and Repair Thermal Limiting Fuse: Service and Repair A/C Compressor Thermal Protector Replacement 1. Remove the bolt, the ground terminal (A), and the holder (B). Disconnect the field coil connector (C), then remove the thermal protector (D). 2. Replace the thermal protector (A) with a new one, and apply silicone Sealant (B) to the bottom of the thermal protector. 3. Install in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair Component Replacement/Inspection After Deployment NOTE: Before doing any SRS repairs, use the HDS SRS menu method to check for DTCs; refer to the DTC Troubleshooting Index for the less obvious deployed parts (seat belt tensioners, front sensors, side airbag sensors, etc.), After a collision where the seat belt tensioners deployed, replace these items: - Seat belt tensioners - Seat belt buckle tensioners - SRS unit - Front impact sensors After a collision where the front airbag(s) deployed, replace these items: - SRS unit - Deployed airbag(s) - Seat belt tensioners - Seat belt buckle tensioners - Front impact sensors After a collision where the side airbag(s) deployed, replace these items: - SRS unit - Deployed side airbag(s) - Side impact sensor(s) for the side(s) that deployed During the repair process, inspect these areas: - Inspect all the SRS wire harnesses. Replace, don't repair, any damaged harnesses. - Inspect the cable reel for heat damage. If there is any damage, replace the cable reel. After the vehicle is completely repaired, turn the ignition switch ON (II). If the SRS indicator comes on for about 6 seconds and then goes off, the SRS airbag system is OK. If the indicator does not function properly, use the HDS SRS menu method to read the DTC. If this doesn't retrieve any codes, use the HDS SCS menu method. If you still cannot retrieve a code, go to Symptom Troubleshooting. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5051 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5052 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Driver's Air Bag - Replace Torx Bolts Properly Air Bag: Technical Service Bulletins Driver's Air Bag - Replace Torx Bolts Properly SOURCE: Honda Service News September 2004 TITLE: Replace Drivers Air Bag Torx Bolts Properly APPLIES TO: All Models SERVICE TIP: When replacing a drivers's side air bag, make sure you replace the torx bolts properly. When removing the bolts, use a high-quality bit, making sure the bit is aligned. DON'T USE AIR TOOLS. When installing bolts, always start the bolts by hand to avoid cross-treading, and torque the bolts to the value listed in the service manual. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5057 Air Bag: Diagrams 61. Side Airbag Inflator, Driver's (Side Airbag) 62. Side Airbag Inflator, Passenger's (Side Airbag) 115. Airbag First And Second Inflators, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5058 116. Airbag First And Second Inflators, Passenger's 133. C552(Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement Air Bag: Service and Repair Driver's Airbag Replacement Driver's Air-bag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (B) from the cable reel connector (C). 3. Remove the maintenance cover (A), then remove the two Torx bolts (B) using a Torx T30 bit. 4. Disconnect the horn switch connector (1P) (C). 5. Remove the driver's airbag (D). Installation 1. Connect the horn switch connector (1P) to the driver's airbag. 2. Place the new driver's airbag (A) in the steering wheel, and secure it with new Torx bolts (B), and install the maintenance cover (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5061 3. Connect the cable reel connector (A) to the driver's airbag 4P connector (B), then install the access panel (C) on the steering wheel. 4. Connect the battery negative cable. 5. After installing the airbag, confirm proper system operation: - Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. - Make sure the horn works. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5062 Air Bag: Service and Repair Front Passenger's Airbag Replacement Front Passenger's Airbag Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Remove the glove box stops, and lower the glove box. 3. Disconnect the front passenger's airbag 4P connector (A) from dashboard wire harness B. 4. Remove the three mounting nuts (A) from the bracket. Cover the lid and dashboard with a cloth, and pry carefully with a screwdriver to lift the front passenger's airbag (B) out of the dashboard. NOTE: The airbag lid has pawls on its side which attach it to the dashboard. Installation 1. Place the new front passenger's airbag (A) into the dashboard. Tighten the front passenger's airbag mounting nuts (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5063 2. Connect the front passenger's airbag 4P connector (A) to dashboard wire harness B. 3. Raise the glove box, and reinstall the stops. 4. Reconnect the battery negative cable. 5. After installing the airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5064 Air Bag: Service and Repair Side Airbag Replacement Side Airbag Replacement NOTE: Review the seat replacement procedure before performing repairs or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the side airbag harness 2P connector (A). 3. Remove the seat assembly and seat-back cover. 4. Remove the mounting nut (A) and the side airbag (B). Installation NOTE: - If the side airbag lid is secured by a tape, remove the tape. - Do not open the lid of the side airbag cover. - Use new mounting nuts tightened to the specified torque. - Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment. - Be sure to install the harness wires so that they are not pinched or interfering with other parts. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5065 1. Place the new side airbag on the seat-back frame (A). Tighten the side airbag mounting nuts (B). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Move the front seat and the seat-back through their full ranges of movement, making sure the harness wires are not pinched or interfering with other parts. 5. Reconnect the battery negative cable. 6. After installing the side airbag, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5066 Air Bag: Service and Repair Airbag Disposal Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying Airbags in the Vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners should be deployed while still in the vehicle. The airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, or seat belt tensioner is securely mounted. 3. Confirm that the special tool is functioning properly by following the check procedure on the tool label. Driver's Airbag 4. Remove the access panel from the steering wheel, then disconnect the driver's airbag 4P connector from the cable reel. Front Passenger's Airbag 5. Lower the glove box, then disconnect the front passenger's airbag 4P connector from dashboard wire harness B. Side Airbag 6. Disconnect the side airbag 2P connectors from the floor wire harness. Seat belt tensioner 7. Disconnect the seat belt tensioner 2P connectors from the floor wire harness. Pull the seat belt out all the way, and cut it off. Seat belt buckle tensioner 8. Disconnect the seat belt buckle tensioner 4P connectors from the floor wire harness. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5067 9. Cut off each connector, strip the ends of the wires, and connect the deployment tool alligator clips (A) to the wires. Place the deployment tool at least 30 feet (10 meters) away from the vehicle. NOTE: The driver's airbag and the front passenger's airbag each have four wires, two yellow and two red. Twist each pair of unlike colored wires together, and connect an alligator clip to each pair. 10. Connect a 12 volt battery to the tool. - If the green light on the tool comes on, the igniter circuit is defective and cannot deploy the component. Go to Disposal of Damaged Components. - If the red light on the tool comes on, the component is ready to be deployed. 11. Push the tool's deployment switch. The airbags and tensioners should deploy (deployment is both highly audible and visible: a loud noise and rapid inflation of the bag, followed by slow deflation). If the components deploy and the green light on the tool comes on, continue with this procedure. - If a component doesn't deploy, yet the green light comes on, its igniter is defective. Go to Disposal of Damaged components. - During deployment, the airbags can become hot enough to burn you. Wait 30 minutes after deployment before touching the airbags. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver's Airbag Replacement > Page 5068 12. Dispose of the complete airbag. No part of it can be reused. Place it in a sturdy plastic bag (A), and seal it securely. Dispose of the deployed airbag according to your local regulations. Deploying Components Out of the Vehicle If an intact airbag or tensioner has been removed from a scrapped vehicle, or has been found defective or damaged during transit, storage, or service, it should be deployed as follows: 1. Confirm that the special tool is functioning properly by following the check procedure on the tool label. 2. Position the airbag face up, outdoors, on flat ground, at least 30 feet (10 meters) from any obstacles or people. 3. Follow steps 9 through 11 of the in-vehicle deployment procedure. Disposal of Damaged Components 1. If installed in a vehicle, follow the removal procedure for the driver's airbag, front passenger's airbag, side airbag, seat belt tensioner, and seat belt buckle tensioner. 2. In all cases, make a short circuit by cutting, stripping, and twisting together the two inflator wires. NOTE: The driver's and passenger's airbag each have four wires: twist each pair of like-colored wires together 3. Package the component in the same packaging that the new replacement part came in. 4. Mark the outside of the box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED", "DAMAGED SEAT BELT TENSIONER NOT DEPLOYED" or "DAMAGED SEAT BELT BUCKLE TENSIONER NOT DEPLOYED" so it does not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal. Deployment Tool Check 1. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations 88. In Passenger's Seat (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5073 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5074 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5075 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5076 59. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5077 Air Bag Control Module: Diagrams 197. OPDS Unit (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5078 198. SRS Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the console carpet on the passenger's side, then remove the Torx bolt (A) from the SRS unit. 7. Pull down the console carpet on the driver's side, then disconnect the connectors. Remove the Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push them into position until they click. NOTE: When tightening the Torx bolts to the specified torque, be careful to turn them in so that their heads rest squarely on the brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5081 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5082 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedures before performing repairs or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the passenger's side airbag harness 2P connector. 3. Remove the front passenger's seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit 8P connector D and sensor connector (B) from the OPDS unit (C). 5. Remove the two screws (E) and the OPDS unit. Installation 1. Place the new OPDS unit (A) on the seat-back frame. Tighten the two screws (B), and connect the OPDS unit 8P connector D and sensor connector (C) to the OPDS unit. Reinstall the cover (E). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5083 Air Bag Control Module: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Unit When a seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: A new (uninitialized) OPDS unit installed with a faulty OPDS sensor can cause DTC 15-1. 1. Erase the DTC memory (see "Erasing the DTC Memory"). 2. Make sure the front passenger's seat is dry. Set the seat-back in a normal position, and make sure there is nothing on the seat. 3. Make sure the ignition switch is OFF and the MES connector is not shorted. 4. Connect the HDS to the DLC (A). 5. Turn the ignition switch ON (II). 6. From the HDS Main Menu, select SRS, then Misc. Test, then adjustments. In the Adjustment Menu, select OPDS INIT. Follow the screen prompts to initialize the OPDS. 7. Turn the ignition switch OFF. 8. Disconnect the HDS from the DLC. NOTE: If the OPDS system fails to initialize after several attempts, replace the OPDS sensor and retry. If the OPDS system continues to fail to initialize, replace the OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams 193. Cable Reel Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5087 Clockspring Assembly / Spiral Cable: Service and Repair Cable Reel Replacement Removal 1. Make sure the front wheels are aligned straight ahead. 2. Disconnect the battery negative cable, and wait at least 3 minutes. 3. Remove the driver's airbag. 4. Disconnect the connector (A) from the cruise control set/resume switch, then remove the steering wheel bolt (B). 5. Align the front wheels straight ahead, then remove the steering wheel with a steering wheel puller. Do not tap on the steering wheel or steering column shaft when removing the steering wheel. 6. Remove the dashboard lower cover (A). 7. Remove the column cover screws (A), then remove the column covers (B, C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5088 8. Disconnect the dashboard wire harness 4P connector (A) from the cable reel, then disconnect the dashboard wire harness 5P connector (B) from the cable reel 9. Release the lock tab (A) under the cable reel connector with a 90° hook shaped tool (B) Slide the tool below the cable reel connector just above the lock tab Release the lower lock tab (C), and slide the cable reel off the column 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 least 3 minutes 3. Set the cancel sleeve (A) so the projections (B) are aligned vertically Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 5089 4. Carefully install the cable reel (A) on the steering column shaft Then connect the 5P connector (B) and the 4P connector (C) 5. Install the steering column covers. 6. If necessary, center the cable reel. (New replacement cable reels come centered.) Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise (about 2 1/2 turns) until the arrow mark on the cable reel label points straight up. 7. Align the projections on the cable reel with the holes on the steering wheel, and install the steering wheel with a new steering wheel bolt (A). 8. Install the driver's airbag. 9. Reconnect the battery negative cable. 10. After installing the cable reel, confirm proper system operation: - Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. - After the SRS indicator has turned off, turn the steering wheel fully left and right to confirm the SRS indicator does not come on. - Make sure the horn works. - Make sure the cruise control works. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 5093 48. MES Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 31. Left Front of Vehicle (Bumper Removed) 34. Right Front of Vehicle (Bumper Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5097 87. Left Side of Floor (Right Similar) (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5098 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5099 Impact Sensor: Diagrams 45. Impact Sensor, Left Front 46. Impact Sensor, Right Front 63. Side Impact Sensor, Driver's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5100 64. Side Impact Sensor, Passenger's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement Impact Sensor: Service and Repair Side Impact Sensor Replacement Side Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the appropriate side airbag 2P connector. 3. Remove the seat assembly. 4. Remove the front door sill trim. 5. Disconnect the 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 (B). Installation 1. Install the new side impact sensor with a new Torx bolt (A), then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. 4. Install all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement > Page 5103 Impact Sensor: Service and Repair Front Impact Sensor Replacement Front Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's airbag 4P connector, the front passenger's airbag 4P connector, both seat belt tensioner 2P connectors, and both seat belt buckle 4P connectors. 3. Remove the front inner fender. 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 (C). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5112 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5113 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5114 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5115 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5116 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5117 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5118 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5119 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5120 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5121 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5122 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5128 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5129 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5130 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5131 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5132 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5133 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5134 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5135 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5136 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5137 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5138 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5147 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5148 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5149 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5150 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5151 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5152 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5153 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5154 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5155 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5156 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5157 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5163 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5164 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5165 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5166 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5167 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5168 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5169 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5170 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5171 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5172 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign OPDS Unit Warranty Extension > Page 5173 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 5174 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams 197. OPDS Unit (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Customer Interest: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing Child Seat: Customer Interest Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Customer Interest: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 5186 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Customer Interest: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 5187 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing Child Seat: All Technical Service Bulletins Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 5193 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 5194 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Other Service Bulletins for Child Seat: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - MIL ON/DTC's P0706 or P1706 05-058 October 28, 2005 Applies To: 2004-05 Civic and CR-V - See VEHICLES AFFECTED MIL Comes On With DTC P0706 or P1706, Engine May Not Crank SYMPTOM The MIL comes on with DTC P0706 or P1706 (open in transmission range switch circuit), and/or the engine may not crank intermittently. PROBABLE CAUSE Poor continuity within the internal bands of the transmission range switch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the transmission range switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Other Service Bulletins for Child Seat: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 5200 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Other Service Bulletins for Child Seat: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 5201 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Other Service Bulletins for Child Seat: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 5207 PARTS INFORMATION Gear position switch: Civic P/N 28900-PLX-013, H/C 7997406 CR-V P/N 28900-PPV-013, H/C 8006116 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 743105 Flat Rate Time: 0.3 hour Failed Part: Civic P/N 28900-PLX-003 H/C 6568976 CR-V P/N 28900-PRP-003 H/C 6734859 Defect Code: 06601 Symptom Code: 03203 Template ID:Civic 05-058A CR-V 05-058B Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Use the HDS to retrieve DTCs. If DTC P0706 or P1706 is present, go to REPAIR PROCEDURE. Crank the engine with the gear selector in Park and in neutral. If the vehicle cranks in neutral, but not in Park position, go to REPAIR PROCEDURE. Otherwise, refer to the service manual for troubleshooting. REPAIR PROCEDURE 1. Replace the transmission range switch: Civic ^ Refer to page 14-179 of the 2001-05 Civic Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. CR-V ^ Refer to page 14-250 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword RANGE, and select Transmission Range Switch Replacement (A/T) from the list. 2. Clear the DTC with the HDS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Other Service Bulletins for Child Seat: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 5208 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Page 5209 Child Seat: Description and Operation Attachment points are provided for a rear seat mounted child restraint system which uses a top tether. The attachment points are located on the rear shelf, just behind the rear seat-back. When using a child seat with a top tether, install the child seat anchor plates securely. WARNING: Do not use the child seat anchor plate for any other purpose; it is designed exclusively for installation of a child seat. Additional information at Restraint Systems / Seat Belt Systems / Child Restraint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations Air Bag Control Module: Component Locations 88. In Passenger's Seat (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5215 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5216 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5217 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Component Locations > Page 5218 59. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5219 Air Bag Control Module: Diagrams 197. OPDS Unit (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5220 198. SRS Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement Air Bag Control Module: Service and Repair SRS Unit Replacement SRS Unit Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's and front passenger's airbag connectors. 3. Disconnect the side airbag connectors. 4. Disconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 5. Remove the dashboard center lower cover. 6. Pull down the console carpet on the passenger's side, then remove the Torx bolt (A) from the SRS unit. 7. Pull down the console carpet on the driver's side, then disconnect the connectors. Remove the Torx bolts (A), then pull out the SRS unit. Installation 1. Install the new SRS unit (A) with Torx bolts (B), then connect the connectors (C) to the SRS unit; push them into position until they click. NOTE: When tightening the Torx bolts to the specified torque, be careful to turn them in so that their heads rest squarely on the brackets. 2. Reinstall the dashboard center lower cover. 3. Reconnect the driver's and front passenger's airbag connectors. 4. Reconnect the side airbag connectors. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5223 5. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 6. Reconnect the battery negative cable. 7. Initialize the OPDS unit. 8. After installing the SRS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5224 Air Bag Control Module: Service and Repair OPDS Unit Replacement OPDS Unit Replacement NOTE: Review the seat replacement procedures before performing repairs or service. Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the passenger's side airbag harness 2P connector. 3. Remove the front passenger's seat assembly and seat-back cover. 4. Remove the cover (A), then disconnect the OPDS unit 8P connector D and sensor connector (B) from the OPDS unit (C). 5. Remove the two screws (E) and the OPDS unit. Installation 1. Place the new OPDS unit (A) on the seat-back frame. Tighten the two screws (B), and connect the OPDS unit 8P connector D and sensor connector (C) to the OPDS unit. Reinstall the cover (E). 2. Install the seat-back cover. 3. Install the seat assembly, then connect the side airbag harness 2P connector. 4. Reconnect the battery negative cable. 5. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. 6. Initialize the OPDS unit. 7. After installing the OPDS unit, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > SRS Unit Replacement > Page 5225 Air Bag Control Module: Service and Repair Initializing the OPDS Unit Initializing the OPDS (Occupant Position Detection System) Unit When a seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTE: A new (uninitialized) OPDS unit installed with a faulty OPDS sensor can cause DTC 15-1. 1. Erase the DTC memory (see "Erasing the DTC Memory"). 2. Make sure the front passenger's seat is dry. Set the seat-back in a normal position, and make sure there is nothing on the seat. 3. Make sure the ignition switch is OFF and the MES connector is not shorted. 4. Connect the HDS to the DLC (A). 5. Turn the ignition switch ON (II). 6. From the HDS Main Menu, select SRS, then Misc. Test, then adjustments. In the Adjustment Menu, select OPDS INIT. Follow the screen prompts to initialize the OPDS. 7. Turn the ignition switch OFF. 8. Disconnect the HDS from the DLC. NOTE: If the OPDS system fails to initialize after several attempts, replace the OPDS sensor and retry. If the OPDS system continues to fail to initialize, replace the OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5234 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5235 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5236 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5237 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5238 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5239 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5240 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5241 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5242 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5243 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5244 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5250 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5251 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5252 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5253 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5254 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5255 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5256 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5257 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5258 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5259 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Classification Module - Air Bag: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5260 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5266 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 5267 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair Child Seat Tether Anchor Removal/Installation Middle 1. Remove the child seat tether anchor cover (A) in the rear trim panel (B). 2. Remove the anchor bolt (C), then remove the child seat tether anchor (D). Do not remove the toothed washer (E) from the tether anchor. 3. Install the anchor in the reverse order of removal, and apply liquid thread lock to the anchor bolt. Side 1. Remove the rear bulkhead covers from both sides. 2. Remove the anchor bolt (A), then remove the child seat tether anchor (B) from behind the seat-back on each side of the cargo compartment. Do not remove the toothed washer (C) from the tether anchor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Page 5272 3. Install the anchors in the reverse order of removal, and apply liquid thread lock to the anchor bolts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA04V550000 > Nov > 04 > Recall 04V550000: Front Seat Belt Anchor Defect Seat Belt: Recalls Recall 04V550000: Front Seat Belt Anchor Defect Make / Models : Model/Build Years: Honda / Civic SI 2004-2005 MANUFACTURER: American Honda Motor Co. NHTSA CAMPAIGN ID Number : 04V550000 Recall Date : NOV 17, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 416 SUMMARY: On certain passenger vehicles, some front seat belt anchors may have been installed with an incorrect washer, which could restrict anchor movement. As a result, the seat belt may be improperly positioned for certain occupants. CONSEQUENCE: An improperly positioned belt could increase the risk of injury in the event of a crash. REMEDY: Dealers will inspect the front seat belt anchors for restricted movement. If an anchor does not rotate freely, the dealer will replace the washer with a countermeasure washer. the recall is expected to begin on December 6, 2004. owners should contact Honda at 1-800-999-1009. NOTES: Honda Recall NO. P55. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA04V550000 > Nov > 04 > Recall 04V550000: Front Seat Belt Anchor Defect Seat Belt: All Technical Service Bulletins Recall 04V550000: Front Seat Belt Anchor Defect Make / Models : Model/Build Years: Honda / Civic SI 2004-2005 MANUFACTURER: American Honda Motor Co. NHTSA CAMPAIGN ID Number : 04V550000 Recall Date : NOV 17, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 416 SUMMARY: On certain passenger vehicles, some front seat belt anchors may have been installed with an incorrect washer, which could restrict anchor movement. As a result, the seat belt may be improperly positioned for certain occupants. CONSEQUENCE: An improperly positioned belt could increase the risk of injury in the event of a crash. REMEDY: Dealers will inspect the front seat belt anchors for restricted movement. If an anchor does not rotate freely, the dealer will replace the washer with a countermeasure washer. the recall is expected to begin on December 6, 2004. owners should contact Honda at 1-800-999-1009. NOTES: Honda Recall NO. P55. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 5286 Seat Belt: Testing and Inspection Inspection Out of Vehicle For front seat belt retractors with seat belt tensioners, review the SRS component locations and the precautions and procedures before performing repairs or service. Retractor, Front and Rear 1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15° from the mounted position. The seat belt should lock when the retractor is leaned over 40°. Do not attempt to disassemble the retractor. 3. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Retractor, Rear Center 1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15° from the mounted position. 3. Lean the retractor over 40°, and make sure that the seat belt does not lock when pulled out over 900 mm (35.4 in.). Do not attempt to disassemble the retractor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 5287 4. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. In-vehicle 1. Check that the seat belt is not twisted or caught on anything. 2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts and check that the washers and other parts are not damaged or improperly installed. 3. Check the seat belts for damage or discoloration. If necessary, clean the seat belts with soap and water only, then wipe them off with a clean towel. NOTE: Dirt buildup in the loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol. 4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact. 5. For rear center shoulder belt, check that the seat belt locks when pulled out over 400 mm (15.7 in.) with the seat-back folded down. 6. Make sure that the seat belt will retract automatically when released. 7. For each passenger's seat belt, check the seat belt retractor locking mechanism ALR (automatic locking retractor). This function is for securing child seats. 1. Pull the seat belt all the way out to engage the ALR. The seat belt should retract with a soft, ratcheting sound, but not extend. This is normal. 2. To disengage the ALR, release the seat belt and allow it to fully retract, then pull the seat belt out part-way. The seat belt should retract and extend normally. 8. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt Seat Belt: Service and Repair Front Seat Belt Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Front Seat Belt 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Slide the front seat forward fully. 4. Remove the lower anchor cap (A), and remove the lower anchor bolt (B). 5. Remove the rear side trim panel. 6. Remove the upper anchor cover (A), and remove the upper anchor bolt (B). 7. Disconnect the SRS seat belt tensioner connector (A). Remove the retractor mounting self-tapping ET screw (B) and the retractor bolt (C), then remove the front seat belt (D) and retractor (E). 8. If necessary, remove the front seat belt protector (F). 9. Remove the B-pillar upper trim Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt > Page 5290 10. Remove the shoulder anchor adjuster (A). 11. Install the seat belt in the reverse order of removal, and note these items: - If the threads on the retractor mounting self-tapping ET screw are worn out, use an oversized self-tapping ET screw (P/N 90133-SZ4-003) made specifically for this application. - Check that the retractor locking mechanism functions. - Follow the Anchor Bolt Installation diagrams carefully when assembling the washers, collars, and bushings of the upper and lower anchor bolts. - If the seat belt tensioner has been deployed, replace the front seat belt protector with a new one. - Apply liquid thread lock to the anchor bolts before reinstallation. - Tighten the bolts by hand first, then tighten to specification with a torque wrench. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt. - Make sure the seat belt tensioner connector is plugged in properly. - Reconnect the negative cable to the battery. - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. Seat Belt Buckle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt > Page 5291 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. Detach the seat belt switch connector clip (A), seat belt buckle tensioner connector clip (B), and harness clip (C). 5. Remove the center anchor bolt (A), and remove the seat belt buckle (B). 6. Pull the seat belt switch/tensioner harness (C) out through the hole in the seat track. 7. Install the buckle in the reverse order of removal, and note these items: - Follow the Center Anchor Bolt Installation diagram carefully when assembling the collar and washers of the center anchor bolt - Apply liquid thread lock to the center anchor bolt before reinstallation. - Tighten the bolt by hand first, then tighten to specification with a torque wrench. - Apply liquid thread lock to the seat mounting bolts before reinstallation - Reconnect the negative cable to the battery. - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt > Page 5292 Seat Belt: Service and Repair Rear Seat Belt Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Rear Seat Belt 1. Remove the rear seat cushion. 2. Remove the lower anchor bolt (A). 3. Remove the rear side trim panel. 4. Remove the retractor mounting self-tapping ET screw (A) and the retractor bolt (B), then remove the rear seat belt (C) and retractor (D). 5. Install the seat belt in the reverse order of removal, and note these items: - If the threads on the retractor mounting self-tapping ET screw are worn out, use an oversized self-tapping ET screw (P/N 90133-SZ4-003) made specifically for this application. - Apply liquid thread lock to the anchor bolt before reinstallation. - Tighten the bolt by hand first, then tighten to specification with a torque wrench. - Check that the retractor locking mechanism functions. - Before installing the anchor bolt, make sure there are no twists or kinks in the seat belt. Center Belt and Seat Belt Buckles 1. Remove the seat cushion. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt > Page 5293 2. Remove the center anchor bolts (A), and remove the seat belt buckles (B) and center belt (C). 3. Remove the right seat-back 4. Remove the seat-back cover. 5. Remove the seat-back pad from the seat-back frame. 6. Remove the screw, and release the hooks (A), then remove the retractor cover (B). 7. Remove the seat belt guide (A) from the pin (B), and release the center belt (C) from the seat belt guide. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt > Page 5294 8. Remove the retractor mounting bolt (A) and the retractor bolt (B), then remove the center belt (C) and retractor (D) from the seat-back frame (E) 9. install the seat belt and buckles in the reverse order of removal, and note these items: - Check that the retractor locking mechanism functions. - Follow the Center Anchor Bolt Installation diagram carefully when assembling the washers of the center anchor bolt (except center shoulder belt). - Apply liquid thread lock to the anchor bolts before reinstallation. - Tighten the bolts by hand first, then tighten to specification with a torque wrench. - Before installing the center anchor bolt, make sure there are no twists or kinks in the center belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles Seat Belt Buckle: Service and Repair Front Seat Belt Buckles Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Seat Belt Buckle 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the preset buttons. 2. Disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. Detach the seat belt switch connector clip (A), seat belt buckle tensioner connector clip (B), and harness clip (C). 5. Remove the center anchor bolt (A), and remove the seat belt buckle (B). 6. Pull the seat belt switch/tensioner harness (C) out through the hole in the seat track. 7. Install the buckle in the reverse order of removal, and note these items: - Follow the Center Anchor Bolt Installation diagram carefully when assembling the collar and washers of the center anchor bolt. - Apply liquid thread lock to the center anchor bolt before reinstallation. - Tighten the bolt by hand first, then tighten to specification with a torque wrench. - Apply liquid thread lock to the seat mounting bolts before reinstallation - Reconnect the negative cable to the battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 5299 - Do the ECM/PCM idle learn procedure. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - Reset the clock. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 5300 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Center Belt and Seat Belt Buckles 1. Remove the seat cushion. 2. Remove the center anchor bolts (A), and remove the seat belt buckles (B) and center belt (C). 3. Remove the right seat-back. 4. Remove the seat-back cover. 5. Remove the seat-back pad from the seat-back frame. 6. Remove the screw, and release the hooks (A), then remove the retractor cover (B). 7. Remove the seat belt guide (A) from the pin (B), and release the center belt (C) from the seat belt guide. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 5301 8. Remove the retractor mounting bolt (A), and the retractor bolt (B), then remove the center belt (C) and retractor (D) from the seat-back frame (E). 9. Install the seat belt and buckles in the reverse order of removal, and note these items: - Check that the retractor locking mechanism functions. - Follow the Center Anchor Bolt Installation diagram carefully when assembling the washers of the center anchor bolt (except center shoulder belt). - Apply liquid thread lock to the anchor bolts before reinstallation. - Tighten the bolts by hand first, then tighten to specification with a torque wrench. - Before installing the center anchor bolt, make sure there are no twists or kinks in the center belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 89. Under Side of Passenger's Seat 90. Under Side of Driver's Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5305 Seat Belt Buckle Switch: Diagrams 107. Seat Belt Switch, Driver's 108. Seat Belt Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection Seat Belt Retractor: Testing and Inspection Inspection Out of Vehicle For front seat belt retractors with seat belt tensioners, review the SRS component locations and the precautions and procedures before performing repairs or service. Retractor, Front and Rear 1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 ° from the mounted position. The seat belt should lock when the retractor is leaned over 40 °. Do not attempt to disassemble the retractor. 3. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Retractor, rear center 1. Before installing the retractor, check that the seat belt can be pulled out freely. 2. Make sure that the seat belt does not lock when the retractor (A) is leaned slowly up to 15 ° from the mounted position. 3. Lean the retractor over 40 °, and make sure that the seat belt does not lock when pulled out over 900 mm (35.4 in.). Do not attempt to disassemble the retractor. 4. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. In-vehicle Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Page 5309 1. Check that the seat belt is not twisted or caught on anything. 2. After installing the anchors, check for free movement on the anchor bolts. If necessary, remove the anchor bolts and check that the washers and other parts are not damaged or improperly installed. 3. Check the seat belts for damage or discoloration. If necessary, clean the seat belts with soap and water only, then wipe it off with a clean towel. NOTE: Dirt buildup in the loops of the upper anchors can cause the seat belts to retract slowly. Wipe the inside of the loops with a clean cloth dampened in isopropyl alcohol. 4. Check that the seat belt does not lock when pulled out slowly. The seat belt is designed to lock only during a sudden stop or impact. 5. For rear center shoulder belt, check that the seat belt locks when pulled out over 400 mm (15.7 in.) with the seat-back folded down. 6. Make sure that the seat belt will retract automatically when released. 7. For each passenger's seat belt, check the seat belt retractor locking mechanism ALR (automatic locking retractor). This function is for securing child seats. -1 Pull the seat belt all the way out to engage the ALR. The seat belt should retract with a soft, ratcheting sound, but not extend. This is normal. -2 To disengage the ALR, release the seat belt and allow it to fully retract, then pull the seat belt out part-way. The seat belt should retract and extend normally. 8. Replace the seat belt with a new assembly if there is any abnormality. Do not disassemble any part of the seat belt for any reason. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams 59. Seat Belt Tensioner, Driver's 60. Seat Belt Tensioner, Passengers's 126. Seat Belt Buckle Tensioner, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 5313 127. Seat Belt Buckle Tensioner, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 31. Left Front of Vehicle (Bumper Removed) 34. Right Front of Vehicle (Bumper Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5318 87. Left Side of Floor (Right Similar) (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5319 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5320 Impact Sensor: Diagrams 45. Impact Sensor, Left Front 46. Impact Sensor, Right Front 63. Side Impact Sensor, Driver's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5321 64. Side Impact Sensor, Passenger's (Side Airbag) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement Impact Sensor: Service and Repair Side Impact Sensor Replacement Side Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the appropriate side airbag 2P connector. 3. Remove the seat assembly. 4. Remove the front door sill trim. 5. Disconnect the 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 (B). Installation 1. Install the new side impact sensor with a new Torx bolt (A), then connect the floor wire harness 2P connector (B) to the side impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the side impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. 4. Install all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Side Impact Sensor Replacement > Page 5324 Impact Sensor: Service and Repair Front Impact Sensor Replacement Front Impact Sensor Replacement Removal 1. Disconnect the battery negative cable, and wait at least 3 minutes before beginning work. 2. Disconnect the driver's airbag 4P connector, the front passenger's airbag 4P connector, both seat belt tensioner 2P connectors, and both seat belt buckle 4P connectors. 3. Remove the front inner fender. 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 (C). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (B) to the front impact sensor (C). 2. Reconnect the battery negative cable. 3. After installing the front impact sensor, confirm proper system operation: Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 89. Under Side of Passenger's Seat 90. Under Side of Driver's Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5328 Seat Belt Buckle Switch: Diagrams 107. Seat Belt Switch, Driver's 108. Seat Belt Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5337 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5338 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5339 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5340 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5341 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5342 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5343 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5344 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5345 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5346 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Recalls for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5347 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension Technical Service Bulletin # 06-009 Date: 080205 Campaign - OPDS Unit Warranty Extension 06-009 February 5, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: OPDS Unit or OPDS Sensor Triggers SRS DTC(s) 15-1, 15-2, 15-3 (Supersedes 06-009, dated September 21, 2007) Updated information is shown with asterisks. BACKGROUND *NOTE: Because of a class action settlement, the warranty extension coverage for the OPDS unit and the OPDS sensor on 2002 Accords, 2002-04 Civics, 2003-04 Civic Hybrids, 2002-04 CR-Vs, 2003 Elements, 2002 Odysseys, and 2003-04 Pilots purchased or leased between April 13, 2002, and November 7, 2006, is now 10 years or 157,500 miles, whichever occurs first. For more information, refer to Service Bulletin 06-085, Warranty Extension: Vehicle Warranty Mileage.* Several vehicle models may have a problem with the OPDS (occupant position detection system) that causes the SRS indicator to stay on. Typically, one or more of these DTCs will be set: ^ SRS DTC 15-1 (faulty OPDS unit or OPDS not initialized) ^ SRS DTC 15-2 (faulty side airbag indicator circuit) ^ SRS DTC 15-3 (faulty OPDS sensor) To ensure continued reliability with the OPDS, American Honda is extending the warranty on the OPDS unit and the OPDS sensor to 10 years or 150,000 miles, whichever occurs first. This warranty extension does not apply to any vehicle that has ever been declared a total loss, or any that has been issued a salvage, branded, or similar title under any state's law. To check for vehicle eligibility, you must do a VIN status inquiry Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5353 VEHICLES AFFECTED CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification of this warranty extension. A example of the customer notification is shown in this service bulletin. CORRECTIVE ACTION Repair the vehicle as indicated by the INSPECTION PROCEDURE. If needed, replace the OPDS unit. In rare cases where an updated OPDS unit was already installed, replace the OPDS sensor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5354 PARTS INFORMATION TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5355 WARRANTY CLAIM INFORMATION Out of warranty: Any repairs to the SRS system for problems other than the 15-1, 15-2, and 15-3 DTCs that are done after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. INSPECTION PROCEDURE NOTE: ^ When you check for SRS DTCs with the HDS, codes other than 15-1, 15-2, and 15-3 are not covered by this warranty extension bulletin. ^ If the vehicle is covered by warranty, repair it using the normal warranty repair procedures. If the vehicle's warranty is expired, give your customer an estimate for the cost of the repair. Do the appropriate inspection, based on the DTC. SRS DTC 15-1 Clear the DTC with the HDS. ^ If DTC 15-1 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-1 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-1 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-2 1. Inspect the connections and the wiring in the side airbag cutoff indicator circuit. ^ If all the connections and the wiring are OK, go to step 2. ^ If any of the connections or the wiring are faulty, repair the circuit, then go to step 2. 2. Clear the DTC with the HDS. ^ If DTC 15-2 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. ^ If DTC 15-2 sets again, continue with normal troubleshooting. ^ If the OPDS unit causes DTC 15-2 to set repeatedly, yet passes the other troubleshooting steps, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. SRS DTC 15-3 1. Clear the DTC with the HDS. ^ If DTC 15-3 does not set again, go to step 2. ^ If DTC 15-3 sets again, continue with normal troubleshooting. 2. Ask your customer if electrical devices such as a laptop computer or a fluorescent map light are ever used near the front passenger's seat-back. (Some electrical devices that plug into the vehicle's accessory power socket, especially those using a power inverter/converter, can interfere with the seat-back sensors and cause SRS DTC 15-3 to set.) ^ If your customer uses any of these devices operate the device near the front passenger's seat-back. If DTC 15-3 sets again, clear it, then return the vehicle to the customer. Advise the customer to avoid using the device near the front passenger's seat-back. ^ If your customer does not use any of these devices and DTC 15-3 does not set again, go to REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT. REPAIR PROCEDURE A: OPDS UNIT REPLACEMENT Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5356 1. On Accords and Pilots, remove the front passenger's seat-back panel by prying out the bottom. Replace the two lower clips. 2. On all models except Accords and Pilots, unzip the two seat cover zippers on the back of the front passenger's seat. 3. Pull back the seat-back cover from the left side bolster to access the OPDS unit cover. 4. Remove the OPDS unit cover from the seat frame. 5. Check the part number of the installed OPDS unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5357 ^ If the OPDS unit has an original part number, go to step 6. ^ If the OPDS unit has a new part number (refer to PARTS INFORMATION) or higher, go to REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT. 6. Recline the seat-back to access the OPDS unit mounting screws. 7. Remove the mounting screws from the OPDS unit, and gently pull out the unit. 8. Disconnect the OPDS connectors, then remove the OPDS unit. 9. Install a new OPDS unit, then snap on its cover. 10. Slip the seat-back cover over the OPDS unit. 11. On Accords, check the seat-back clip attachment bosses on the seat-back panel: ^ If the attachment bosses are OK, go to step 12. ^ If the seat-back has a pocket, and the attachment bosses are deformed or damaged, do the repair procedure in S/B 02-010, Seat-Back Panel Is Loose or Detached. Then go to step 12. ^ If the seat-back does not have a pocket, and the attachment bosses are deformed or damaged, replace the seat-back. Then go to step 12. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5358 12. On Accords and Pilots, install the new seat-back clips on the seat-back panel. Turn the clips so their retaining tabs are horizontal. 13. On Accords and Pilots, install the seat-back panel. 14. On all models except Accords and Pilots, zip the seat-back cover closed. 15. Initialize the OPDS unit. ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode. Initializing the OPDS Unit: HDS Method NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Turn the ignition switch to ON (II), then turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. Also verify the correct date and time. 6. From the System Selection menu, select SRS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5359 7. From the Mode menu, select Miscellaneous Test. 8. From the Miscellaneous Test menu, select OPDS Initialization. 9. Follow the remaining screen prompts to complete the OPDS initialization. If the initialization fails repeat the process two more times. If the initialization fails again, check for SRS DTCs, then troubleshoot them using the appropriate service manual. Initializing the OPDS Unit: Manual Mode NOTE: Non-Honda seat covers will interfere with the performance of the OPDS and are not recommended. 1. Adjust the front passenger's seat-back to an upright position, then remove anything on or near the seat. 2. Turn the ignition switch to LOCK (0). 3. Connect the HDS to the vehicle's DLC (data link connector). 4. Keep the ignition switch at LOCK (0), and turn on the HDS. 5. At the screen prompts, enter the VIN and the odometer reading. 6. From the Select Mode screen, select SCS, and follow the screen prompts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5360 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5361 7. Connect the SCS service connector to the 2P MES (memory erase signal) connector, as shown. Do not use a jumper wire. 8. Turn the ignition switch to ON (II). 9. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 10. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 11. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5362 12. Watch the SRS indicator: ^ If the indicator blinks twice and then goes off, the OPDS unit is initialized. Turn the ignition switch to LOCK (0), and disconnect the HDS. ^ If the indicator blinks twice and then stays on, the OPDS unit is initialized, but SRS DTCs need to be cleared. Go to step 13. ^ If the indicator stays on without first blinking, the OPDS unit is not initialized. Repeat steps 3 thru 12. 13. Turn the ignition switch to LOCK (0), then disconnect the HDS. 14. Reconnect the SCS service connector to the MES connector. Do not use a jumper wire. 15. Turn the ignition switch to ON (II). 16. Watch the SRS indicator. (It comes on for about 6 seconds and then goes off.) Disconnect the SCS service connector from the MES connector within 4 seconds after the indicator goes off. 17. When the SRS indicator comes on again, connect the SCS service connector to the MES connector within 4 seconds after the indicator comes on. 18. When the SRS indicator goes off, disconnect the SCS service connector from the MES connector within 4 seconds. (The SRS indicator blinks twice to indicate that the memory has been cleared.) 19. Turn the ignition switch to LOCK (0), and wait for 10 seconds. 20. Turn the ignition switch to ON (II). (The SRS is OK if the SRS indicator comes on for 6 seconds and then goes off.) If the DTC clearing fails, repeat the process two more times. If the DTC clearing fails again, check for set SRS DTCs, and troubleshoot them with the appropriate service manual. REPAIR PROCEDURE B: OPDS SENSOR REPLACEMENT 1. Remove the seat-back cover from the front passenger's seat: ^ Using the appropriate service manual, go to section 20 (Body), and do the removal steps under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the removal steps in the procedure. 2. Slide the seat-back cushion (foam) off the seat-back frame. (The OPDS sensor is built into the seat-back cushion.) 3. Slide a new seat-back cushion over the seat-back frame. Make sure the cushion is centered. 4. Install the seat-back cover: ^ Using the appropriate service manual, go to section 20 (Body), and do the installation step under Front Seat Cover Replacement, or ^ Online, enter keyword SEAT COVER, then select Front Seat Cover Replacement from the list, and do the installation step in the procedure. 5. Initialize the OPDS unit: ^ To initialize with the HDS, go to Initializing the OPDS Unit: HDS Method in this service bulletin. ^ To initialize with the SCS service connector, go to Initializing the OPDS Unit: Manual Mode in this service bulletin. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-009 > Feb > 08 > Campaign - OPDS Unit Warranty Extension > Page 5363 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 5364 SRS - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information > Diagrams 204. Antenna Amplifier Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Service and Repair Antenna Mast: Service and Repair Antenna Mast Replacement 1. Remove the rear part of headliner. 2. Disconnect the antenna lead connector (A) and 1P connector (B) from the antenna mast (C). 3. Remove the mounting nut and the antenna. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair Antenna Cable: Technical Service Bulletins Audio System - Revised Poor Reception Repair 08-088 October 2, 2009 Applies To: ALL 2004-10 Models Service Manual Update: Poor AM or FM Reception (Supersedes 08-088, dated November 20, 2008, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY ^ In Applies To, 2010 models were added. ^ Under TOOL IN FORMATION, a new antenna adapter was added, and photos of all the adapters were added.* SYMPTOM The AM or FM radio reception is poor or filled with static. NOTE: If the vehicle is 2006-07 Ridgeline, refer to Service Bulletin 07-079, Poor AM Reception or Static While Driving Over Bumps, before using the following REPAIR PROCEDURE. CORRECTIVE ACTION Test the antenna circuit using the test antenna, and repair or replace any damaged AM/FM antenna leads or parts. *TOOL INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair > Page 5378 NOTE: Adapter TIN 07AAJ-000A700 has a small barrel adapter on one end with a standard barrel adapter on the other end. All other adapters have a standard barrel adapter on the end that is not shown.* WARRANTY CLAIM INFORMATION None. This bulletin is for information only. REPAIR PROCEDURE NOTE: ^ Vehicles may have the following parts that you need to check. Refer to the applicable service manual for more information on these parts: - AM/FM antenna sublead - AM/FM antenna lead - AM/FM antenna amplifier (may be built into the AM/FM antenna) - AM/FM antenna ^ There are several different antenna styles and locations. Refer to the applicable service manual for specific part information and locations. ^ Aftermarket metallic window tinting can affect AM/ FM window antennas. If the vehicle is equipped with a window antenna, check all the other parts first. If the reception is still poor and the vehicle has aftermarket tinting, remove the tinting, then retest. If the reception is still poor, replace the AM/FM antenna. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair > Page 5379 ^ To prevent rattles, slapping, or other noises, make sure to attach the sublead and the lead to the vehicle harness or the vehicle using clips, wire ties, or electrical tape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair > Page 5380 ^ Refer to the following illustrations for the names and general locations of the AM/FM antenna and its parts. These images are examples only. Refer to the applicable service manual for model-specific information. 1. Do the Seek Stop Test: ^ Refer to the Audio section of the applicable service manual, or ^ Online, enter keyword SEEK, then select Seek Stop Test from the list. - If the number of AM and FM stations is within 10 percent of those on a known-good vehicle no repair is needed at this time. - If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, go to step 2. 1. Do the Seek Stop Test: ^ Refer to the Audio section of the applicable service manual, or ^ Online, enter keyword SEEK, then select Seek Stop Test from the list. - If the number of AM and FM stations is within 10 percent of those on a known-good vehicle no repair is needed at this time. - If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, go to step 2. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair > Page 5381 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped). NOTE: Eject all the discs before removing the audio unit to prevent damaging the CD player's load mechanism. 3. Disconnect the AM/FM antenna lead from the AMI FM antenna amplifier lead. NOTE: Refer to the applicable service manual, because you may need to remove trim, the headliner, or other parts. 4. Connect the test antenna to the AM/FM antenna lead using the appropriate adapter. 5. Do the Seek Stop Test: ^ If the number of AM and FM stations the vehicle receives is within 10 percent of those on a known-good vehicle, go to step 15. ^ If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, go to step 6. 6. Disconnect the AM/FM antenna sublead from the AM/FM antenna lead. 7. Connect the test antenna to the AM/FM antenna sublead (the harness connected to the audio unit) using the appropriate adapter. 8. Do the Seek Stop Test: ^ If the number of AM and FM stations the vehicle receives is within 10 percent of those on a known-good vehicle, go to step 13. ^ If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, go to step 9. 9. Disconnect the antenna cable connector from the audio unit. 10. Connect the test antenna to the audio unit using the appropriate adapter. 11. Repeat the Seek Stop Test: ^ If the number of AM and FM stations the vehicle receives increases and is within 10 percent of those on a known-good vehicle, go to step 12. ^ If the number of AM and FM stations doesn't improve, or is not within 10 percent of those on a known-good vehicle, replace the audio unit, then retest. 12. Reconnect the antenna cable connector to the audio unit. 13. At the AM/FM antenna sublead, do the troubleshooting to check the voltage and the continuity: ^ Refer to Poor AM or FM Radio Reception or Interference Troubleshooting in the applicable service manual, or ^ Online, enter keyword FM, then select Symptom Troubleshooting: Poor AM or FM radio reception or interference from the list. - If the voltage and continuity tests are OK, go to step 14. - If the Poor AM or FM radio reception troubleshooting results are NG, replace the AM/FM antenna sub lead. 14. Reconnect the AM/FM antenna sublead to the AM/ FM antenna lead. 15. At the AM/FM antenna lead, do the troubleshooting to check the voltage and the continuity: ^ Refer to Poor AM or FM Radio Reception or Interference Troubleshooting in the applicable service manual, or ^ Online, enter keyword FM, then select Symptom Troubleshooting: Poor AM or FM radio reception or interference from the list. - If the voltage and continuity tests are OK, go to step 16. - If the Poor AM or FM radio reception troubleshooting results are NG, replace the AM/FM antenna lead. 16. Substitute a known-good AM/FM antenna amplifier. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Audio System - Revised Poor Reception Repair > Page 5382 NOTE: ^ Some vehicles do not have an AM/FM antenna amplifier, or have one that is built into the AM/FM antenna. In these cases, substitute a known- good AM/FM antenna. ^ Refer to the applicable service manual, because you may need to remove the headliner, the carpet, or other parts to access the AM/FM antenna amplifier. 17. Repeat the Seek Stop Test: ^ If the number of AM and FM stations the vehicle receives is within 10 percent of those on a known-good vehicle, replace the original AM/FM antenna amplifier, then recheck. ^ If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, and it has a separate antenna amplifier, repair or replace the AM/FM antenna. ^ If the vehicle receives at least 10 percent fewer stations than a known-good vehicle, and it doesn't have an antenna amplifier, or has one built into the AM/FM antenna, replace the original AM/FM antenna. 18. Repeat the Seek Stop Test to confirm the repair. 19. Reinstall all remaining parts. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5392 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5393 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5399 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5400 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Relay and Control Unit Location - Dashboard 64. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 5403 72. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 5404 67. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5405 Alarm Module: Diagrams 159. Immobilizer Control Unit-Receiver 183. Security Control Unit Connector (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair Alarm System Transponder: Service and Repair Immobilizer Control Unit-Receiver Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 7P connector (A) from the immobilizer control unit-receiver (B), 4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (C). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with the HDS, then check the immobilizer system. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5413 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5414 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5415 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5416 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5417 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5418 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Keyless Entry Receiver: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 5422 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 5423 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 5424 140. Keyless Receiver Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 5425 Keyless Entry Receiver: Testing and Inspection Keyless Receiver Unit Input Test NOTE: Refer to Multiplex Troubleshooting to check for Mode 1 DTCs and troubleshoot. 1. Remove the driver's dashboard lower cover. 2. Remove the audio unit. 3. Disconnect the 5P connector (A) from the keyless receiver unit (B). 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. With the connector still disconnected, make the input test at the connector. - If test indicates a problem, find and correct the cause, then recheck the system. - If the input test proves OK, go to step 6. 6. Reconnect the 5P connector, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, replace the keyless receiver unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5434 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5435 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5441 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5442 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5447 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5448 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5449 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5450 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5451 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5452 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5453 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5454 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5455 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5456 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5457 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5458 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5459 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5460 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5461 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5462 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5463 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5464 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5465 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5466 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5467 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5468 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5469 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5470 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5471 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5477 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5478 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5479 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5480 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5481 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5482 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5483 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5484 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5485 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5486 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5487 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5488 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5489 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5490 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5491 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5492 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5493 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5494 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5495 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5496 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5497 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5498 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5499 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5500 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 5501 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 5502 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 5503 Keyless Entry Transmitter: Testing and Inspection Transmitter Test NOTE: - If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty. Replace the transmitter. - If any door is open, you cannot lock the door with the transmitter. - If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. - The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch. 1. Press the lock or unlock button five or six times to reset the transmitter. - If the locks work, the transmitter is OK. - If the locks don't work, go to step 2. 2. Open the transmitter and check for water damage, - If you find any water damage, replace the transmitter. - If there is no water damage, go to step 3. 3. Replace the transmitter battery (A) with a new one, and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button five or six times. If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, go to step 4. 4. Reprogram the transmitter, then try to lock and unlock the doors. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 5504 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be stored in the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the hatch are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec, turn the ignition switch OFF. 4. Within 1 to 4 sec, turn the ignition switch ON (II). 5. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 6. Within 1 to 4 sec, turn the ignition switch OFF. 7. Within 4 sec, turn the ignition switch ON (II). 8. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec, turn the ignition switch OFF. 10. Within 4 sec, turn the ignition switch ON (II). 11. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 sec, push the transmitter lock or unlock button again. 13. Within 10 sec, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. 14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation of the transmitter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Diagrams 205. Security LED (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics Technical Service Bulletin # 07-012 Date: 070216 Music Link(R) - System Information/Diagnostics 07-012 February 16, 2007 Applies To: ALL - with accessory Music Link installed Music Link (For iPod) General Information and Symptom Troubleshooting BACKGROUND Honda Music Link is a Honda accessory designed to let the customer play music from an Apple(R) ipod(R) through the vehicle's audio system. The basic Music Link kit includes the Music Link interface unit, an audio unit bus cable, the Music Link harness, a CD-ROM, and the Quick Reference Guide. The CD-ROM includes a detailed User's Guide and some optional ITS (text-to-speech) software that lets the customer play music by playlist, artist, album, or genre. ^ The CD-ROM is for home computer use only. Do not insert it into a vehicle CD player. ^ Quick Reference Guides, User's Guides, and the latest TTS software versions can be downloaded from http://musiclink.honda.com. ^ For customer assistance and questions regarding TTS software loading, have the customer contact American Honda's Automobile Customer Service Department. The GENERAL INFORMATION section of this service bulletin covers these subjects: ^ Music Link iPod Information Resources ^ Resources for Installation Instructions ^ Music Link First-Use Information ^ iPod Reset Procedure Information The TROUBLESHOOTING section includes troubleshooting for these symptoms: ^ Check mark is not shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. ^ Static, or weak or no volume over speakers only in Music Link mode. ^ Music Link has no sound, check mark is shown on the iPod display screen. ^ Music Link has no sound, the disc number and track number flashes on the audio display. ^ Check mark is shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. ^ iPod music and XM radio music play at the same time (Pilot). ^ Music Link will not do Disc 1-4 search functions. ^ Artist is not categorized in the correct grouping when using (Disc 2) search function. ^ Song/artist is not categorized in the correct grouping when using Disc 1-4 search functions. PARTS INFORMATION Bus Harness: P/N 08-8-1H1-10030, H/C 8387060 Music Link Harness: P/N 08-8-1H1-10031, H/C 8387052 2-Port Bus Harness: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5513 P/N 08A31-0F1-000, H/C 7512999 Music Link Interface Unit: P/N 08-8-1H1-10101, H/C 8582603 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. FLAT RATE TIMES Failed Part: P/N 08~8-1H1-10031 H/C 8387052 Defect Code: 03214 Symptom Code: 01201 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Disclaimer General Information Music Link iPod Information Resources ^ Online at http//musiclink.honda.com/Tech Faq.html ^ Music Link Information Sheet (Honda ServiceNews, March 2006) ^ Music Link Frequently Asked Questions (Honda ServiceNews, March 2006) ^ Quick Reference Guide (supplied in Music Link kit) ^ User's Guide and Quick Reference Guide are available online: http://musiclink.honda.com/Down_Ref.html ^ General information: www.apple.com, then select support. ^ iPod firmware (unit software) version information: www.apple.com, then select Support. ^ To find out what (unit software) is loaded on the iPod: - Go to the Main Menu. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5514 - Select Settings. - Select About. ^ iPod reset procedure: http://docs.info.apple.com/ article.html?artnum=61705 Resources for Installation Instructions Online, enter the model and year, enter the keyword MUSIC LINK, and select the appropriate installation instructions. Music Link First-Use Information After installing the Music Link kit, switch the audio unit to AUX (auxiliary) mode and verify the audio unit displays CDC EJECT or CD4 EJECT. Connect the iPod to the Music Link connector. Make sure the check mark is displayed on the iPod display screen and that you hear music. ^ The Music Link disc supplied in the kit contains the TTS software and the User's Guide. It is for home computer use only. ^ The customer needs to load the TTS software/User's Guide on his/her home computer in order for all of the search functions (Disc 1-4) to operate. ^ Only the shuffle functions (Disc 5-6) will operate without the TTS software installed (see the Quick Reference Guide). ^ For the search functions (Disc 1-4) to operate properly, TTS software must be run after any songs are changed (added or removed) on the iPod. ^ You can change the Disc position on most audio units by using the Disc - (preset number 5) and Disc + (preset number 6). Always refer to the User's Guide for proper operation. iPod Reset Procedure Information The iPod reset procedure applies to these Apple iPod models: ^ Fifth-generation or later iPod (also known as iPod with video) ^ iPod nano(R) ^ iPod with color display (iPod photo) ^ iPod mini(R) NOTE: To view this information online, log on to http//docs.info.apple.com/article.html?artnum=6 1705 To reset the customer's iPod: 1. Cycle the Hold switch on and off (slide it to Hold, then turn it off again). 2. Press and hold the Menu and Select buttons for 6-10 seconds until the Apple logo appears. NOTE: If you are having difficulty resetting the iPod, set it on a flat surface. As you press the Select button, make sure your finger does not touch any part of the click wheel. Also make sure that you press the Menu button toward the outside of the click wheel and not near the center. 3. If the above steps do not work, try connecting the iPod to a power adapter and plug the power adapter into an electrical outlet, or connect the iPod to your computer. Make sure the computer is on and isn't set to sleep mode. BEFORE TROUBLESHOOTING ^ Before troubleshooting, ask the customer these questions: - What is the main issue? - What model and generation iPod do you have? Refer to www.apple.com. - What version iPod firmware (unit software) is loaded? ^ Go to the Main Menu. ^ Select Settings. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5515 ^ Select About. - What iTunes version are you using? - What TTS software version is installed? ^ Make sure you have the customer's iPod for troubleshooting. ^ Turn on the iPod, and verify its battery is fully charged before testing. If the battery is low, the iPod will not "make up" when connected. ^ Some iPod protective cases cause the Music Link iPod connector to be installed crookedly or not fully engaged. Be sure to remove the protective case before troubleshooting. ^ Go to http//musiclink.honda.com/Tech Faq.html to view technical FAQs and troubleshooting. TROUBLESHOOTING Check mark is not shown on the iPod display screen, radio will not switch to CD-C or CD-4 mode. NOTE: Remove the iPod protective case, if installed. 1. At the Music Link interface unit, make sure both connectors are fully engaged, and the cables do not have any broken or bent pins. NOTE: To release the Music Link interface unit connectors, you must pull back on the lock sleeves. Does either cable have the connector partially disengaged, or are any pins broken or bent? Yes - Reconnect or replace the loose or damaged cable. No - Go to step 2. 2. At the audio unit, make sure the cable connectors and the connector pin fits are tight. Also check that the optional Y-bus harness (if installed) connector and connector pin fits are tight. Do the cable connections and pins fit properly? Yes - Replace the Music Link interface unit and the cable. No - Repair the faulty connection at the audio unit. Static, or weak or no volume over speakers only in Music Link mode. NOTE: Remove iPod protective case, if installed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5516 1. At the iPod, make sure the iPod connector is fully engaged. Is the iPod connector fully engaged? Yes - Go to step 2. No - Properly connect the iPod connector and retest. Replace the cable if the connector is loose or damaged. 2. Disconnect the customer's iPod. 3. Connect headphones to the iPod, and listen to the sound quality. Is the sound quality normal in the headphones? Yes - Go to step 4. No - There is static from the customer's uploaded music. If the volume is weak or low, verify the iTunes sound level setting. 4. Connect a known-good iPod and retest. NOTE: Known-good test iPods are available from Tech Line. Is the sound quality normal over the speakers? Yes - The vehicle is functioning normally. Do an iPod reset on the customer's iPod and retest. If the problem does not go away, have the service advisor explain to the customer that the vehicle is operating properly and advise the customer to: ^ Install the latest iPod firmware. ^ Consult the general information at www.apple.com. This is not a comprehensive list, only a suggested starting point for the customer to troubleshoot the iPod. No - Go to step 5. 5. Disconnect the known-good iPod. 6. Do a vehicle battery cable reset: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II) and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 7. Reconnect the customer's iPod and retest. Is the sound quality normal over the speakers? Yes It is an intermittent audio unit/Music Link failure, and the system is OK at this time. No - Do the "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD4 mode" troubleshooting. Music Link has no sound, check mark is shown on iPod display screen. 1. At the Music Link interface unit, make sure both connectors are fully engaged, and the cables do not have any broken or bent pins. NOTE: To release the Music Link interface unit connectors, you must pull back on the lock sleeves. Does either cable have the connector partially disengaged, or are any pins broken or bent? Yes - Reconnect or replace the loose or damaged cable. No - Go to step 2. 2. At the audio unit, make sure the cable connectors and the connector pin fits are tight. Also check that the optional Y-bus harness (if installed) connector and connector pin fits are tight. Do the cable connections and pins fit properly? Yes - Substitute a known-good iPod and retest. If the sound is normal, do an iPod reset, and retest. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5517 NOTE: Known-good test iPods are available from Tech Line. No - Repair the faulty connection at the audio unit. Music Link has no sound, the disc number and track number flashes on the audio display. Disconnect and reconnect the iPod, then retest. Does Music Link operate normally? Yes - The iPod connector pins are loose. Replace the cable if the connector is damaged. No - There is a firmware error. Advise the customer to install the latest iPod firmware (unit software). Check mark is shown on iPod display screen, radio does not switch to CD-C or CD-4 mode. 1. Make sure the audio unit works in all other modes. Does the audio unit work in all other modes? Yes - Go to step 2. No - Do a vehicle battery cable reset, then retest: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II) and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 2. Remove the Music Link interface unit, and verify the software version on the unit label is SW 1.06 or higher. Is the software version SW 1.06 or higher? Yes - Do the "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD-4 mode" troubleshooting. No - Replace the Music Link interface unit and iPod cable. iPod music and XM radio music play at the same time (Pilot). There is a software compatibility issue in the XM receiver unit. Refer to S/B 06-061, XM(R) Satellite Radio and Audio Accessories Play at the Same Time for repair information. Music Link will not do Disc 1-4 search functions. NOTE: TTS software must be loaded on the customer's home computer before Disc 1-4 search functions work. 1. Use a known-good iPod to verify that the search functions (Disc 1-4) work. NOTE: Known-good test iPods are available from Tech Line. Does the known-good iPod do search functions (Disc 1-4)? Yes - Verify with the customer if the TTS software is loaded. If the customer needs assistance, refer the customer to American Honda's Automobile Customer Service Department for assistance with TTS software loading problems (see page 6 of this bulletin). No - Do the battery cable reset, then retest: ^ Remove the negative and positive battery cables. Use a jumper wire to short the two cables together, then turn the ignition switch to ON (II), and wait 15 minutes. ^ Turn the ignition switch to LOCK (0), and remove the jumper wire. Reconnect the positive battery cable first, then reconnect the negative cable. 2. If the problem does not go away, do "Check mark is not shown on iPod display screen, radio will not switch to CD-C or CD-4 mode" troubleshooting. Artist is not categorized in the correct grouping when using (Disc 2) search function. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Music Link(R) - System Information/Diagnostics > Page 5518 Make sure the "Compilations" setting is switched off in the settings menu on the customer's iPod: - Go to the Main Menu. - Select Settings. - See Compilation. Is the "Compilations" setting switched off? Yes - There is a TTS software program error. Tell the customer to rerun the TTS software. No - Change the "Compilations" setting on the customer's iPod to off. Song/Artist is not categorized in the correct grouping when using Disc 1-4 search functions. Remind the customer that the TTS software must be run after any songs are changed on the iPod, and advise them to run the TTS software and retest the iPod search functions. Explain to the customer that once the TTS software has run: ^ If the iPod functions properly, there was an intermittent TTS software program error. ^ If the iPod does not function properly, direct the customer to contact Customer Service for assistance with TTS software loading problems. CUSTOMER INFORMATION NEEDED BEFORE CALLING HONDA'S CUSTOMER SERVICE DEPARTMENT Print this page, and give it to the customer if they are experiencing a ITS software-related issue. Direct them to answer the questions, then contact American Honda's Automobile Customer Service Department at (800) 999-1009. Customer Information Before calling customer service, go to http//musiclink.honda.com/Tech_Faq.html and view the technical FAQs and troubleshooting. Also, go to www.apple.com, select support, and view the technical FAQs and troubleshooting. Please have the following information ready when contacting customer service: ^ What is the main issue? ^ What type of iPod do you have? Refer to www.apple.com. ^ What version iPod firmware (unit software) is loaded? To find out what firmware (unit software) is loaded on the iPod: - Go to the Main Menu. - Select Settings. - Select About. ^ What version iTunes are you using on your home computer? ^ When you connect your iPod to the vehicle's Music Link connector, is the check mark displayed on your iPod display screen? ^ What type of computer do you have (Mac or PC)? ^ What operating system are you using? ^ Have you loaded the ITS software on your home computer? ^ Do you run the ITS software every time you connect your iPod to your home computer? Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions DVD Player: Technical Service Bulletins Audio System - CD/DVD Precautions Adhesive Labels or Protective Disc Covers on CDs or DVDs: A Big Taboo NOTE: This article applies to all Honda models with a factory- or dealer-installed CD/DVD player or changer. We can't emphasize this enough: Never put adhesive labels or protective disc covers on recordable CDs or DVDs to be used in automotive CD/DVD players or changers. Here's why: ^ Recordable CDs and DVDs are actually thicker than their pre-recorded brethern. Automotive players and changers use rollers to draw the disc into the unit. The added thickness of an adhesive label or a protective disc cover can cause the disc to jam when it's loaded into or ejected from the unit. ^ CD/DVD players or changers are exposed to high temperatures inside the vehicle. High temperature can cause the label adhesive to soften. This can cause the label to curl on the edges and even form bubbles. Curled edges can catch on the rollers and bubbles add thickness to the disc. Either one can cause the disc to jam. To cut down on customer-caused damage, all '05 and later 0/Ms include this notice: Do not use CDs with adhesive labels. The label can curl up and cause the CD to jam in the unit. Anytime a service customer comes in with a loading or ejecting problem for a CD/DVD player or changer, ask if he or she used any discs with adhesive labels or protective disc covers. If the answer is yes, contact your DPSM for possible goodwill assistance. If the answer is no, then replace the audio unit under normal warranty. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5523 DVD Player: Technical Service Bulletins Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair 06-001 February 26, 2010 Applies To: 1998 and Later Models - ALL Audio, Navigation, and RES Unit In-Warranty Exchange and Out-of-Warranty Repair (Supersedes 06-601, dated March 4, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under OUT-OF-WARRANTY REPAIR, the address for Pioneer Electronics Service was changed.* COVERAGE This bulletin applies to all Honda audio units, CD players/changers, cassette tape players, navigation units, and rear entertainment system (RES) units, both in warranty and out of warranty. COMPONENT REPLACEMENT POLICY Use only remanufactured components for warranty repairs on customer vehicles. Follow the warranty information and procedures given in this service bulletin. ^ Remanufactured audio, navigation, and RES units are not available for non-warranty repairs. ^ Use new components to repair new, unsold vehicles. ^ A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. ^ You must receive authorization from your District Parts and Service Manager (DPSM) before ordering a new component. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: From the Flat Rate Manual Flat Rate Time: From the Flat Rate Manual Failed Part: Use the RM part number from the repair order without the RM (example: 08A06-341-110) Defect Code: From the Flat Rate Manual Symptom Code: From Audio Customer Contention Codes in the Flat Rate Manual Part used for repair: Use the RM part number from the repair order (example: 08A06-341-110RM) IN-WARRANTY DIAGNOSIS Service Advisor: Interview the customer to get as much information as possible. Information like where and when the problem occurs is vital to your diagnosis. This information also helps you to determine if the audio, navigation, or RES system is operating normally, or if a problem exists. Write the complaint on the repair order. NOTE: For CD/DVD related problems, you must verify if the customer used discs with adhesive labels. Service Technician: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5524 1. Print out the appropriate system worksheet from an Interactive Network (iN) workstation. ^ From the iN main menu, click on SERVICE. ^ Click on (ISIS) Service Publications. ^ Click on SEARCH BY PUBLICATION. ^ Click on Job Aids. ^ Click on Audio System Worksheet, Navigation System Worksheet, or Rear Entertainment System Worksheet. 2. Duplicate and confirm the problem using the customer information written on the repair order or have the customer demonstrate the problem, then write down the results on the worksheet. Using the SYMPTOM TROUBLESHOOTING INDEX or the DTC INDEX (if applicable) in the applicable service manual, find the symptom that matches the customers complaint, and follow the diagnostic procedure: ^ Refer to the appropriate section in the service manual, or ^ From the iN main menu: - Click on SERVICE. - Click on ISIS (Service Publications). - Click on SEARCH BY VEHICLE. - Enter the model and the model year. - Enter a keyword: AUDIO, NAVIGATION, or RES, and the DTC (if applicable) - Select the appropriate Service Bulletin, ServiceNews article, or Symptom Troubleshooting from the list. 3. Repair the vehicle according to your diagnosis, then confirm the repair by trying to duplicate the customer's original complaint, or check to see if the DTC returns: ^ If the problem is gone, return the vehicle to the customer. ^ If the problem is still there, go to step 4. 4. Replace the audio/navigation/RES unit with a remanufactured unit: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5525 ^ For warranty repairs, go to the IN-WARRANTY EXCHANGE procedure. ^ For vehicle service contract (VSC) and certified used car (CUC) repairs, call. ^ For goodwill repairs, contact your dealership's District Parts and Service Manager (DPSM). IN-WARRANTY EXCHANGE Service Technician: NOTE: ^ Use the iN to order a remanufactured audio, navigation, or RES unit. Do not call the Remanufactured Parts Dealer Service Group. ^ A Tech Line reference number is not required to submit the order. Check Yes, and enter the Reference Number only when there is a preexisting Tech Line contact. 1. With your completed Audio/Navigation/RES Worksheet, go to an iN workstation. 2. From the iN main menu, click on SERVICE, then click on AUDIO, then select Warranty Audio Order. 3. Select the model, year, and keyword (AUDIO, NAVIGATION, or RES) for the vehicle you are working on, then click on Search. 4. Review all displayed publications for additional repair information. If you cannot repair the problem, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5526 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5527 NOTE: Once you submit your order, you can track it using the Warranty Audio VIN Inquiry screen on the iN. For details, go to WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS in this service bulletin. 7. You will receive a remanufactured audio/navigation/RES unit packed in a reusable shipping box. Save this box and the packing materials. You must return the failed audio/navigation/RES unit core in this box. Otherwise your dealership risks being billed a core loss charge, ranging from $800 to $2,500, depending on the unit. 8. Remove the failed audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or, ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate removal procedure from the list. 9. Install the remanufactured audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate installation procedure from the list. 10. If the remanufactured unit has a shipping cover and shipping screws, make sure you transfer them to the faulty unit being returned. Also be sure to transfer all of the mounting brackets to the replacement unit. Failure to do this may result in dash squeaks and rattles. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is stuck in the unit, leave it there for these reasons: ^ The manufacturer needs it for diagnosis and testing. ^ Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core. Customer media (CDs, CD magazines, DVDs, DVD-As, cassette tapes, etc.) will be properly removed by the supplier at the point of tear down and inspection of the failed unit, and mailed to your dealer. Make sure the failed audio/navigation/RES unit core is not disassembled! If the core is disassembled, your dealership will be debited a core loss charge ranging from $800 to $2,500, depending on the unit. 11. Put the failed audio/navigation/RES unit core in the same box that the remanufactured unit came in. NOTE: If you do not return the failed audio/navigation/RES unit core in this same box, your warranty claim will be debited and the core will be sent back to your dealership. Parts Manager: 12. The Warranty Audio/Navigation/RES Unit Order form you submitted is kept on the iN for 60 days. Print out a copy to put in the box with your core return: ^ From the iN main menu, click on SERVICE. ^ Click on Transactions. ^ Click on Advanced Search, and enter a date range. ^ Click on Filtered by Service. ^ Under Transaction Description, click on Warranty Audio Order, then go back to the top of the page and click on Search. ^ Scroll down to the appropriate VIN, then select it to view the form. ^ Review the form, then print out a copy by clicking on the printer icon. 13. Print out a copy of the Core Return Update Acknowledgement to put in the box with your core return: ^ From the iN main menu, click on PARTS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5528 ^ Click on Returns and Surplus. ^ Click on Audio Core Return. ^ Select the appropriate VIN to view the Update Core Return information screen. ^ Review the form, then print out a copy by clicking on the printer icon. 14. Place the printed copies of the Warranty Audio/Navigation/RES Unit Order form and the Core Return Update Acknowledgement into the core return box with the failed audio/navigation/RES unit core. NOTE: If you return a failed audio/navigation/RES core without the proper forms, your warranty claim will be debited and the core will be sent back to your dealership. 15. Ship the failed audio/navigation/RES unit core to the appropriate location by using the prepaid shipping label that came with the remanufactured audio/navigation/RES unit. NOTE: If the failed audio/navigation/RES unit core is not received at the specified address within 30 days from the order date of the remanufactured audio/navigation/RES unit, your warranty claim will be debited, and your dealership will be issued a core loss charge ranging between $800 and $2,500. If you know that you cannot return the core within 30 days, call the Remanufactured Parts Dealer Service Group, and ask for an extension. ^ If you call for an extension and the core is not received within 60 days from the order date, you will be debited the full amount of the warranty claim. ^ If you do not call for an extension, and the core is received between 31 and 60 days from the order date of the remanufactured audio/navigation/RES unit, a $250 late core charge will be assessed. WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS Here is a list of answers to the most frequently asked questions about the warranty audio order program: Question: When do I use the warranty audio order program? Answer: Use the program when you are replacing an audio/navigation/RES unit under warranty (including goodwill) that has an internal failure. NOTE: The customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is removed by the supplier at tear down and inspection of the failed unit, and mailed to your dealership. Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core, and your dealership will be issued a core loss charge ranging between $800 and $2,500. Remanufactured audio/navigation/RES units are not available for non-warranty repairs. New components should be used to repair new, unsold vehicles. A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. Your DPSM must authorize ordering a new component. Question: How do I order a remanufactured audio/navigation/RES unit? Answer: For a warranty replacement, use the ordering information IN WARRANTY EXCHANGE. For goodwill repair, contact your DPSM. For a non-warranty repair, see OUT-OF-WARRANTY REPAIR. Question: Who do I call for questions on the Warranty Audio Order Program? Answer: For administrative questions, call the Remanufactured Parts Dealer Service Group. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5529 Question: Who do I call if I need help diagnosing the problem or if I have technical questions about the unit? Answer: If you cannot find the answers in the appropriate service manual, service bulletins, or ServiceNews articles on iN, create a Tech Line access code, then call Tech Line: 1. From the iN main menu, select SERVICE. 2. Select Tech Line. A dropdown menu appears, then select Tech Line. The ISIS main screen appears. 3. Select SEARCH BY VEHICLE, and enter any vehicle with any keyword like NAVI, AUDIO, or RES. 4. At the top of the screen you will see this statement: If you cannot resolve the problem with the information below, then click Tech Line. Select Tech Line. 5. The Tech Line access code screen appears. Fill in all the required fields, then select SUBMIT. 6. Have the access number ready when you call Tech Line. Question: Do I need a Tech Line reference number to order a remanufactured audio/navigation/RES unit? Answer: No. Question: What year and model audio/navigation/RES unit can I order through the warranty audio order program? Answer: Most current models are available through the vehicle's standard warranty period. If your application is not available, you will receive a message instructing you to call the Re manufactured Parts Dealer Service Group at 888-997-7278. Question: How can I track my order once I submit it? Answer: To track your order, go the Warranty Audio Order VIN Inquiry screen on the iN. 1. From the iN main menu, click on PARTS. 2. Click on Parts Ordering. 3. Click on Audio VIN Inquiry. 4. Enter a date in the All Orders Accepted Since box, then click on Submit. The AUDIO VIN INQUIRY ACKNOWLEDGEMENT screen appears, listing orders by VIN, ORD REF (Order Reference), STAT (Status), SHIP DATE, SHIPPER, and PART NUMBER. The status of your order is displayed by one of these codes: Codes generated by RPO Tech Line: ^ PEND - Your order is waiting to be processed by RPO Tech Line. ^ HOLD - Your order is waiting for additional dealer diagnosis. ^ ERR - Your order caused an error; call. ^ DENY - RPO Tech Line denied your order; call. ^ APPR - RPO Tech Line approved your order and forwarded it to AHM Parts. Codes generated by AHM Parts Division: ^ BO/TOS - Your order is on back order or is temporarily out of stock. ^ CAN/BOC - Your order has been cancelled contact your assigned parts center. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5530 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5531 ^ Online, enter keyword AUDIO, NAVI, or RES, and select the appropriate removal procedure from the list. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, navigation DVD, etc.) is stuck in the unit, leave it there. The manufacturer will remove and return it. 3. Obtain an Out-of-Warranty/New Replacement component repair form, and complete the Technician section.To obtain the form, do this: ^ On ISIS, click on Technical Library, then click on Job Aids. ^ Select the applicable form from the list, and print it out: - Out-of-Warranty/New Replacement Audio System Component Repair Form - Out-of-Warranty/New Replacement Navigation System Component Repair Form - Out-of-Warranty/New Replacement Rear Entertainment System Component Repair Form Parts Manager: 4. Complete the parts manager's section of the Out-of-Warranty/New Replacement component repair form. Make sure you include your name, department, and dealership phone number on the form. 5. Identify the manufacturer. Units sent to the wrong manufacturer may not be shipped back within the usual 5-7 days. ^ Look for the number code on the face of the unit. ^ If the unit has no number code on its face, check the label on the unit housing, and compare the first two or three letters of the radio reference number (or the audio unit model number) to this list: Alpine - CM, CD, MR, or MF Clarion - PH Fujitsu Ten - CE or SD Panasonic - CQ or CR Pioneer KEH or DEH 6. Contact the manufacturer (see step 9) to request an estimate for the cost of the repair plus shipping. 7. Complete the required paperwork: ^ Paying by check - Make a dealership check out to the manufacturer for the cost of repair and return shipping. Make sure to include the check number on the form. NOTE: For all Panasonic products, make your check out to Komtec Electronics. ^ Paying by credit card (Visa or Mastercard only) - When you use a credit card, fill in all of these fields on the component repair form: - Credit card number - Credit card expiration date Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5532 - The name as it appears on the credit card - Signature (authorized card holder) - Phone number - Authorized charge amount NOTE: If you send in a faulty unit without a check or complete credit card information, the manufacturer may send it back to you unrepaired, or they may repair it and send it back to you C.O.D. ^ Print two copies of the completed Out-of-Warranty/New Replacement component repair form. Keep one copy with the repair order, and include the other copy with the faulty unit when you send it to the manufacturer. 8. Carefully pack the faulty unit and the paperwork in a suitable box, and label the box clearly. You are responsible for lost or damaged units; keep all shipping documents and insurance receipts. 9. Ship the faulty unit to the appropriate manufacturer via UPS. Alpine Electronics of America c/o Standard Radio Engineering Corp. 2012 Abalone Ave., Unit D Torrance, CA 90501 800-421-2284, Ext. 860304 Bose Corporation Automotive Systems Division-Service Framingham, MA 01701-9168 800-231-2673 S3 Clarion Factory Service Center 241 Beaver Rd. Walton, KY 41094 800-347-8667 (You must get authorization from Clarion before shipping units) Fujitsu Ten 19600 5. Vermont Ave. Torrance, CA 90502 800-237-5413 FTH Group Inc. (Kenwood Accessory Parts) 16685 E. Johnson Dr. City of Industry, CA 91745 626-333-2435 (You must get an RMA authorization number from www.fthgroupinc.com; from the home page, select Consumer Products) Komtec Electronics (Panasonic) 6590 Darin Way Cypress, CA 90630 714-903-3300 (Make sure your check is made out to Komtec) * Pioneer Electronics Service, Inc. 1925 E. Dominguez St. Long Beach, CA 90801 800-553-3756* Visteon c/o Model Electronics 615 E. Crescent Ave. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5533 Ramsey, NJ 07446 800-433-9657 (Visteon offers an open line of credit. Call their 800 number to establish an account.) NOTE: ^ The manufacturer will repair the unit and ship it back within 5-7 working days, via UPS ground prepaid or 2nd Day Air (whichever you requested). Do not forget to include the shipping cost in your dealership payment. Units damaged by misuse or mishandling cannot be shipped back within the usual 5-7 days. ^ Each manufacturer's guarantee for the repair differs. To confirm the repair guarantee, contact the manufacturer using the phone number listed above. 10. To check on the status of your repair order, call the manufacturer. If your customer has any further questions or concerns, have them call Automobile Customer Service at 800-999-1009. NOTE: A damaged unit may need extra repair. If so, the manufacturer will call you with an estimate of any added charges. ^ If you accept the estimate, mail a dealership check for the additional amount to the manufacturer, authorize the increased amount to be applied to the credit card payment, or have the manufacturer ship the unit back to you, and you pay the difference upon arrival (C.O.D.). ^ If you reject the estimate, the faulty unit will be returned to you along with a refund. However, you will be charged $30.00 (C.O.D.) for diagnosis, shipping, and handling. The unit will be shipped back to you, via UPS Ground. COMPLETING THE OUT-OF-WARRANTY/NEW REPLACEMENT AUDIO SYSTEM COMPONENT REPAIR FORM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5534 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5535 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 5536 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair Navigation System: Technical Service Bulletins Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair 06-001 February 26, 2010 Applies To: 1998 and Later Models - ALL Audio, Navigation, and RES Unit In-Warranty Exchange and Out-of-Warranty Repair (Supersedes 06-601, dated March 4, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under OUT-OF-WARRANTY REPAIR, the address for Pioneer Electronics Service was changed.* COVERAGE This bulletin applies to all Honda audio units, CD players/changers, cassette tape players, navigation units, and rear entertainment system (RES) units, both in warranty and out of warranty. COMPONENT REPLACEMENT POLICY Use only remanufactured components for warranty repairs on customer vehicles. Follow the warranty information and procedures given in this service bulletin. ^ Remanufactured audio, navigation, and RES units are not available for non-warranty repairs. ^ Use new components to repair new, unsold vehicles. ^ A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. ^ You must receive authorization from your District Parts and Service Manager (DPSM) before ordering a new component. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: From the Flat Rate Manual Flat Rate Time: From the Flat Rate Manual Failed Part: Use the RM part number from the repair order without the RM (example: 08A06-341-110) Defect Code: From the Flat Rate Manual Symptom Code: From Audio Customer Contention Codes in the Flat Rate Manual Part used for repair: Use the RM part number from the repair order (example: 08A06-341-110RM) IN-WARRANTY DIAGNOSIS Service Advisor: Interview the customer to get as much information as possible. Information like where and when the problem occurs is vital to your diagnosis. This information also helps you to determine if the audio, navigation, or RES system is operating normally, or if a problem exists. Write the complaint on the repair order. NOTE: For CD/DVD related problems, you must verify if the customer used discs with adhesive labels. Service Technician: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5541 1. Print out the appropriate system worksheet from an Interactive Network (iN) workstation. ^ From the iN main menu, click on SERVICE. ^ Click on (ISIS) Service Publications. ^ Click on SEARCH BY PUBLICATION. ^ Click on Job Aids. ^ Click on Audio System Worksheet, Navigation System Worksheet, or Rear Entertainment System Worksheet. 2. Duplicate and confirm the problem using the customer information written on the repair order or have the customer demonstrate the problem, then write down the results on the worksheet. Using the SYMPTOM TROUBLESHOOTING INDEX or the DTC INDEX (if applicable) in the applicable service manual, find the symptom that matches the customers complaint, and follow the diagnostic procedure: ^ Refer to the appropriate section in the service manual, or ^ From the iN main menu: - Click on SERVICE. - Click on ISIS (Service Publications). - Click on SEARCH BY VEHICLE. - Enter the model and the model year. - Enter a keyword: AUDIO, NAVIGATION, or RES, and the DTC (if applicable) - Select the appropriate Service Bulletin, ServiceNews article, or Symptom Troubleshooting from the list. 3. Repair the vehicle according to your diagnosis, then confirm the repair by trying to duplicate the customer's original complaint, or check to see if the DTC returns: ^ If the problem is gone, return the vehicle to the customer. ^ If the problem is still there, go to step 4. 4. Replace the audio/navigation/RES unit with a remanufactured unit: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5542 ^ For warranty repairs, go to the IN-WARRANTY EXCHANGE procedure. ^ For vehicle service contract (VSC) and certified used car (CUC) repairs, call. ^ For goodwill repairs, contact your dealership's District Parts and Service Manager (DPSM). IN-WARRANTY EXCHANGE Service Technician: NOTE: ^ Use the iN to order a remanufactured audio, navigation, or RES unit. Do not call the Remanufactured Parts Dealer Service Group. ^ A Tech Line reference number is not required to submit the order. Check Yes, and enter the Reference Number only when there is a preexisting Tech Line contact. 1. With your completed Audio/Navigation/RES Worksheet, go to an iN workstation. 2. From the iN main menu, click on SERVICE, then click on AUDIO, then select Warranty Audio Order. 3. Select the model, year, and keyword (AUDIO, NAVIGATION, or RES) for the vehicle you are working on, then click on Search. 4. Review all displayed publications for additional repair information. If you cannot repair the problem, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5543 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5544 NOTE: Once you submit your order, you can track it using the Warranty Audio VIN Inquiry screen on the iN. For details, go to WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS in this service bulletin. 7. You will receive a remanufactured audio/navigation/RES unit packed in a reusable shipping box. Save this box and the packing materials. You must return the failed audio/navigation/RES unit core in this box. Otherwise your dealership risks being billed a core loss charge, ranging from $800 to $2,500, depending on the unit. 8. Remove the failed audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or, ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate removal procedure from the list. 9. Install the remanufactured audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate installation procedure from the list. 10. If the remanufactured unit has a shipping cover and shipping screws, make sure you transfer them to the faulty unit being returned. Also be sure to transfer all of the mounting brackets to the replacement unit. Failure to do this may result in dash squeaks and rattles. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is stuck in the unit, leave it there for these reasons: ^ The manufacturer needs it for diagnosis and testing. ^ Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core. Customer media (CDs, CD magazines, DVDs, DVD-As, cassette tapes, etc.) will be properly removed by the supplier at the point of tear down and inspection of the failed unit, and mailed to your dealer. Make sure the failed audio/navigation/RES unit core is not disassembled! If the core is disassembled, your dealership will be debited a core loss charge ranging from $800 to $2,500, depending on the unit. 11. Put the failed audio/navigation/RES unit core in the same box that the remanufactured unit came in. NOTE: If you do not return the failed audio/navigation/RES unit core in this same box, your warranty claim will be debited and the core will be sent back to your dealership. Parts Manager: 12. The Warranty Audio/Navigation/RES Unit Order form you submitted is kept on the iN for 60 days. Print out a copy to put in the box with your core return: ^ From the iN main menu, click on SERVICE. ^ Click on Transactions. ^ Click on Advanced Search, and enter a date range. ^ Click on Filtered by Service. ^ Under Transaction Description, click on Warranty Audio Order, then go back to the top of the page and click on Search. ^ Scroll down to the appropriate VIN, then select it to view the form. ^ Review the form, then print out a copy by clicking on the printer icon. 13. Print out a copy of the Core Return Update Acknowledgement to put in the box with your core return: ^ From the iN main menu, click on PARTS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5545 ^ Click on Returns and Surplus. ^ Click on Audio Core Return. ^ Select the appropriate VIN to view the Update Core Return information screen. ^ Review the form, then print out a copy by clicking on the printer icon. 14. Place the printed copies of the Warranty Audio/Navigation/RES Unit Order form and the Core Return Update Acknowledgement into the core return box with the failed audio/navigation/RES unit core. NOTE: If you return a failed audio/navigation/RES core without the proper forms, your warranty claim will be debited and the core will be sent back to your dealership. 15. Ship the failed audio/navigation/RES unit core to the appropriate location by using the prepaid shipping label that came with the remanufactured audio/navigation/RES unit. NOTE: If the failed audio/navigation/RES unit core is not received at the specified address within 30 days from the order date of the remanufactured audio/navigation/RES unit, your warranty claim will be debited, and your dealership will be issued a core loss charge ranging between $800 and $2,500. If you know that you cannot return the core within 30 days, call the Remanufactured Parts Dealer Service Group, and ask for an extension. ^ If you call for an extension and the core is not received within 60 days from the order date, you will be debited the full amount of the warranty claim. ^ If you do not call for an extension, and the core is received between 31 and 60 days from the order date of the remanufactured audio/navigation/RES unit, a $250 late core charge will be assessed. WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS Here is a list of answers to the most frequently asked questions about the warranty audio order program: Question: When do I use the warranty audio order program? Answer: Use the program when you are replacing an audio/navigation/RES unit under warranty (including goodwill) that has an internal failure. NOTE: The customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is removed by the supplier at tear down and inspection of the failed unit, and mailed to your dealership. Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core, and your dealership will be issued a core loss charge ranging between $800 and $2,500. Remanufactured audio/navigation/RES units are not available for non-warranty repairs. New components should be used to repair new, unsold vehicles. A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. Your DPSM must authorize ordering a new component. Question: How do I order a remanufactured audio/navigation/RES unit? Answer: For a warranty replacement, use the ordering information IN WARRANTY EXCHANGE. For goodwill repair, contact your DPSM. For a non-warranty repair, see OUT-OF-WARRANTY REPAIR. Question: Who do I call for questions on the Warranty Audio Order Program? Answer: For administrative questions, call the Remanufactured Parts Dealer Service Group. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5546 Question: Who do I call if I need help diagnosing the problem or if I have technical questions about the unit? Answer: If you cannot find the answers in the appropriate service manual, service bulletins, or ServiceNews articles on iN, create a Tech Line access code, then call Tech Line: 1. From the iN main menu, select SERVICE. 2. Select Tech Line. A dropdown menu appears, then select Tech Line. The ISIS main screen appears. 3. Select SEARCH BY VEHICLE, and enter any vehicle with any keyword like NAVI, AUDIO, or RES. 4. At the top of the screen you will see this statement: If you cannot resolve the problem with the information below, then click Tech Line. Select Tech Line. 5. The Tech Line access code screen appears. Fill in all the required fields, then select SUBMIT. 6. Have the access number ready when you call Tech Line. Question: Do I need a Tech Line reference number to order a remanufactured audio/navigation/RES unit? Answer: No. Question: What year and model audio/navigation/RES unit can I order through the warranty audio order program? Answer: Most current models are available through the vehicle's standard warranty period. If your application is not available, you will receive a message instructing you to call the Re manufactured Parts Dealer Service Group at 888-997-7278. Question: How can I track my order once I submit it? Answer: To track your order, go the Warranty Audio Order VIN Inquiry screen on the iN. 1. From the iN main menu, click on PARTS. 2. Click on Parts Ordering. 3. Click on Audio VIN Inquiry. 4. Enter a date in the All Orders Accepted Since box, then click on Submit. The AUDIO VIN INQUIRY ACKNOWLEDGEMENT screen appears, listing orders by VIN, ORD REF (Order Reference), STAT (Status), SHIP DATE, SHIPPER, and PART NUMBER. The status of your order is displayed by one of these codes: Codes generated by RPO Tech Line: ^ PEND - Your order is waiting to be processed by RPO Tech Line. ^ HOLD - Your order is waiting for additional dealer diagnosis. ^ ERR - Your order caused an error; call. ^ DENY - RPO Tech Line denied your order; call. ^ APPR - RPO Tech Line approved your order and forwarded it to AHM Parts. Codes generated by AHM Parts Division: ^ BO/TOS - Your order is on back order or is temporarily out of stock. ^ CAN/BOC - Your order has been cancelled contact your assigned parts center. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5547 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5548 ^ Online, enter keyword AUDIO, NAVI, or RES, and select the appropriate removal procedure from the list. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, navigation DVD, etc.) is stuck in the unit, leave it there. The manufacturer will remove and return it. 3. Obtain an Out-of-Warranty/New Replacement component repair form, and complete the Technician section.To obtain the form, do this: ^ On ISIS, click on Technical Library, then click on Job Aids. ^ Select the applicable form from the list, and print it out: - Out-of-Warranty/New Replacement Audio System Component Repair Form - Out-of-Warranty/New Replacement Navigation System Component Repair Form - Out-of-Warranty/New Replacement Rear Entertainment System Component Repair Form Parts Manager: 4. Complete the parts manager's section of the Out-of-Warranty/New Replacement component repair form. Make sure you include your name, department, and dealership phone number on the form. 5. Identify the manufacturer. Units sent to the wrong manufacturer may not be shipped back within the usual 5-7 days. ^ Look for the number code on the face of the unit. ^ If the unit has no number code on its face, check the label on the unit housing, and compare the first two or three letters of the radio reference number (or the audio unit model number) to this list: Alpine - CM, CD, MR, or MF Clarion - PH Fujitsu Ten - CE or SD Panasonic - CQ or CR Pioneer KEH or DEH 6. Contact the manufacturer (see step 9) to request an estimate for the cost of the repair plus shipping. 7. Complete the required paperwork: ^ Paying by check - Make a dealership check out to the manufacturer for the cost of repair and return shipping. Make sure to include the check number on the form. NOTE: For all Panasonic products, make your check out to Komtec Electronics. ^ Paying by credit card (Visa or Mastercard only) - When you use a credit card, fill in all of these fields on the component repair form: - Credit card number - Credit card expiration date Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5549 - The name as it appears on the credit card - Signature (authorized card holder) - Phone number - Authorized charge amount NOTE: If you send in a faulty unit without a check or complete credit card information, the manufacturer may send it back to you unrepaired, or they may repair it and send it back to you C.O.D. ^ Print two copies of the completed Out-of-Warranty/New Replacement component repair form. Keep one copy with the repair order, and include the other copy with the faulty unit when you send it to the manufacturer. 8. Carefully pack the faulty unit and the paperwork in a suitable box, and label the box clearly. You are responsible for lost or damaged units; keep all shipping documents and insurance receipts. 9. Ship the faulty unit to the appropriate manufacturer via UPS. Alpine Electronics of America c/o Standard Radio Engineering Corp. 2012 Abalone Ave., Unit D Torrance, CA 90501 800-421-2284, Ext. 860304 Bose Corporation Automotive Systems Division-Service Framingham, MA 01701-9168 800-231-2673 S3 Clarion Factory Service Center 241 Beaver Rd. Walton, KY 41094 800-347-8667 (You must get authorization from Clarion before shipping units) Fujitsu Ten 19600 5. Vermont Ave. Torrance, CA 90502 800-237-5413 FTH Group Inc. (Kenwood Accessory Parts) 16685 E. Johnson Dr. City of Industry, CA 91745 626-333-2435 (You must get an RMA authorization number from www.fthgroupinc.com; from the home page, select Consumer Products) Komtec Electronics (Panasonic) 6590 Darin Way Cypress, CA 90630 714-903-3300 (Make sure your check is made out to Komtec) * Pioneer Electronics Service, Inc. 1925 E. Dominguez St. Long Beach, CA 90801 800-553-3756* Visteon c/o Model Electronics 615 E. Crescent Ave. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5550 Ramsey, NJ 07446 800-433-9657 (Visteon offers an open line of credit. Call their 800 number to establish an account.) NOTE: ^ The manufacturer will repair the unit and ship it back within 5-7 working days, via UPS ground prepaid or 2nd Day Air (whichever you requested). Do not forget to include the shipping cost in your dealership payment. Units damaged by misuse or mishandling cannot be shipped back within the usual 5-7 days. ^ Each manufacturer's guarantee for the repair differs. To confirm the repair guarantee, contact the manufacturer using the phone number listed above. 10. To check on the status of your repair order, call the manufacturer. If your customer has any further questions or concerns, have them call Automobile Customer Service at 800-999-1009. NOTE: A damaged unit may need extra repair. If so, the manufacturer will call you with an estimate of any added charges. ^ If you accept the estimate, mail a dealership check for the additional amount to the manufacturer, authorize the increased amount to be applied to the credit card payment, or have the manufacturer ship the unit back to you, and you pay the difference upon arrival (C.O.D.). ^ If you reject the estimate, the faulty unit will be returned to you along with a refund. However, you will be charged $30.00 (C.O.D.) for diagnosis, shipping, and handling. The unit will be shipped back to you, via UPS Ground. COMPLETING THE OUT-OF-WARRANTY/NEW REPLACEMENT AUDIO SYSTEM COMPONENT REPAIR FORM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5551 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5552 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 5553 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams 176. CD Changer (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Testing and Inspection Radio/Stereo Noise Filter: Testing and Inspection Noise Condenser Capacity Test 1. Remove the right rear side trim panel. 2. Disconnect the 2P connector (A) from the noise condenser. 3. Use a commercially available condenser tester. Connect the condenser tester probes, and the measure condenser capacity. 4. If it is not within the specification, replace the noise condenser. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams 69. Speaker, Driver's Door 70. Speaker, Left Rear 71. Speaker, Passenger's Door Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 5566 72. Speaker, Right Rear 80. Tweeter, Left 81. Tweeter, Right Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 5567 Speaker: Service and Repair Speaker Replacement Door Speaker 1. Remove the door panel. NOTE: If you pull the speaker out too far from the door, you will damage the lower clips (A). 2. Pull the top of the speaker (B) straight out, just enough to release the upper clip. Then lift the speaker straight up to release the lower clips. 3. Disconnect the 2P connector (C), and remove the speaker. Tweeter Carefully pry the tweeter (A) out of the mirror mount cover, then disconnect the 2P connector (B) from the tweeter. Rear 1. Remove the speaker cover (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 5568 2. Remove the three screws, then disconnect the 2P connector (B) from the speaker (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5578 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5579 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Alarm Module: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5585 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 5586 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations Alarm Module: Component Locations Relay and Control Unit Location - Dashboard 64. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 5589 72. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 5590 67. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 5591 Alarm Module: Diagrams 159. Immobilizer Control Unit-Receiver 183. Security Control Unit Connector (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5595 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5596 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5597 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5598 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5599 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 5600 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair Towing Information: Service and Repair Towing If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment - The operator loads the vehicle on the back of a truck. This is the only way of transporting the vehicle. To accommodate flat-bed equipment, the vehicle is equipped with towing hooks (A) and tie down hooks (B). The towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots can be used to secure the vehicle to the truck. Wheel Lift Equipment - The tow truck uses two pivoting arms that go under the tires (front or rear) and lifts them off the ground. The other two wheels remain on the ground. This is an acceptable 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 off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the vehicle must be towed with the front wheels on the ground, do the following: - Release the parking brake. - Shift the transmission to Neutral. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE: - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission, the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Locations Body Control Systems: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Locations > Page 5609 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Locations > Page 5610 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions Body Control Systems: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5613 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5614 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5615 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5616 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5617 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5618 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5619 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5620 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5621 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5622 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5623 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5624 Body Control Systems: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5625 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5626 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5627 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5628 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5629 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5630 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5631 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5632 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5633 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5634 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5635 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5636 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5637 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5638 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5639 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5640 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5641 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5642 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5643 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5644 Body Control Systems: Electrical Diagrams Multiplex Control System - Circuit Diagram Part 1 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Diagram Information and Instructions > Page 5645 Multiplex Control System - Circuit Diagram Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Diagrams > Page 5646 Body Control Systems: Description and Operation System Description The Multiplex Control System has four internal functions: - Multiplexing (send multiple signals over shared wires) - Wake up/sleep (runs at full power only on demand to reduce battery draw) - Fail-safe (fixes or ignores faulty signals) - Self-diagnosis (Mode 1 for the system. Mode 2 for input lines) The system controls the function of these circuits: - Entry light control (ignition key light and ceiling light) - Wiper/washer intermittent wipe and park functions - Keyless/power door lock - Meter assembly, temperature gauge, and indicator lights - HVAC (compressor and fan control) - Key-in reminder - Headlight reminder - Seat belt reminder Multiplex Communication To reduce the number of wire harnesses, digital signals are sent via shared multiplex communication lines rather than sending normal electrical signals through individual wires. - The input signals from each switch are converted to digital signals at the central processing unit (CPU). - The digital signals are sent from the transmitting unit to the receiving unit as serial signals. - The transmitted signal is converted to a switch signal at the receiving unit, and it operates the related component or monitors a switch. - There are exclusive communication lines between the ECM, the gauge assembly, keyless receiver unit, and the under-dash fuse/relay box. Wake-up and Sleep The multiplex control system has "wake-up" and "sleep" functions to decrease parasitic draw on the battery when the ignition switch is OFF. - In the sleep mode, the multiplex control unit stops functioning (communication and CPU control) when it is not necessary for the system to operate. - As soon as any operation is requested (for example, a door is unlocked), the related control unit in the sleep mode immediately wakes up and begins to function. - When the ignition switch is turned OFF, and the driver's or front passenger's door is opened, then closed, there is about a 10 second delay before the control unit goes from the wake-up mode to the sleep mode. - If any door is open, the sleep mode will not function. - If a key is in the ignition switch, the sleep mode will not function. - When in sleep mode, the draw is reduced from 70 - 80 mA to less than 10 mA. Fail-safe To prevent improper operation, the multiplex control system has a fail-safe function. In the fail-safe mode, the output signal is fixed when any part of the system malfunctions (for example a faulty control unit or communication line). Each control unit has a hardware fail-safe function that fixes the output signal when there is any CPU malfunction, and a software fail-safe function that ignores the signal from the malfunctioning control unit and allows the system to operate normally. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Multiplex Control System Troubleshooting Body Control Systems: Testing and Inspection Multiplex Control System Troubleshooting Troubleshooting MODE 1 Test 1. Remove the driver's dashboard lower cover. 2. Check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. Are the fuses OK? YES - Go to step 3. NO - Find and repair the cause of the blown fuse. 3. Turn the ignition switch ON (II). If the driver's seat belt is unbuckled the seat belt reminder will chime 6 times. 4. Set the ceiling light to the center position and close all the doors. 5. Connect the special tool (A) to the multiplex inspection connector (B). 6. After about 5 seconds the spotlight and ceiling light should come on for 2 seconds, go out, then blink on for 0.2 second to show the system is now in mode 1. Did the spotlight and ceiling light indicate mode 1? YES - Go to step 8. NO - Go to step 7. 7. Check for continuity between terminal 4 of the under-dash fuse/relay box connector J and body ground. Is there continuity? YES - Replace the under-dash fuse/relay box. NO - Repair the open in the wire. If the wire is OK, repair G301. 8. If the DTCs are present, the spotlight and ceiling light will blink to indicate the DTC(s). If more than one DTC is present, the DTCs will be displayed in ascending order. If there are no DTCs the spotlight and ceiling light will not blink again after the Mode 1 indication. Are there any DTCs? YES - Go to step 9. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Multiplex Control System Troubleshooting > Page 5649 NO - Go to the Mode 2 test. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Multiplex Control System Troubleshooting > Page 5650 9. Troubleshoot the DTC(s) in the order indicated using the given charts. If a faulty control unit is suspected, substitute it with a known food part and recheck for DTCs, If the DTC(s) is still present, go to the next step listed for the DTC. - If the DTC(s) is no longer present replace the original part. MODE 2 Test 1. From Mode 1, disconnect the special tool from the multiplex inspection connector for 5 to 10 seconds, and then reconnect it. 2. The spotlight and ceiling light should come on for 2 seconds, go out, then blink twice, 0.2 seconds each time. The system is now in Mode 2. 3. Operate the switches listed below: If the circuit is OK, the spotlight and ceiling light will blink once. If the circuit is faulty, the lights will not blink. Tip: Operate the switches most closely related to the problem you are diagnosing is a quick way of testing the circuits integrity. 4. If all inputs were confirmed, or multiple circuits failed at the same time in Mode 2, go to the multiplex sleep mode test. If a single switch fails in Mode 2, troubleshoot its circuit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Multiplex Control System Troubleshooting > Page 5651 Body Control Systems: Testing and Inspection Multiplex Control Unit Input Test Multiplex Control Unit Input Test 1. Remove the driver's dashboard lower cover. 2. Disconnect the under-dash fuse/relay box connectors C, E, F, J, K, O, P, Q, X and Y. NOTE: All connectors are wire side of female terminals. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Multiplex Control System Troubleshooting > Page 5652 4. Reconnect the connectors to the under-dash fuse/relay box, turn the ignistion switch ON (II) to keep the system awake and make sure these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Description and Operation Front Bumper: Description and Operation Door and Bumper Reinforcement Beams Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel (HSS). If HSS is heated, the strength of the steel will be reduced. If HSS is damaged, as in a vehicle accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten them. For this reason, door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged. NOTE: If a door beam is damaged, the whole door panel assembly should be replaced. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Description and Operation > Page 5657 Front Bumper: Service and Repair Front Bumper Removal/Installation NOTE: - Have an assistant help you when removing and installing the front bumper. - Take care not to scratch the front bumper and body. - Put on gloves to protect your hands. 1. Remove the front bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure both 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. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Description and Operation Rear Bumper: Description and Operation Door and Bumper Reinforcement Beams Door and bumper reinforcement beams used on Honda vehicles are made from a metal equivalent to High Strength Steel (HSS). If HSS is heated, the strength of the steel will be reduced. If HSS is damaged, as in a vehicle accident, where the door and bumper reinforcement beams are bent, the beams may crack if an attempt is made to straighten them. For this reason, door and bumper reinforcement beams should NEVER be repaired; they should be replaced if they are damaged. NOTE: If a door beam is damaged, the whole door panel assembly should be replaced. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Description and Operation > Page 5661 Rear Bumper: Service and Repair Rear Bumper Removal/Installation Special Tools Required KTC trim tool set SOJATP2014 NOTE. - Have an assistant help you when removing and installing the rear bumper. - Take care not to scratch the rear bumper and body. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Put on gloves to protect your hands. 1. Remove the rear bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure 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. - Make sure the upper spacers of the rear bumper engage the clips on the body securely. - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlets (B) Take care not to scratch the body. 3. Install the air outlets by pushing on the hook portions until the hooks snap into place. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Remove the windshield side trim from both sides. 3. Pull the hood rear seal (A) away from the cowl covers, then remove it, and using a clip remover, detach the clips (B) from the cowl covers. Take care not to scratch the cowl covers. 4. Detach the clips (C, D, E) by carefully pulling the passenger's cowl cover (F) upward, to release the hooks (G), and pull the cover forward to release the hooks (H), then remove the cover. Take care not to scratch the body. 5. Detach the clips (C, D, E) by carefully pulling the driver's cowl cover (I) upward, then pull the cover forward to release the hooks (J), and remove the cover. Take care not to scratch the body. 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Door Outer Handle Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door pane - Plastic cover, as necessary 2. Raise the glass fully. 3. Remove the lock rod protector (A). -1 Remove the screw. -2 Release the protector from the latch protector (B). -3 Pull the protector down to release the hook (C) from the door. 4. Disconnect the cylinder rod (A), and release the retainer clip (B), then remove the lock cylinder (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 5676 5. Disconnect the outer handle rod (A). 6. Remove the maintenance cap (B), and remove the bolts securing the outer handle (C) while holding the handle from outside. Release the hook (D), then remove the outer handle protector (F). 7. Pull out the outer handle (A), then remove it. 8. Install the handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the door locks and opens properly. - When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder installation, then tighten the handle bolts. - Install the lock cylinder retaining clip on the handle, then install the lock cylinder. 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 covers perimeter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair Door Latch Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary 2. Raise the glass fully. 3. Remove the lock rod protector (see step 3 of Door Outer Handle Replacement). 4. Pull the glass run channel (A) away as necessary, and remove the bolt, then remove the center lower channel (B) by pulling it downward. 5. Disconnect the cylinder rod (see step 4 of Door Outer Handle Replacement). 6. Disconnect the outer handle rod (see step 5 of Door Outer Handle Replacement). 7. Disconnect the actuator connectors (A), and release the inner handle cable (B) from the door by detaching the cable clip (C). 8. Remove the screws, then remove the latch (A) through the hole in the door. Take care not to bend the outer handle rod (B), cylinder rod (C), lock Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 5680 rod (D), and inner handle cable (E). 9. Install the latch in the reverse order of removal, and note these items. - Make sure the actuator connectors are plugged in properly, and that each rod and cable are connected securely. - When reinstalling the door panel, make sure the plastic cover is installed properly, and is sealed around the covers perimeter. - Make sure the door locks and opens properly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair Door Panel Removal/Installation Special Tools Required Trim pad remover, Snap-on A 177 A or equivalent, commercially available. NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. 1. Remove the mirror mount cover. 2. Insert a hex wrench through the hole (A) in the door grip base (B). Push the door grip cover (C) out to release the hook (D) and tab (E), and pull out the cover to release the tabs (F) and hook (G) by hand, then remove the cover. 3. Remove the armrest cover (A). Take care not to scratch the door panel. -1 Pry out the front edge of the cover to release the hooks (B). -2 Pry out the bottom and rear edge of the cover to release the hooks (C). -3 Pry out along the top to release the tabs (D). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 5684 4. Remove the screws (A, B), and release the tabs (C), then remove the door grip base (D). Remove the screw (A) securing the door panel from the armrest portion. 5. Pull out the switch panel (A) to release the hook (B), then remove the panel from the door panel. Disconnect the power window switch connector (C). 6. Release the clips that hold the door panel (A) with a commercially available trim pad remover (B), then remove the door panel by pulling it upward. Remove the door panel with as little bending as possible to avoid creasing or breaking it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 5685 7. Disconnect the inner handle cable (A) from the inner handle (B), and disconnect the power door lock switch connector (C) (driver's). Take care not to bend the cable. 8. Detach the harness clip (A) from the door panel (B). 9. Install the door panel in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the cable is connected securely, and the connector is plugged in properly. - Check the window and power door lock operations. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed, but the striker can be adjusted slightly up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel (C) between the body and striker. 2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (D). Do not tap the striker too hard. 4. Loosen the screws, and remove the shop towel. 5. Lightly tighten the screws. 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the A-pillar, remove the door stop mounting bolt (A). 2. Detach the clips (B, C), then remove the door weatherstrip (D). 3. Install the weatherstrip in the reverse order of removal and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (E) securely. - Apply liquid thread lock to door stop mounting bolt before installation. - Check for water leaks (see step 7 of Door Glass Adjustment). - Test-drive and check for wind noise. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair 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. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Component Locations Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Component Locations > Page 5700 84. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Page 5701 Front Door Window Motor: Diagrams 55. Power Window Motor, Passenger's 124. Power Window Motor, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to drop the glass inside the door. 3. Disconnect and detach the connector (Al and harness clip (B) from the door. 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 the regulator (A) where shown. 6. Install the glass and regulator in the reverse order of removal, and note these items: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 5705 - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks (see step 7 of Door Glass Adjustment). - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Fuel Door Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5715 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5716 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5717 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5718 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5719 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5720 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5721 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5722 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5723 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5724 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5730 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5731 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5732 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5733 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5734 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5735 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5736 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5737 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5738 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Fuel Door Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5743 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5744 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5745 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5746 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5747 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5748 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5749 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5750 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5751 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5752 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM Electric Load Sensor: All Technical Service Bulletins Electrical - DTC P1298 Stored in ECM/PCM 05-006 May 6, 2005 Updated information is noted by asterisks. Applies To: 2001-05 Civic - ALL *2002-04 CR-V - ALL* DTC P1298 Is Stored in the ECM/PCM (Supersedes 05-006, dated February 25, 2005, to change the CR-V model-year range) SYMPTOM DTC P1298 (electrical load detector (ELD) circuit high voltage) is stored in the ECM/PCM. PROBABLE CAUSE The electronic load detector (ELD) has a faulty solder joint. CORRECTIVE ACTION Replace the ELD. NOTE: Previously, if an ELD required replacement, you had to replace the under-hood fuse/relay box. To reduce repair costs, replacement ELDs are now available. PARTS INFORMATION Electronic Load Detector: P/N 38255-S5A-003, H/C 7987571 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 121195 Flat Rate Time: 0.4 hour Failed Part: Civic P/N 38250-S5A-A03 H/C 7472277 CR-V P/N 38250-S9A-A01 H/C 6890594 Defect Code: 06402 Symptom Code: 01201 Template ID: 05-006A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 5758 REPAIR PROCEDURE 1. Make sure you have the anti-theft code for the audio unit. Write down the customer's audio presets. 2. Disconnect the negative battery cable from the battery. 3. Remove the under-hood fuse/relay box cover. 4. Release the three clips, and remove the under- hood fuse/relay box from the holder. CR-V only: Release the wire harness clip from the fuse/relay box holder Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 5759 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 5760 7. Remove the four screws that hold the two fuses, and remove the fuses. 8. Release the tab that holds the ELD, and pull up on the ELD to remove it. 9. Remove the bus bar from the ELD, and insert the bar into the new ELD. 10. Install the new ELD and bus bar into the fuse/relay box. 11. Reinstall the two fuses. 12. Reinstall the 3P ELD connector and the lower fusel relay box cover. 13. Reinstall the fuse/relay box onto its holder. CR-V only: Reinstall the wire harness clip onto the holder. 14. Reinstall the fuse/relay box cover. 15. Reconnect the negative battery cable. 16. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 5761 ^ Start the engine and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. 17. CR-V only: Reset the power window control unit: ^ Turn the ignition switch to ON (II). ^ Make sure the driver's window is fully closed. ^ Push down and hold the window switch until the window goes all the way down. ^ Pull back and hold the window switch until the window goes all the way up, then hold the switch for at least 2 more seconds. 18. Enter the audio unit anti-theft code, and set the clock. Enter the audio presets. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5771 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5772 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5773 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5774 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5775 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5776 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5777 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5778 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5779 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Fuel Door Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5784 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5785 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5786 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5787 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5788 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5789 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5790 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5791 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5792 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Door Lock Cylinder: > 05-006 > May > 05 > All Technical Service Bulletins for Fuel Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5793 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Actuator > Component Information > Service and Repair Fuel Door Release Actuator: Service and Repair Fuel Fill Door Opener Replacement 1. Using a flat-tip screwdriver wrapped with protective tape, detach the hooks (A) by prying the front side cap (B), then remove it from the left door sill trim (C), and loosen the bolt (D) securing the fuel fill door opener. 2. Remove the left door sill trim. 3. Remove the opener (A) from the bolt (B). 4. Disconnect the fuel fill door opener cable (A), then remove the opener (B). Take care not to bend the cable. 5. Install the opener in the reverse order of removal, and note these items. - Make sure the opener cable is connected properly. - Make sure the fuel fill door opens properly and locks securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable > Component Information > Service and Repair Fuel Door Release Cable: Service and Repair Fuel Fill Door Opener Cable Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures in the SRS section before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Door sill trim - Rear side trim panel 2. Pull the carpet back as necessary. 3. Disconnect the fuel fill door opener cable (A) from the opener (B) (see step 3 of Fuel Filler Door Opener Replacement). 4. KC model: Remove the left middle floor cross-member gusset. 5. Remove the cushion tape (C), and release the cable from the clips (D, E). 6. Remove the fuel fill door latch (F) from the body by turning it 90 °. 7. Remove the fuel fill door opener cable from the vehicle. Take care not to bend the cable. 8. Install the opener cable in the reverse order of removal, replace the cushion tape, and replace the clip if it is damaged. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement 1. Disconnect the windshield washer tubes (A). 2. Using a clip remover, detach the clips. Release the hooks (B), then remove the hood insulator (C). Take care not to scratch the hood. 3. Install the insulator in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Latch Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body. 1. Remove the bolts, then remove the hood latch (A) from the body. 2. Disconnect the hood opener cable (B) from the hood latch. Take care not to bend the cable. 3. Install the hood latch in the reverse order of removal, and note these items. - Apply multipurpose grease to each location of the hood latch indicated by the arrows. - Make sure the hood opener cable is connected properly. - Make sure the cable actuates the latch before you close the hood. - Adjust the hood latch alignment (see step 3 of Hood Adjustment). - Make sure the hood opens properly and locks securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Opener Cable Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items: - Front bumper - Front inner fender, left side - Kick panel, left side 2. Disconnect the hood opener cable (A) from the hood latch (B), and remove the bolts (C), then remove the hood release handle (D) from the body. 3. Using a clip remover, detach the clips (E), and remove the grommet (F) from the body, then remove the hood opener cable from the vehicle. Take care not to bend the cable. 4. Install the cable in the reverse order of removal, and replace any damaged clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Component Locations Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Component Locations > Page 5815 112. Middle of Hatch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 5816 42. Hatch Lock Actuator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 5817 Power Trunk / Liftgate Lock Actuator: Testing and Inspection Hatch Lock Actuator Test 1. Open the hatch. 2. Remove the hatch lower trim panel. 3. Disconnect the 2P connector from the hatch lock actuator. 4. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair Hatch Handle Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Hatch lower trim panel - Rear license trim panel 2. Remove the rear window wiper motor. 3. Disconnect the hatch opener cable (A) from the hatch handle (B), and remove the nuts. 4. Pull out the hatch handle (A), then remove it. 5. Install the handle in the reverse order of removal, and note these items: - Make sure the hatch opener cable is connected securely. - Make sure the hatch opens properly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Hatch Latch Replacement NOTE: Put on gloves to protect your hands. 1. Remove the hatch lower trim panel. 2. Disconnect the hatch opener cable (A), cylinder rod (B), hatch actuator connector (C), and hatch latch switch connector (D), and detach the hatch actuator connector and hatch latch switch connector from the hatch. 3. Remove the bolts, then pull the hatch latch (E) out, then remove it. 4. Install the latch in the reverse order of removal, and note these items: - Make sure each connector is plugged in properly, and the rod and cable are connected properly. - Make sure the cable actuates the latch before you close the hatch. - Make sure the hatch opens properly and locks securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5835 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5836 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5837 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5838 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5839 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5840 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5841 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5842 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5843 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5844 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5850 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5851 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5852 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5853 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5854 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5855 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5856 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5857 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5858 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5863 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5864 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5865 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5866 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5867 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5868 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5869 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5870 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5871 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 5872 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5878 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5879 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5880 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5881 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5882 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5883 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5884 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5885 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5886 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 5887 Trunk / Liftgate Lock Cylinder: Service and Repair Hatch Lock Cylinder Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Hatch lower trim panel. - Rear license trim. 2. Disconnect the cylinder 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). 4. Install the lock cylinder in the reverse order of removal, and note these items: - Make sure the rod is connected properly. - Make sure the hatch opens properly and locks securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair 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) at the hatch and body, then release the support strut from the pivot bolts (D). Do not remove the clips from the support strut. 2. Set the clips (A) to the original position, then reattach the support strut (B) on the pivot bolts (C) by pushing on the support strut. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 5895 Interior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 5896 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 5897 111. Middle of Hatch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 5898 41. Hatch Latch Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 5899 Trunk / Liftgate Switch: Testing and Inspection Hatch Latch Switch Test 1. Open the hatch. 2. Remove the hatch lower trim panel. 3. Disconnect the 2P connector (A) from the hatch latch (B), 4. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the hatch open. - There should be no continuity with the hatch closed. 5. If the continuity is not as specified, replace the hatch latch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Hatch Weatherstrip Replacement 1. Remove the hatch weatherstrip (A) by pulling out on it. 2. Locate the painted alignment mark (B) 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 in the direction shown. Make sure there are no wrinkles in the weatherstrip. 3. Check for water leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair Emblem Replacement NOTE: When removing an emblem, take care not to scratch the body. Use dental floss to cut the adhesive safely. 1. To remove the front "H" emblem and front type emblem, remove the front bumper. 2. Clean the bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Page 5907 3. Apply the emblems as shown. - When install in the side 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. - For '03-05 models: When installing the LEV emblem on the quarter glass, align the application tape with the edge of the black ceramic and alignment mark on the quarter glass, then press the emblem into place, and remove the application tape. 4. After installing the front "H" emblem and front type emblem, reinstall the front bumper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Remove the windshield side trim from both sides. 3. Pull the hood rear seal (A) away from the cowl covers, then remove it, and using a clip remover, detach the clips (B) from the cowl covers. Take care not to scratch the cowl covers. 4. Detach the clips (C, D, E) by carefully pulling the passenger's cowl cover (F) upward, to release the hooks (G), and pull the cover forward to release the hooks (H), then remove the cover. Take care not to scratch the body. 5. Detach the clips (C, D, E) by carefully pulling the driver's cowl cover (I) upward, then pull the cover forward to release the hooks (J), and remove the cover. Take care not to scratch the body. 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Frame > Component Information > Service and Repair License Plate Frame: Service and Repair Rear License Trim Replacement NOTE: Put on gloves to protect your hands. 1. Remove the hatch lower trim panel. 2. From inside the hatch, remove the bolts securing the rear license trim (A) and hatch lock cylinder (B). 3. From inside the hatch, release the clips (A, B) while holding the rear license trim (C), then remove the trim. Take care not to scratch the hatch. 4. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: Customer Interest Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 5922 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 5923 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: All Technical Service Bulletins Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 5929 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 5930 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Cable: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5936 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5937 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5938 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5939 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5945 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5946 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5947 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Moulding / Trim: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 5948 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing Front Fender Liner: Service and Repair Front Wheelhouse/Damper Housing Removal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5955 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse, and leave the transmission mount bracket attached to the front side frame. - Check the wheelhouse upper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and wheelhouse upper extension as an assembly. If possible. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5956 - Replace the wheelhouse upper extension, damper housing and damper housing extension as an assembly. - Check the transmission mount bracket position, and check for damage. If necessary, replace it. Installation 1. Set the new damper housing assembly, front wheelhouse and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front subframe, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for differences in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5957 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, damper housing extension and wheelhouse upper extension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5958 - From the dashboard upper side, plug weld the holes in the damper housing. - Weld the front wheelhouse, damper housing, and front side frame. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5959 - Weld the wheelhouse upper member. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5960 Front Fender Liner: Service and Repair Front Inner Fender Replacement Front Inner Fender Replacement NOTE: Take care not to scratch the body. 1. Remove the front inner fender (A). 1. On the back of the wheel arch, remove the 5 crews (B). 2. From under the front bumper (C), remove the screws (B) securing the front bumper,'splash shield (D), and front inner fender, and remove the clip (E) securing the front air spoiler, front bumper, and front inner fender. 3. From the wheel arch, remove the clips (F, G) securing the front inner fender (and splash shield) to the body. 4. Release the hook (H) from the splash shield, then remove the front inner fender. 2. Install the inner fender in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5961 Front Fender Liner: Service and Repair Front Fender Fairing Replacement Front Fender Fairing Replacement 1. Remove the front inner fender as necessary. 2. Open the front door. From outside the door, remove the upper clip (A), and from inside the door, remove the lower clip (A) securing the front fender fairing (B) and front fender (C). 3. From the wheel arch, remove the clip (A), and release the clip (B), then remove the front fender fairing (C). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse/Damper Housing > Page 5962 4. Install the fender fairing in the reverse order of removal, and note these items. - Replace any damaged clips. - Route the side turn signal light harness (A) through the notch (B) in the front fender fairing(C). - Before installing the upper and lower clips, bend the mounting tabs (D) on the fender fairing into position as shown. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Rear Inner Fender Replacement '04-05 Models NOTE: Take care not to scratch the rear inner fender and body. 1. Remove the rear wheel. 2. Remove the rear inner fender (A) Left side is shown; right side is similar. 1. Remove the screws (B, C) securing the rear bumper (D) and rear inner fender. 2. Remove the clips (E), then remove the rear inner fender. 3. Install the rear inner fender in the reverse order of removal, and replace any damaged clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter Subframe: Technical Service Bulletins Body/Frame - Universal Subframe Removal Adapter 05-066 November 24, 2005 Applies To: See VEHICLES AFFECTED Universal Front Subframe Removal Adapter (Replaces 01-043, Civic Front Sub frame Removal Adapter, dated September 11, 2001) The universal front subframe removal adapter is a required tool. When properly fitted to a transmission jack and the vehicle's front subframe, the adapter provides a convenient way to remove the subframe. Front subframe removal is required for transmission or engine removal. NOTE: The adapter will only support the subframe it will not support the entire powertrain assembly. Refer to the WARNING label on the adapter. VEHICLES AFFECTED 2003-06 Accord - ALL 2005-06 Accord Hybrid - ALL 2001-06 Civic - ALL 2001-06 Civic GX - ALL 2003-06 Civic Hybrid - ALL 2002-06 Civic Si - ALL 2002-06 CRV - ALL 2003-06 Element - ALL ORDERING INFORMATION The universal front subframe removal adapter is TIN VSB02C000016. To order additional adapters, call the Honda Tool and Equipment Program. USING THE ADAPTER NOTE: The adapter is designed to be used with the transmission jack, (new model number NRI-72500D), available through the Honda Tool and Equipment Program. (The old model number LSL-W93714 can still be used.). The adapter also works with many commercially available transmission jacks. 1. Loosen the four bolts that hold the adapter's adjustable arms to its center plate. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter > Page 5972 2. Line up the slots in the arms with the bolt holes on the corners of the jack base, then attach the adapter to the jack base with the bolts that came with the jack. Tighten all of the bolts securely. 3. Raise the jack to vehicle height. 4. With the rear bar of the adapter spanning the sides of the subframe, route the adapter's strap around the front of the subframe. Pull the strap as tightly as possible, insert the pin through the appropriate loop, then tighten the wing nut. 5. With all of the vehicle parts properly supported or removed (see Engine or Transmission Removal in the appropriate service manual), carefully lower the subframe using the controls on the jack. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Page 5973 Subframe Torque Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Front Grille Replacement 1. Remove the front bumper. 2. Remove the front grille (A). Take care not to scratch the front bumper (B). 1. Remove the screws (C). 2. Remove the clips (D). 3. Release the bottom hooks (E) of the grille. 4. Pull out the bottom of the grille to release the upper hooks (F). 5. Pull out the grille to release the slits (G) from the ribs (H), then remove the grille. 3. Install the grille in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. 4. Reinstall the front bumper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair Carpet Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to damage, wrinkle, or twist the carpet. - Be careful not to damage the dashboard or other interior trim pieces. 1. Remove these items: - Front seats, both sides - Driver's dashboard under cover - Passenger's dashboard lower cover - Rear seat cushion - Kick panels, both sides - Door sill trim, both sides - Consoles, front and rear 2. Remove the nut (A), and use a 6 mm hex wrench, to release the clip (B), then remove the footrest (C). 3. Using a utility knife, cut the carpet (A) under the heater areas (B), and in the parking brake lever area (C) as shown, then pull back the carpet. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 5981 4. Remove the clip (A), and release the fasteners (B). Pull the carpet out from both rear side trim panels (D), then remove the carpet (C). 5. Install the carpet in the reverse order of removal, and note these items: - Apply liquid thread lock to the seat mounting bolts before reinstallation. - Take care not to damage, wrinkle, or twist the carpet. - Make sure the seat harnesses are routed correctly. - Slip the carpet under the rear side trim panel on each side properly. - Replace the clip if it's damaged. - Reattach the cut areas with wire ties. - When installing a new carpet (A), cut it at areas (B) and (C). Work the carpet into place under the heater from both sides, and reattach the cut areas with wire ties. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5987 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5988 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5989 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5990 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5991 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5992 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5993 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5994 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 5995 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6001 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6002 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Beverage Holder Removal/Installation NOTE: - Take care not to scratch the dashboard. - Put on gloves to protect your hands. 1. Remove the dashboard. 2. Remove the screws, then remove the beverage holder (A). 3. Install the beverage holder in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6011 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6012 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6013 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6014 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6015 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6016 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6017 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6018 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6019 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures Headliner Removal/Installation NOTE: - When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. - Take care not to bend and scratch the headliner. - Be careful not to damage the dashboard and other interior trim. 1. Remove these items: - A-pillar trim, both sides - B-pillar upper trim, both sides - Hatch weatherstrip, as necessary - C-pillar trim, both sides - Moonroof switch - Spotlights - Ceiling light 2. Remove the sunvisor (A) and holder (B) from both sides. -1 Remove the caps (C). -2 Remove the screws. -3 Remove the sunvisor from the body and holder. -4 Using a flat-tip screwdriver, push the hook (D), and turn the holder 90 °, then pull it out. 3. From both rear passenger's, remove the caps (A), and remove the screws, then remove the grab handles (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6024 4. Remove the headliner. -1 Remove the socket plug (A). -2 Remove the remaining door opening trim (B) from each roof portion. -3 Detach the clips (C), and release the fasteners (D) by pulling the front portion of the headliner (E) down. -4 With the help of an assistant, release the clips (F) of the headliner from the moonroof frame (G), and release the headliner from the clips (H) by sliding the headliner forward, and lowering the headliner. -5 Remove the headliner through the passenger's opening. 5. Install the headliner in the reverse order of removal, and note these items: - When reinstalling the headliner through the passenger's door opening, be careful not to fold or bend it. Also, be careful not to scratch the body. - Check that both sides of the headliner are securely attached to the trim. - Replace any clips that remain in the roof during removal. Reinstall the clips back in the headliner before installation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6025 Headliner: Removal and Replacement Headliner Removal/installation Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend and scratch the headliner. - Be careful not to damage the dashboard and other interior trim. 1. Remove these items: - A-pillar trim, both sides - B-pillar upper trim, both sides - Hatch weatherstrip, as necessary - C-pillar trim, both sides - Moonroof switch - Spotlights - Ceiling light 2. Remove the sunvisor (A) and holder (B) from both sides. 1. Remove the caps (C). 2. Remove the screws. 3. Remove the sunvisor from the body and holder. 4. Using a flat-tip screwdriver, push the hook (D), and turn the holder 900, then pull it out. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 6026 3. Remove the caps (A) from both rear passenger grab handles (B). Remove the screws, and then remove the handles. 4. Remove the headliner (A). 1. Remove the socket plug (B). 2. Remove the remaining door opening trim (C) from each roof portion. 3. Detach the rear clips (D) by pulling the rear portion of the headliner down. 4. Detach the front clips (E).6 and release the fasteners (F) by pulling the front portion of the headliner down. 5. With the help of an assistant, release the clips (G) of the headliner from the moonroof frame (H) by sliding the head liner forward,and lowering it. 6. Remove the headliner through the passenger's door opening. 5. Install the headliner in the reverse order of removal, and note these items: - When reinstalling the headliner through the passenger's door opening, be careful not to fold or bend it. Also, be careful not to scratch the body. - Check that both sides of the headliner are securely attached to the trim. - Remove any clips that remain in the roof during removal, and reinstall them back in the headliner before installation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair Scuff Plate: Service and Repair Trim Removal/Installation - Door Area Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the door sill trim and B-pillar upper trim, remove the rear side trim panel as necessary. 2. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Apply liquid thread lock to the anchor bolts before reinstallation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal/Installation - Cargo Floor Area Trim Panel: Service and Repair Trim Removal/Installation - Cargo Floor Area Trim Removal/Installation - Cargo Floor Area Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels 1. To remove the rear trim panel, remove the child seat tether anchor. 2. Remove the trim as shown. 3. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal/Installation - Cargo Floor Area > Page 6034 Trim Panel: Service and Repair Trim Removal/Installation - Door Area Trim Removal/Installation - Door Area Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. Remove the trim as shown. To remove the door sill trim and B-pillar upper trim, remove the rear side trim panel as necessary. 2. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Apply liquid thread lock to the anchor bolts before reinstallation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal/Installation - Cargo Floor Area > Page 6035 Trim Panel: Service and Repair Trim Removal/Installation - Rear Side Area Trim Removal/Installation - Rear Side Area Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend or scratch the trim and panels. 1. To remove the rear side trim panel, remove these items: - Rear seat cushion and rear seat-back - Cargo floor mat and cargo area floor - Rear trim panel 2. Remove the trim as shown. On the right side, disconnect the cargo compartment light connector. 3. Install the parts in the reverse order of removal, and note these items: - Replace any damaged clips, and push the clips into place securely. - Make sure the cargo compartment light connector is plugged 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 (P/N 901 37-S1A-EO1) made specifically for this application. - When installing the rear side shelf, slip the rear seat belt through the slit in the trim. - Apply liquid thread lock to the anchor bolts before reinstallation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal/Installation - Cargo Floor Area > Page 6036 Trim Panel: Service and Repair Trim Removal/Installation - Hatch Area Trim Removal/Installation - Hatch Area Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Put on gloves to protect your hands. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components - Take care not to bend or scratch the trim and panels. 1. Remove the trim in the sequence shown. - Hatch upper trim panel - Left hatch side trim - Right hatch side trim - Hatch lower trim panel 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Door Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6047 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6048 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6049 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6050 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6051 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6052 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6053 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6054 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6055 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6056 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6062 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6063 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6064 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6065 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6066 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6067 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6068 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6069 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6070 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Door Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6075 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6076 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6077 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6078 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6079 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6080 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6081 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6082 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6083 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6084 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6090 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6091 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6092 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6093 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6094 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6095 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6096 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6097 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks Cutting Sidewinder-Type Keys > Page 6098 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Locations 86. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Knob > Component Information > Locations > Page 6102 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Starting System - Unable To Key In Ignition Switch Key: Technical Service Bulletins Starting System - Unable To Key In Ignition Switch Can't Turn Ignition Switch? Check for Locked Steering Got a service customer complaining he or she can't turn the ignition switch to start the engine? The reason could just be the steering column lock pin is engaged with the front wheels turned. Here's what typically happens: Some folks use the steering wheel to help support themselves while climbing in or out of the vehicle. This is very common among elderly or disabled drivers. Doing this turns the front wheels, which twists the tires against the ground. The twisted tires apply torque to the steering column. With the ignition switch in LOCK (0), the steering column lock pin is engaged. But the applied torque on the steering column binds the lock pin, making it tough to turn the ignition switch. The ignition switch won't turn to ON (II) if the lock pin isn't disengaged from the steering column. Tell your customer there's nothing wrong with the ignition switch itself. All he or she needs to do is turn the steering wheel from side to side while turning the switch. This usually releases the lock pin so the engine can be started. In some cases, though, your customer may need to give a good tug on the wheel. This could easily happen when parking on a hill and the wheels are turned sharply before the engine is shut off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6111 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6112 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6113 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6114 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6115 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6116 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Keyless Entry Receiver: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 6120 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 6121 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 6122 140. Keyless Receiver Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 6123 Keyless Entry Receiver: Testing and Inspection Keyless Receiver Unit Input Test NOTE: Refer to Multiplex Troubleshooting to check for Mode 1 DTCs and troubleshoot. 1. Remove the driver's dashboard lower cover. 2. Remove the audio unit. 3. Disconnect the 5P connector (A) from the keyless receiver unit (B). 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. With the connector still disconnected, make the input test at the connector. - If test indicates a problem, find and correct the cause, then recheck the system. - If the input test proves OK, go to step 6. 6. Reconnect the 5P connector, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, replace the keyless receiver unit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: Customer Interest Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 6132 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 6133 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself Keyless Entry Transmitter: All Technical Service Bulletins Antitheft System - Alarm Will Not Arm/Arms By Itself 05-025 July 1, 2005 Applies To: 2001-05 Civic - ALL 2002-05 CR-V - ALL 2003-04 Element - ALL Accessory Security System Changes Modes By Itself (Supersedes 05-025, dated June 10, 2005, to update the information indicated by black bars and asterisks.) SYMPTOM The security system will not arm or it arms by itself. PROBABLE CAUSE Key switch contact chatter causes the control unit to change modes. CORRECTIVE ACTION * Civic: Replace the security control unit, and reprogram the remote(s).* * CR-V and Element: Replace the security control unit and the microphone, then reprogram the remote(s).* * NOTE: You must replace the microphone on the CR-V and Element because the security control units are matched to their microphones when they are manufactured. Using the original microphone may result in security system problems.* PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Before starting, make sure you have all of the remotes (three maximum) the customer wishes to use. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 6139 1. Remove the driver's dashboard lower cover. (See the body section of the appropriate service manual.) 2. Replace the security control unit. ^ Civic: Remove the security control unit, and install the new security control unit. ^ * CR-V and Element: Remove the security control unit and microphone. Install the new security control unit and new microphone.* 3. Reprogram the keyless receiver unit. NOTE: The codes of up to three transmitters can be stored in the keyless receiver unit memory. If a fourth code is stored, the code that was input first will be erased. It is important to maintain the time limits between the steps. Make sure the doors and the trunk/tailgate/hatch are closed, and that you have all of the remotes the customer wishes to use. ^ Turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition switch to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 05-025 > Jul > 05 > Antitheft System - Alarm Will Not Arm/Arms By Itself > Page 6140 ^ Within 1 to 4 seconds, turn the ignition switch to LOCK (0). ^ Within 1 to 4 seconds, turn the ignition to ON (II). ^ Within 1 to 4 seconds, push the transmitter lock or unlock button. ^ Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. ^ Within 10 seconds, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock button. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. ^ Turn the ignition switch to LOCK (0), and pull out the key. 4. Confirm proper operation of the transmitters. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6145 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6146 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6147 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6148 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6149 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6150 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6151 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6152 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6153 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6154 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6155 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6156 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6157 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6158 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6159 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6160 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6161 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6162 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6163 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6164 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6165 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6166 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6167 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6168 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6169 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information Technical Service Bulletin # 98-011 Date: 040220 Keyless Entry - Remote Transmitter Information 98-011 February 20, 2004 Applies To: ALL Keyless Remote Transmitter Information (Supersedes 98-011, dated February 6, 2003) Updated information is shown by asterisks and a black bar. This service bulletin gives you information about keyless remote transmitters for most Honda vehicles. Each procedure describes transmitter programming (if applicable), transmitter ordering, and transmitter batteries. A remote transmitter quick reference guide is shown below. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6175 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6176 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6177 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6178 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6179 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6180 Remote Transmitter Quick Reference Guide 90-93 Accord, 92-93 Civic & Prelude, 93 Del SOL 1990-93 Accord (2-door and 4-door) with dealer-installed security system 1992-93 Civic with dealer-installed security system 1993 del Sol with dealer-installed security system 1992-93 Prelude with dealer-installed security system Programming the Transmitter NOTE: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6181 This system uses ROM chips that match the transmitter to the security system control unit. When replacing a lost or stolen transmitter, you need to use the three ROM chips (provided with the new transmitter) to match the old transmitter with the new transmitter and the control unit. 1. Remove the rear cover from the old transmitter and the new one. 2. Remove the ROM chip from the old transmitter by sliding its socket holder toward the ROM chip. 3. Insert a new ROM chip into the socket holder, then slide the socket holder toward the socket to lock the chip in place. 4. Repeat step 3 to install a ROM chip into the new transmitter. 5. Reinstall the rear covers on the transmitters. 6. Remove the security system control unit from under the driver's seat. 7. Open the access cover on the control unit, and replace the ROM chip. (Use the same procedure as in steps 2 and 3.) 8. Press the reset button next to the ROM chip. 9. Close the access cover, and reinstall the control unit. If you are replacing a damaged transmitter, don't replace the ROM chips in the transmitters and the control unit; just remove the chip from the old transmitter and install it in the new one. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. If your customer wants to add a third transmitter to the system, you need to order a four ROM chip set directly from Alpine Electronics of America. The Alpine part number for the four ROM chip set is 5319. This ROM chip set does not come with a transmitter. Order the additional transmitter from American Honda. If you have questions about how to order a four ROM chip set, call Alpine's parts department at (800) 421-2284, extension 8885. Batteries for the Transmitter Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6182 The battery number is CR2025. Each transmitter uses one battery. 94-95 Accord, Civic, Del SOL, Prelude & 95 Odyssey 1994-95 Accord with dealer-installed security system 1994-95 Civic with dealer-installed security system 1994-95 del Sol with dealer-installed security system 1994-95 Prelude with dealer-installed security system 1995 Odyssey with dealer-installed security system Programming the Transmitter NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the system's memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes, and then reprogram them. To do this, refer to the security system owner's manual. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the dashboard lower cover. (Continue to hold the button during this procedure, or programming will be cancelled.) The LED on the upper steering column cover flashes when the system is in programming mode. 3. Press the top button on the transmitter. Check that the parking lights flash to confirm that the transmitter's code was accepted. 4. Press the top button on each of the remaining transmitters. Check that the parking lights flash after each transmitter code is accepted. 5. Release the Valet-Disarm button to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 96-98 Civic EX & Except EX, Civic 1996-98 Civic EX with factory-installed keyless entry system 1996-98 Civic (except EX) with dealer-installed keyless entry system 1996-98 Civic with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6183 Programming the Transmitter NOTES: ^ The system accepts up to four transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all the transmitters once you're in the programming mode. 1. Turn the ignition switch to ON (II). 2. Press and hold the Valet-Disarm button on the radio (between the AM/FM and CD/TAPE buttons) to enter the programming mode. (Continue to hold the button during this procedure, or programming will be cancelled.) Check that the power door locks cycle to confirm that you're in the programming mode. 3. Within 5 seconds, press the "Lock" or "Unlock" button on the transmitter. Check that the power door locks cycle to confirm that the code was accepted. 4. Within 10 seconds, press the "Lock" or "Unlock" button on each of the remaining transmitters. 5. After all the transmitters have been programmed, release the Valet-Disarm button to exit programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Civic, 03-04 Accord, Element, Pilot 1999-00 Civic Value Package with factory-installed keyless entry system 1999-04 Civic EX with factory-installed keyless entry system or dealer-installed security system *1999-03 Civic (except EX) with dealer-installed keyless entry system or security system 2002-04 Civic Si with factory-installed keyless entry system or dealer-installed security system 2003-04 Civic Hybrid with factory-installed keyless entry system or dealer-installed security system 2004 Civic (except LX & EX) with dealer-installed keyless entry system or security system 2004 Civic LX with factory-installed keyless entry system or dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6184 2003-04 Accord DX with dealer-installed security system 2003-04 Element with dealer-installed keyless entry system or security system 2004 Element EX with factory-installed keyless entry system or dealer-installed security system 2003-04 Pilot EX models with factory-installed security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 91-93 Accord 5-D00R EX Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6185 1991-93 Accord 5-door EX with factory-installed keyless entry or dealer-installed security system Programming the Transmitter The transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. To order a transmitter, you need the vehicle's VIN, the code number from the power door lock control unit, and the ignition key code number. The power door lock code number is a five-digit number etched into the plastic case of the control unit (mounted under the driver's seat). The ignition key code number is a four-digit number stamped on the metal shank of all five original keys delivered with the car. Replacement transmitters are manufactured to match the code of the keyless entry system. The new ignition key is cut to match the vehicle's ignition switch, front door locks, tailgate lock, and glove compartment lock. To order this transmitter, use the controlled parts ordering screen on the iN system. The transmitters are manufactured in Japan; delivery takes 4 to 6 weeks. Batteries for the Transmitter The battery is not replaceable. 91-93 Accord 5-Door LX 1991-93 Accord 5-door LX with dealer-installed security system Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter Transmitters can be ordered directly from Kenwood USA only by authorized Honda dealers. Send a completed order form (copy it from the Accessory Replacement Parts section of the Dealer Parts Price List) along with a dealer check for $30.00 (payable to Kenwood U.S.A. Corp.) to this address: Kenwood Service Corp. P.O. Box 22745 Long Beach, CA 90501-5745 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6186 On the order form, you must include the serial number of the keyless control unit or the number from one of the original transmitters. If you need a transmitter shipped overnight, fill out the order form, then call Kenwood at (500) 552-4690, or fax them at (310) 595-1029 (weekdays from 5:30A.M. thru 4:00 P.M. Pacific time). You will need to give the information on the order form to the Kenwood representative. The transmitter will be sent to your dealership COD. Additional shipping and handling charges will be applied to the order. Batteries for the Transmitter The battery number is CR1220. Each transmitter uses two batteries. 94-97 Accord 5-Door EX, 95-98 Odyssey EX 1994-97 Accord 5-door EX with factory-installed keyless entry system 1995-98 Odyssey EX with factory-installed keyless entry system Programming the Transmitter NOTE: ^ The system accepts up to two transmitters. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. 1. Open the driver's door. 2. Push the driver's power door lock switch to the unlock position and hold it. (Continue to hold the switch during this procedure.) 3. Insert the key into the ignition switch, then remove it. Repeat this four more times (five times total) within 10 seconds. (You must complete steps 3 and 4 within 10 seconds or the system will exit the programming mode.) 4. Insert the key into the ignition switch. After you insert the key, make sure the power door locks cycle to confirm that the system is in the programming mode. 5. Press the "LOCK" or "UNLOCK" button on the transmitter. All the power door locks (except the driver's door) should cycle to confirm that the system accepted the transmitter's code. 6. To program a second transmitter, press its "LOCK" or "UNLOCK" button within 10 seconds of programming the first transmitter. 7. Release the master power door lock switch to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. 96-04 Accord, CRV, DelSOL, Ody., Prelude, S2000, Insight, Pilot 1996-02 Accord with dealer-installed security system 1998-02 Accord DX & LX with dealer-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6187 1997-01 CR-V with dealer-installed security system 1996-97 del Sol with dealer-installed security system 1996-98 Odyssey with dealer-installed security system *1999-04 Odyssey LX with dealer-installed keyless entry system or security system* 1996-01 Prelude with dealer-installed security system *2000-04 S2000 with dealer-installed security system 2000-04 Insight with dealer-installed security system 2003-04 Pilot LX with dealer-installed keyless entry system or security system* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6188 1997 Accord SE With Factory-Installed Security System 1997 Accord SE with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Accord EX & 00-02 Accord SE 1998-02 Accord EX with factory-installed security system 2000 and 2002 Accord SE with factory-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6189 (Not interchangeable with CR-V and S2000 remote transmitter) Transmitter Identification The transmitter for the 1995-99 Accord and the 2000-02 Accord look identical, but they are not interchangeable. The 1995-99 transmitter works the doors of a 2000-02 Accord, but it does not open the trunk. If you are not sure which transmitter you have, press and hold the trunk release button while looking at the LED. The LED on the 1995-99 transmitter comes on in about 1.1 seconds. The LED on the 2000-02 transmitter comes on in about 0.5 second. Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 03-04 Accord LX and EX 2003-04 Accord LX and EX with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6190 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR1616. Each transmitter uses one battery. 97-04 CR-V & 00-04 S2000 *1997-04 CR-V LX with dealer-installed keyless entry system 1998-04 CR-V EX with factory-installed keyless entry system 2000-01 CR-V SE with factory-installed keyless entry system 2000-04 S2000 with factory-installed keyless entry system 2002-04 CR-V with dealer-installed security system* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6191 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete each step within 4 seconds of the previous step to keep the system from exiting the programming mode. Program the transmitters within 10 seconds. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-04 Odyssey EX 1999-00 Odyssey EX with factory-installed keyless entry system or dealer-installed security system *2001-04 Odyssey EX models with factory- installed security system* *Transmitter Identification Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6192 The 1999-00 transmitter is not interchangeable with the 2001-04 transmitter. To tell them apart, look at the FCC ID on the back. 1999-00 - FCC ID: E4EG8DN 2001-04 - FCC ID: OUCG8D-440H-A* Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 99-01 Prelude With Factory-Installed Keyless Entry System 1999-01 Prelude with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6193 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 88-91 Prelude With Dealer-Installed Security System 1988-91 Prelude with dealer-installed security system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6194 Programming the Transmitter This transmitter is not programmable. Ordering a Transmitter This transmitter is no longer available. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses two batteries. 97-99 EV Plus With Factory-Installed Security System 1997-99 EV Plus with factory-installed security system Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1, 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 5. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only through Tech Line. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 00-04 Insight With Factory-Installed Keyless Entry System 2000-04 Insight with factory-installed keyless entry system Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6195 Programming the Transmitter NOTES: ^ The system accepts up to three transmitters. The transmitter codes are stored in a stacking-type memory. If a fourth transmitter code is programmed, the code for the first transmitter is erased. ^ Entering the programming mode cancels all learned transmitter codes, so none of the previously programmed transmitters will work. You must reprogram all of the transmitters once you are in the programming mode. ^ You must complete steps 1-6 within 4 seconds of the previous step to keep the system from exiting the programming mode. 1. Turn the ignition switch to ON (II). 2. Press the "Lock" or "Unlock" button on one of the transmitters. (An unprogrammed transmitter can be used for this step.) 3. Turn the ignition switch to LOCK (0). 4. Repeat steps 1 2, and 3 two more times using the same transmitter used in step 2. 5. Turn the ignition switch to ON (II). 6. Press the "Lock" or "Unlock" button on the same transmitter. Make sure the power door locks cycle to confirm that the system is in programming mode. 7. Within 10 seconds, press the "Lock" or "Unlock" button on each transmitter. Make sure the power door locks cycle after you press each transmitter button to confirm that the system accepted the transmitter's code. 8. Turn the ignition switch to LOCK (0) to exit the programming mode. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 94-95 Passport (Except 1995-1/2) 1994-95 Passport (except 19951A) with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to four transmitters. If you program a fifth transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter four times. This will remove the missing transmitter from memory, since only four transmitters can be accepted. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6196 Programming the Transmitter 1. Locate the security system control unit under the driver's seat. 2. Rub your finger over the label on the top of the control unit until you find the depression. Once you find it, push your finger through the label to expose the hole underneath. Inside the hole is a square, yellow button; this is the programming button. 3. Turn the ignition switch to ON, then turn it to LOCK. 4. Press and hold the programming button. Check that the security siren emits four separate chirps followed by a five-chirp burst. This confirms that the system is in programming mode. The siren then emits prompting chirps at 3-second intervals. 5. Release the programming button. 6. After a prompting chirp, press the "LOCK" button on the transmitter. Verify that the siren emits a confirmation chirp to confirm that the transmitter's code was accepted by the control unit. If you wait more than 30 seconds after the prompting chirp before programming a transmitter, or wait more than 30 seconds between programming transmitters, the siren emits three chirps and the system exits the programming mode. 7. To program additional transmitters, wait for another prompting chirp, then press the "LOCK" button. (You can program up to four transmitters per vehicle.) 8. To exit the programming mode, turn the ignition switch to ON, then turn it to LOCK. 9. Test all the transmitters. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is 23-144 (Radio Shack), A-23 (Eveready), or MS-21/MN-21 (Duracell). Each transmitter uses one battery. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6197 96-97 Passport With Dealer-Installed Security System 1996-97 Passport with dealer-installed security system NOTES: ^ The system uses a stacking-type memory that accepts up to two transmitters. If you program a third transmitter, the memory for the first transmitter is pushed out, and it will no longer work. ^ To clear a lost or stolen transmitter from the system's memory, program a transmitter two times. This will remove the missing transmitter from memory, since only two transmitter codes can be accepted. ^ Another way to clear a lost or stolen transmitter is to erase all transmitter codes and then reprogram them. To do this, refer to the security system owner's manual. Programming the Transmitter 1. Move the driver's seat forward. Locate the security system control unit mounted on the floor underneath the seat. 2. Turn the ignition switch to ON. 3. Use a pen or pencil to press and hold the green programming button on the side of the control unit. When the security system LED on the instrument panel comes on, release the programming button. (Steps 3 and 4 must be done within 5 seconds of each other.) 4. Press and release the top button on the transmitter. Verify that the LED goes out, the siren chirps once, and the front sidemarker lights flash to confirm that the transmitter's code was accepted by the control unit. 5. Turn the ignition switch to LOCK, then to ON. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6198 6. Press and hold the green programming button on the side of the control unit until the LED on the instrument panel begins to flash, then release the button. (Steps 6 and 7 must be done within 5 seconds of each other.) 7. Press and release the bottom button on the transmitter. Verify that the LED goes out, the siren chirps twice, and the front sidemarker lights flash twice to confirm that the transmitter's code was accepted by the control unit. 8. Turn the ignition switch to LOCK. Test the transmitter you just programmed. If it doesn't work repeat steps 2 thru 7. 9. If you have another transmitter to program, repeat steps 2 thru 7. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2025. Each transmitter uses one battery. 98-02 Passport With Factory-Installed Security System 1998-02 Passport with factory-installed security system Programming the Transmitter To program the transmitters, use one of these two procedures: ^ Procedure One cancels all learned transmitter codes and adds one new transmitter. None of the previously programmed transmitters will work. Use this programming procedure only if all transmitters were lost or stolen, or if a new control unit has been installed. ^ Procedure Two adds additional transmitters without cancelling any of the previously learned codes. The system will accept up to four transmitters. Procedure One (cancels all codes, adds one new transmitter) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position five times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Procedure Two (adds transmitters) 1. Open the driver's door. 2. Turn the ignition switch to the ACC position and then to the LOCK position three times. (This step must be completed within 10 seconds, or the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 98-011 > Feb > 04 > Keyless Entry - Remote Transmitter Information > Page 6199 system will not enter the programming mode.) 3. Within 10 seconds, close and open the door two times. 4. Turn the ignition switch to the ACC position and then to the LOCK position three times. Close and open the door. (Complete this process within 10 seconds.) Verify that the power door locks cycle once to confirm that the system is in programming mode. 5. Within 20 seconds, press the "LOCK" button on the transmitter you are programming. Verify that the door locks cycle once. 6. Within 20 seconds, press the "UNLOCK" button on the transmitter. Verify that the door locks cycle once to confirm that the system has accepted the transmitter's code. Turning the Audible Chirp On/Off (1998-99 only) NOTE: On '00-02 Passports, the audible chirp sounds only when you push the LOCK button on the transmitter a second time. 1. Open the driver's door, then insert the key in the driver's door lock. 2. Turn the key to the "LOCK" position, then to the "UNLOCK" position. Repeat this two more times. (Complete this procedure within 10 seconds.) 3. Within 10 seconds, close and open the door two times. 4. Within 10 seconds, turn the key to the "LOCK" position, and then to the "UNLOCK" position, three times. Close and open the door once. Verify that the power door locks cycle once to confirm that the chirp has been turned on/off. Ordering a Transmitter Transmitters can be ordered only by authorized Honda dealers. Order them from American Honda using normal parts ordering procedures. Batteries for the Transmitter The battery number is CR2016. Each transmitter uses two batteries. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 6200 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 6201 Keyless Entry Transmitter: Testing and Inspection Transmitter Test NOTE: - If the doors unlock or lock with the transmitter, but the LED on the transmitter does not come on, the LED is faulty. Replace the transmitter. - If any door is open, you cannot lock the door with the transmitter. - If you unlocked the doors with the transmitter, but do not open any of the doors within 30 seconds, the doors relock automatically. - The doors do not lock or unlock with the transmitter if the ignition key is inserted in the ignition switch. 1. Press the lock or unlock button five or six times to reset the transmitter. - If the locks work, the transmitter is OK. - If the locks don't work, go to step 2. 2. Open the transmitter and check for water damage, - If you find any water damage, replace the transmitter. - If there is no water damage, go to step 3. 3. Replace the transmitter battery (A) with a new one, and try to lock and unlock the doors with the transmitter by pressing the lock or unlock button five or six times. If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, go to step 4. 4. Reprogram the transmitter, then try to lock and unlock the doors. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 6202 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be stored in the keyless receiver unit memory. (If a fourth code is stored, the code which was input first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the hatch are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 3. Within 1 to 4 sec, turn the ignition switch OFF. 4. Within 1 to 4 sec, turn the ignition switch ON (II). 5. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 6. Within 1 to 4 sec, turn the ignition switch OFF. 7. Within 4 sec, turn the ignition switch ON (II). 8. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 9. Within 1 to 4 sec, turn the ignition switch OFF. 10. Within 4 sec, turn the ignition switch ON (II). 11. Within 1 to 4 sec, push the transmitter lock or unlock button with the transmitter aimed at the receiver in the multiplex control unit behind the driver's side of the dash. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 sec, push the transmitter lock or unlock button again. 13. Within 10 sec, aim the transmitters (up to two additional ones) whose codes you want to store at the receiver, and press the transmitter lock or unlock buttons. Confirm that you can hear the sound of the door lock actuators after each transmitter code is stored. 14. Turn the ignition switch OFF, and pull out the key. 15. Confirm proper operation of the transmitter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Power Door Lock Actuator: Locations 86. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 6207 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 6208 Power Door Lock Actuator: Diagrams 29. Door Lock Actuator, Driver's 30. Door Lock Actuator, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 6209 Power Door Lock Actuator: Testing and Inspection Door Lock Actuator Test Driver's door 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Passenger's door 1. Remove the passenger's door panel. 2. Disconnect the 2P connector from the actuator. 3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the actuator, apply battery voltage only momentarily. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 6210 4. If the actuator does not operate as specified, replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6214 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6215 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations 86. Driver's Door (Passenger's Similar) 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6219 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6220 Power Door Lock Switch: Diagrams 98. Door Lock Knob Switch, Driver's 99. Door Lock Switch, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No. 2 and No. 3 terminals. - There should be continuity when the door lock knob switch 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. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test > Page 6223 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when the door lock switch is in the LOCKED position and no continuity in the neutral position. - There should be continuity between the No. 2 and No. 3 terminals when in the door lock switch is in the UNLOCKED position and no continuity in the neutral position. 4. If the continuity is not as specified, replace the door lock switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6232 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6233 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6234 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6235 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6236 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6237 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6238 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6239 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6240 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6241 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6247 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6248 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6249 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6250 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6251 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6252 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6253 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6254 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6255 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6260 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6261 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6262 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6263 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6264 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6265 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6266 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6267 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6268 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6269 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks Starter Motor: All Technical Service Bulletins Starting System - Starter Grinds While Engine Cranks 06-025 May 18, 2006 Applies To: 2001-05 Civic 2-door - ALL except CVI 2001-05 Civic 4-door - ALL except Hybrid and GX Starter Grinds While Cranking the Engine SYMPTOM The starter motor intermittently grinds while cranking the engine. PROBABLE CAUSE The female terminal at the starter solenoid may have spread apart, causing a loss of current to the solenoid. CORRECTIVE ACTION Replace the female terminal at the starter solenoid. PARTS INFORMATION Spade Receiver Terminal: P/N 07JAZ-001420A, H/C 8362675 TOOL INFORMATION Terminal Crimping Tool: T/N 07JAZ-001020A WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 7370C3 Flat Rate Time: 0.4 hour Failed Part: P/N 31200-PLM-A51 H/C 6452429 Defect Code: 06601 Symptom Code: 09004 Template ID: 06-025A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. If applicable, make sure you have the anti-theft code for the audio system. Write down the customer's audio unit presets. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Remove the resonator: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 6275 ^ Refer to page 11-199 of the 2001-2005 Civic Service Manual, or ^ Online, enter keyword RESONATOR, and select Resonator Removal/Replacement from the list. 4. Disconnect the female terminal (BLK/WHT wire) from the S terminal of the starter solenoid. NOTE: A/T is shown. M/T is similar 5. Pull the boot back from the female S terminal, and check the terminal for signs of arcing. 6. Check the male S terminal at the starter for signs of arcing. 7. If either terminal has signs of arcing, go to REPAIR PROCEDURE. If neither terminal has signs of arcing, continue your diagnosis using the appropriate service manual. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 6276 1. Cut off the female S terminal from the harness, making the cut as close to the terminal as possible. 2. Strip 6 mm of insulation from the wire using the 2.0 slot on the crimping tool. NOTE: Make sure no wire strands were removed when you stripped the insulation. If any were removed, cut the wire off even with the insulation, and strip it again. 3. Insert the wire into the new terminal so it fits as shown. 4. Using the 2.0 slot on the crimping tool, position the terminal in the tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 6277 5. With the wire inserted in the new terminal as shown in step 3, crimp the wire by squeezing the tool with both hands until the stops make contact. 6. Crimp the insulation by positioning the 5.5 slot on the tool over the insulation crimp section of the terminal and squeezing the tool with both hands until the stops make contact. 7. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 8. Clean the starter side of the S terminal as needed using electric contact cleaner and an electrical connector cleaning brush (Snap-on P/N YA385A or equivalent). Blow out any debris remaining on or around the terminal with compressed air. 9. Apply silicone dielectric grease (3M silicone paste P/N 08946, Permatex Dielectric Tune-up grease P/N 67VR, or equivalent) to the female side of the S terminal, then carefully insert the terminal into the S terminal on the starter side. 10. Slide the boot completely over the S terminal. 11. Reconnect the positive battery cable, then reconnect the negative battery cable. 12. Enter the anti-theft code for the audio unit (if applicable), then enter the customer's audio presets. Set the clock. 13. Confirm that the starter engages properly by starting the engine several times. 14. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > Starting System - Starter Grinds While Engine Cranks > Page 6278 ^ Start the engine, and let it warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle closed and all electrical items off) for 10 minutes. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6288 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6289 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6290 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6291 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6292 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6293 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6294 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6295 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6296 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6301 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6302 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6303 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6304 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6305 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6306 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6307 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6308 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6309 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 06-025 > May > 06 > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6310 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Component Information > Locations Heating/Air Conditioning - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Heated Element: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Power Mirrors - Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Page 6350 Heated Element: Testing and Inspection Function Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Choose the appropriate test based on the symptom: - Both mirrors don't work, go to step 5. - Left mirror doesn't work, go to step 7. - Right mirror doesn't work, go to step 8. - Defogger doesn't work (Canada), go to step 9. Both mirrors 5. Check for voltage between the No. 2 terminal and body ground with the ignition switch ON (II). There should be battery voltage. - If there is no battery voltage, check for: - Blown No. 14 (10 A) fuse in the under-dash fuse/relay box. - An open in the BLK/YEL wire. - If there is battery voltage, go to step 6. 6. Check for continuity between the No. 6 terminal and body ground. There should be continuity. - If there is no continuity, check for: - An open in the BLK wire. - Poor ground (G501). - If there is continuity, check both mirrors individually as described in the next step. Left mirror 7. Connect the No. 2 terminal to the No. 10 terminal, and the No. 5 (or No. 12) terminal to the No. 6 terminal with jumper wires. The left mirror should tilt down (or swing left) with the ignition switch ON (II). If the mirror does not tilt 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 connector. If the wire is OK, check the left mirror actuator. - If the mirror neither tilts down nor swings left, repair the BLU/BLK wire. - If the mirror works properly, check the mirror switch. Right mirror 8. Connect the No. 2 terminal to the No. 11 terminal, and the No. 5 (or No. 13) terminal to the No. 6 terminal with jumper wires. The right mirror should tilt down (or swing left) with the ignition switch ON (II). If the mirror does not tilt down (or does not swing left), check for an open in the GRN/WHT (or WHT/RED) wire between the right mirror and the 13P connector. If the wire is OK, check the right mirror actuator. - If the mirror neither tilts down nor swings left, repair the RED/YEL wire. - If the mirror works properly, check the mirror switch. Defogger (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Page 6351 9. Connect the No. 1 and No. 8 terminals with a jumper wire, and check for voltage between the No. 2 terminal of the mirror connector and body ground. There should be battery voltage and both mirrors should warm up with the ignition switch ON (II). If there is no voltage or neither warms up, check for: An open in the BLK/YEL or ORN wire. - Blown No. 14 (10 A) fuse in the under-dash fuse/relay box. - If only one fails to warm up, check: Its defogger. - Poor ground (G501, G502). - If both warm up, check the defogger switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Switch > Component Information > Locations Power Mirrors - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Switch > Component Information > Locations > Page 6355 Heated Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection Power Mirror Motor: Testing and Inspection Power Mirror Actuator Test 1. Remove the door panel. 2. Disconnect the 6P connector (A) from the power mirror actuator (B). 3. Check actuator operation by connecting power and ground according to the table. 4. If the mirror fails to work properly, replace the mirror actuator. Defogger Test (Canada) 5. Check for continuity between the No. 1 and No. 2 terminals of the 6P connector. There should be continuity. If there is no continuity, check for an open circuit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection > Page 6359 Power Mirror Motor: Service and Repair Power Mirror Actuator Replacement 1. Remove the power mirror. 2. Carefully remove the mirror holder from the mirror housing. Gently pull it out by hand. 3. Disconnect the connector. 4. Remove the cover, then remove the two Torx screws from the mirror connector. 5. Record the terminal locations and wire colors. 6. Cut the wire harness with the wire cutter. 7. Remove the three screws, and separate the mirror housing from the mirror base. 8. Remove the three Torx screws, and separate the actuator (A) from the mirror housing (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection > Page 6360 9. Route the wire harness (A) of the new actuator through the hole in the bracket (B). 10. Insert the terminals into the connector in the original arrangement. 11. Reassemble in the reverse order of disassembly. Be careful not to break the mirror holder when reinstalling it to the actuator. 12. Reinstall the mirror assembly on the door. 13. Operate the power mirror to ensure smooth operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 6364 171. Power Mirror Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 6365 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage Paint: Technical Service Bulletins Paint - Industrial Fallout Paint Damage 99-062 January 15, 2007 Applies To: ALL Paint Damage From Environmental Fallout (Supersedes 99-062, dated October 12, 1999 to update the information marked by the black bars and asterisks) SYMPTOM The exterior paint surface does not feel smooth after the vehicle is washed. PROBABLE CAUSE Environmental fallout (airborne metallic particles, tree sap, paint overspray, road tar, insect residue, etc.) has adhered to the exterior paint surface. NOTE: This form of paint damage should not be confused with acid rain damage. Unlike environmental fallout damage, acid rain damage appears on the paint surface as pits or water spots-possibly black or brown in the center-which may feel smooth to the touch. PREVENTION The shipping wax/wrap guard applied to the vehicle at the factory provides the best protection for the paint finish from environmental fallout and acid rain damage. American Honda strongly recommends that you leave the shipping wax/wrap guard on the vehicle for as long as possible. Your dealership is responsible for maintaining the vehicle's finish after the shipping wax/ wrap guard is removed. CORRECTIVE ACTION Select a product line from one of the manufacturers listed in REQUIRED MATERIALS to clean the paint surface and to wax it after cleaning. Make sure you follow the manufacturer's instructions for each of the products you use. REQUIRED MATERIALS Each of the clays listed should do at least three vehicles. WARRANTY CLAIM INFORMATION Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6371 In warranty: American Honda will reimburse for this repair only under these conditions: ^ It is done during PDI ^ No more than 30 days have elapsed since the vehicle was received at the dealership (according to the date noted on the motor carrier's bill of lading) Operation number: 812355 Flat rate time: 1.0 hour Failed P/N: PDI-PAINT, H/C 3173994 *Defect code: 08103 Symptom code 08811* Skill level: Repair Technician *NOTE: When submitting the claim, make sure you enter the vehicle's date of receipt in the customer contention comment section. The claim will be rejected without this information.* REPAIR PROCEDURE 1. Wash and dry the vehicle out of direct sunlight. 2. Tear off a piece of clay. Shape the piece with your hands into a flat disk about 3 inches in diameter. 3. Spray a 2-to 3-square-foot area of the affected panel with the manufacturer's lubricant. 4. Clean a 1-square-foot section of the sprayed area by rubbing it with the clay. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6372 5. Check your work by running your fingers over the cleaned and lubricated surface to feel for any remaining contamination. ^ If you feel any particles on the cleaned surface fold the clay in half, knead it back into a disk shape, clean the section again, and recheck your work. ^ If the cleaned surface feels smooth, fold the clay in half, knead it back into a disk shape, and go to step 6. NOTE: You must carefully fold and knead the clay to keep a clean side next to the paint surface. Never use clay that has fallen on the ground. Any small pieces of dirt or sand that imbed in the clay will scratch the paint surface. If the clay falls on the ground, discard it and get a fresh piece. 6. Clean the remaining sections of the sprayed area (repeat steps 4 and 5). 7. Wipe the lubricant from all the cleaned sections with a clean terry cloth towel. 8. Clean the rest of the affected panel and any additional panels that need cleaning (repeat steps 3 thru 7). 9. Apply the manufacturer's recommended wax or glaze to all the cleaned panels. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6373 Paint: Technical Service Bulletins Paint - 2004 Paint Codes 03-065 September 23, 2003 Applies To: 2004 Models ALL 2004 Honda Paint Codes Paint formulations are determined by each paint company. For questions about formulas or color matching, call your paint supplier or one of the companies listed at the end of this service bulletin. The number following the paint description is the paint process used during the vehicle manufacture: 1 Two-stage process. Clear coat is applied over the color coat. 2 Two-stage process. A small amount of color is mixed in the clear coat and applied over the color. 3 Single-stage process. No clear coat is applied. Sayama (Japan) Produced Cars, VIN: JHLRD _ _ _ _4C_ _ _ _ _ _ (CR-V) JHMCM _ _ _ _4C_ _ _ _ _ _ (Accord) Marysville (U.S.) Produced Vehicles, VIN: 1HGCM _ _ _ _4A_ _ _ _ _ _ (Accord) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6374 Alliston (Canada) Produced Vehicles, VIN:2H_RL1_ _ _4H_ _ _ _ _ _ (Odyssey) 2HGES1_ _ _4H_ _ _ _ _ _ (Civic) 5FNYF1 8 _ _4H_ _ _ _ _ _ (Pilot) East Liberty (U.S. Produced Vehicles, VIN: 1HGE _ _ _ _ _4L_ _ _ _ _ _ (Civic) 5J6YH _ _ _ _ 4L_ _ _ _ _ _ (Element) Tochigi (Japan) Produced Vehicles, VIN: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6375 JHMAP2_ _ _ 4T_ _ _ _ _ _ (S2000) JHMZE1_ _ _ 4T _ _ _ _ _ _ (Insight) Suzuka (Japan) Produced Cars, VIN: JHMES _ _ _ _4S_ _ _ _ _ _ (Civic) Alabama (U.S.) Produced Vehicles, VIN: 5F_ _ _ _ _ _ _ _4B_ _ _ _ _ _(Odyssey) 5FNYF1 _ _ _ _4B_ _ _ _ _ _ (Pilot) Swindon (U.K.) Produced Vehicles, VIN: SHHEP3_ _ _4U_ _ _ _ _ _(Civic Si) SHSRD_ _ _ _4U_ _ _ _ _ _(CR-V) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6376 Jalisco (Mexico) Produced Vehicles, VIN: 3HGCM5 _ _ _4G _ _ _ _ _ _(Accord) Paint Suppliers* *American Honda does not endorse any paint company or type of paint; this information is for reference only. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 6377 Paint: Technical Service Bulletins Air Fresheners - Bad News For Paint Or Plastic SOURCE: Honda Service News November 2003 TITLE: Hanging Air Fresheners: Bad News for Paint or Plastic APPLIES TO: All Models SERVICE TIP: Never let hanging air fresheners come in contact with painted or plastic surfaces. The chemicals used in them can eat into paint or permanently mar the plastic. Most of these air fresheners actually state on their packages to avoid contact with any surface. Advise your customers to heed those words. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Page 6378 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Page 6379 Paint: Service Precautions General Safety Precaution - Most paints contain substances that are harmful if inhaled or swallowed. - The fallowing precautions are important items in order to maintain safe painting work. 1. Wear an approved respirator and eye protection when painting. 2. Wear approved gloves and appropriate clothing when painting. Avoid contact with skin. 3. Spray paint only in a well ventilated area. 4. Read the paint label before opening the container. Cover spilled paint with sand, or wipe it up at once. 5. If paint gets in your mouth or your skin, rinse and wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. 6. After the painting work is finished, wash your face and gargle with water. 7. Paint is flammable. Store it in a safe place, and keep it away from sparks, flames, or cigarettes. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code and Color Label Location Paint: Application and ID Paint Code and Color Label Location Paint Code Vehicle Identification Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code and Color Label Location > Page 6382 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint Paint: Service and Repair Body Paint General General The 3-coat-3-bake (3C-3B) paint finish give the Civic 3-door a deep gloss and stunning finish. This manual provides information on paint defect, repair, and refinishing. Throughout, the objective is to explain in a simple yet comprehensive manner the basic items you should know about paint repairs. Select the correct material for the defect and repaint or refinish in the correct manner as described. WARNING: - Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container. Spray paint only in a well ventilated area. - Cover spilled paint with sand, or wipe it up at once. - Wear an approved respirator, gloves, eye protection, and appropriate clothing when painting. Avoid contact with skin. - If paint gets in your mouth or on your skin, rinse and wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. - Paint is flammable. Store it in a safe place, and keep it away from sparks, flames, or cigarettes. Basic Rules for Repairing a Paint Finish To repair paint damage, always use the 2-part acrylic urethane paints designated; polish and bake each of the three coats, as in production, to maintain the original film thickness, and to assure the same quality as the original finish. Outline of Factory Painting Process: Features in Each Work Process 1. Pretreatment and Electrodeposition In the pretreatment process, the entire body is degreased, cleaned, and coated with zinc phosphate by dipping. After the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (Cationic Electrodeposition). This produces a thorough corrosion inhibiting coating on the inner surface and corners of the body, pillars, sills, and panel joints. Chipping primer is then applied to the most susceptible areas 2. Intermediate coat The intermediate coat is applied to the prepared surface to further protect against damage. 3. Top Coat Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness, and weather resistance. Sectional View of Paint Coats: Refinishing Processes Refinishing Processes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6385 Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The illustration shows you refinishing methods for various types of paint damage or defects. Preprocessing of Painting Preprocessing of Painting 1. Featheredging NOTE: The paint film damaged area should be sanded flat and smooth. - If this is not done correctly, the end results will not be acceptable. Damage to metal surface: - Sand the damaged area flat and smooth. Use the disc sander and #60 - #80 disc paper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6386 Use the double action sander and #60 - #80 disc paper. - Sand the area larger than the damaged area. Use the double action sander and #180 - #240 disc paper. - If a double action sander is not available, use a rubber pad and wet or dry sandpaper. Use the flexible block and #280, #340, #400, #600 sandpaper. Damage to undercoat, intermediate coat and top coat: Sand the damage area flat and smooth Use the double action sander and #180 - #740 - #320 disc paper. 2. Preparation of metal surface Remove all corrosion from the damaged area. Use a product that removes corrosion. 3. Air blowing/degreasing Use alcohol, and wax and grease remover. Treatment of Metal Surface Treatment of Metal Surface 1. Filling/drying Small cracks or pinholes in the sheet metal should be repaired with a body filler and sanded flat and smooth. Use the 2-part polyester resin putty. - Mix the putty with the hardener in the correct ratio. - Follow the body filler manufacturer's instructions. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6387 - Mix the body filler and hardener quickly. - Apply the body filler in several thin coats, without air bubbles. - Do not try to cover the surface with one heavy coat. - Apply the body filler over the damaged area with a putty knife using light pressure. - After applying the body filler, allow 5 to 6 minutes of normal drying time, then force dry it with infrared lamps or an industrial dryer at 122 degrees F (50 degrees C) - 140 degrees F (60 degrees C). NOTE: Follow the body filler manufacturer's instructions for drying time. 2. Polishing The body filler is dry when a white mark appears after the surface is scratched with your finger nail. -1. Throughly sand the body filler surface. Use the double action sander and #80 - #120 disc paper. -2. Sand the surface evenly, particularly the area that was filled. Use the flexible block and #120 - #180 sandpaper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6388 -3. Featheredge the paint coat Sand the body filler surface until the proper dimensions are met. Use the double action sander and #240 - #320 - #400 discpapers 3. Air blowing/degreasing Use the alcohol, wax and grease remover. Also, clean and degrease the surfaces where masking tape will be attached. Undercoating Undercoating 1. Masking Mask the area surrounding the damage to protect it from the primer surfacer overspray. Use masking tape and paper. 2. Spraying the primer surfacer - Spray the primer surfacer over a wider area than the body filler and the exposed surface of the paint film. - Spray 2 to 3 coats to get 30 microns of thickness. Use the 2-part urethane primer surfacer and a spray gun. - Mix the primer surfacer with the additive and solvent, and in the correct ratio. - Follow the primer surfacer manufacturer's instructions. 3. Drying After spraying primer surfacer, allow for 5 to 10 minutes of normal drying time, then force dry it with infrared lamps or an industrial dryer. NOTE: Follow the primer surfacer manufacturer's instruction for drying time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6389 4. Polishing Check that the primer surfacer has dried thoroughly, then sand the primer surfacer. Use the double action sander and #32O - #4OO - 36OO disc papers. 5. Air blowing/degreasing Use alcohol,and wax and grease remover. Also, clean and degrease the surfaces where masking tape will be attached. Intermediate Coating Intermediate Coating 1. Masking Mask the area surrounding the damage to protect it from the intermediate coat overspray. Use masking tape and paper. 2. Spraying top coat enamel Spray the top coat enamel over the surface until the primer surfacer is fully covered. - Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. 3. Drying After spraying top coat enamel, allow for 5 to 10 minutes of normal drying time, then force dry it with infrared lamps or an industrial dryer. NOTE: Follow the top coat manufacturer's instruction for drying time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6390 4. Polishing Check that the top coat enamel has dried thoroughly, then sand the top coat enamel. Use the double action sander and #6OO - #8OO disc papers. NOTE: Be careful not to polish down to the primer surfacer. When the painting repair is almost done, polish the area that will be top coated. Use the P2000 sandpaper and compound. 5. Air blowing/degreasing Use alcohol, and and grease remover. Also, clean and degrease surfaces where the masking tape will be attached. Top Coating Top Coating 1. Masking Mask the area surrounding the damage to protect it from the top coat overspray. Use masking tape and paper. 2. Spraying top coat enamel/clear coat Spray 2 to 3 double coat until the intermediate coat is fully covered. - Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturers instructions. Drying After spraying the top coat enamel, allow it to air dry, then force dry it with infrared lamps or an industrial dryer. NOTE: Follow the top coat manufacturer's instructions for drying time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6391 Spraying clear coat Spray the top coat clear evenly over the surface of the top coat enamel. Do not try to cover the surface with one heavy coat. Drying After spraying the clear coat, allow it to dry for 10 minutes, then force dry it with infrared lamps or an industrial dryer. NOTE: Follow the top coat manufacturer's instructions for drying times. 3. Polishing/buffing Check that the clear coat has dried thoroughly and that it is cool. -1. Any adhesion or roughness on the top coat should be wet sanded and repaired. Use the P1200 - P2000 sandpaper and a flexible block. -2. Polish all roughness caused by sanding. NOTE: Clean the top coat surface frequently so you don't damage the clear coat with the polishing particles. Use a buffing towel, buffing wool, and compound. -3. Finishes up with buffing. NOTE: Do not use a power buffer. - Don't polish too much; use light hand pressure. Use a buffing sponge, fine compound, very fine compound, then ultra fine compound. 4. After buffing, remove the masking paper and tape, and thoroughly wash the entire vehicle. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6392 Paint: Service and Repair Plastic Parts Paint Features of Plastic Material Features of Plastic Material Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6393 - Check each of the plastic parts for solvent resistance and heat resistance temperatures before you do any repair work. - Select the repair material according to materials of the plastic parts. Refinishing Processes Refinishing Processes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6394 - The illustration shows refinishing methods to various types of paint damage or defects. - Be careful not to deform or damage the parts when force drying. Preprocessing of Painting Preprocessing of Painting 1. Sanding Sand the damage area flat and smooth. Shallow Scratch: Use a flexible block and #240 - #400 - #600 sand paper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6395 Hole/Deep Gouge: Cut out and make any torn or burred area flat. Use a knife, flexible block, and #180 - #240 sand paper. 2. Air blowing/degreasing Clean the damaged area throughly. Use alcohol, and wax and grease remover. Undercoating Undercoating 1. Spraying primer Primer is used to fill cavities in the putty and primer surfacer. Spray primer on the exposed area. - Spray the 2 to 3 coats of primer over the area you applied putty. - Apply primer to the back of the bumper if the damage is a tear or hole. - Bumper primer - Warm the primer if the ambient temperature is below 50 degrees F (10 degrees C). - Follow the bumper primer manufacturer's instructions. - Use a spray gun and a brush. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. Dry the bumper primer thoroughly with an infrared dryer or other suitable method. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6396 2. Filling/Sanding Apply putty to repair any holes or deep gouges. Apply the putty on the damaged area in 2 to 3 steps. - Glue aluminum tape on the outside of the bumper, and apply putty from the other side of the bumper. - Remove the aluminum tape after the putty dries, apply putty from the outside, and fill the hole. Use a special polyester putty and a putty knife. 3. Sanding Sand the surface evenly particularly at the area where the PP material and putty meet Use a flexible block and #240 - #400 - #600 sandpaper 4. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. 5. Spraying primer surfacer NOTE: Spray the bumper primer on the area where the PP material was exposed and around the putty. - Spray the primer surface wider than the putty and painted surfaces of bumper primer. - Spray 2 to 3 coats to get 20 to 30 microns of thickness. Use the 2-component type primer surfacer (gray) and a spray gun. - Follow the materials manufacturer's instructions. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6397 6. Sanding After drying, wet sand the area of the intermediate coat. Use the #600 sandpaper. NOTE: Do not use #600 or less. 7. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. Also clean and degrease the surfaces where the masking tape will be attached. Intermediate Coating Intermediate Coating NOTE: You must do this procedure on the PP parts of the bumper and side sill panel. 1. Masking Mask the area surrounding the damage to protect it from the intermediate coat overspray. Use masking tape and paper. 2. Spraying the top coat enamel - Spray the top coat enamel over the surface until the primer surfacer is fully covered. - Spray 2 to 3 coats to get 15 to 25 microns of thickness. Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. After spraying top coat enamel, allow for 5 to 10 minutes of normal drying, then force dry it with infrared lamps or other industrial dryer. 3. Polishing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6398 Check that the top coat enamel has dried thoroughly, then sand the top coat enamel. Use a flexible block and #600 - #800 - #1000 sandpaper. NOTE: Be careful not to sand down to the primer surfacer. When the painting repair is almost complete, polish the top coat. Use #1500 sandpaper and compound. 4. Air blowing/degreasing Use alcohol, a tack cloth, and wax and grease remover. Clean and degrease the surfaces where the masking tape will be attached. Top Coating Top Coating 1. Masking Mask the area surrounding the damage to protect it from the top coat overspray. Use masking tape and paper. 2. Spraying top coat enamel/clear coat Spray 2 to 3 coats until the intermediate coat is fully covered. NOTE: Do not cover the surface with one heavy coat. - Apply several thin coats. - Use the 2-part polyester urethane top coat enamel and a spray gun. - Mix the top coat enamel with the additive and solvent in the correct ratio. - Follow the top coat manufacturer's instructions. After spraying the top coat enamel, allow for 5 to 10 minutes drying time before you spray the clear coat. Drying NOTE: Take care not to let the heat lamp deform the bumper during the drying process. After spraying the clear coat, allow for 5 to 10 minutes drying time before you force dry it with infrared lamps or other industrial dryer. 3. Polishing/buffing - Check that the clear coat has dried thoroughly. - Wet sand to remove any imperfections. Use a flexible block, soap, and #2000 sandpaper. Using a buffer and compound, remove any polishing marks made from the sandpaper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6399 Use a buffing sponge, and buffing wool and compounds. Finish up with buffing: -1. Wet sand with #2000 sandpaper and soapy water. -2. Remove moisture using compressed air. -3. Finish using fine compound and very fine compound. Polish with an electric polisher. NOTE: Polish lightly. -4. Check the finished area at an angle, and make sure there are no polishing marks. -5. Polish with ultra fine compound and a buffing sponge. -6. Wax the finished area. Use of the Repair Material Use of the Repair Material NOTE: Follow the materials manufacturer's instructions. The use of a special polyester putty for PP bumpers is described here: 1. Filler Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6400 Mixing Ratio: 2. Sanding filler Spray the bumper primer on the area where the PP material was used. 3. Primer surfacer The primer surfacer is used to protect the PP resin surface and fill cavities or flaws before the intermediate coat and top coat. Use the 2-component type primer surfacer (gray). 4. Intermediate coat and top coat Use the 2 part polyester urethane top coat Top coat is also used for an intermediate coat Mixing Ratio NOTE: Be sure to mix the correct amount of the hardener and softener NOTE: Use a spray gun to apply the paint. Do not use a brush. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 6401 Drying Time: Force dry the intermediate coat and top coat. NOTE: Mix only an amount that can be used before it hardens. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations 56. Under Middle of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6406 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6407 Multiplex Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6408 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6409 Keyless Entry Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6410 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6411 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system.See: Body Control Systems/Testing and Inspection 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6415 5. Reconnect all connections to the under dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake and make these input tests at the appropriate connectors on the under dash fuse/relay box If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, go to step 6 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection > Page 6416 6. Disconnect the M, P, K and J connectors from the under-dash fuse/relay box, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 6420 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 6421 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 6422 142. Moonroof Close And Open Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 6423 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 6424 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations 97. Middle of Roof Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 6428 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 6429 143. Moonroof Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 6430 Sunroof / Moonroof Module: Testing and Inspection Moonroof Control Unit Input Test 1. Remove the headliner. 2. Disconnect the 5P connector (A) from the control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the moonroof control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 6431 5. Disconnect the moonroof control unit 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, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair Sunshade Replacement 1. Remove the drain channel. 2. Slide the sunshade (A) until you can see both sunshade slider spacers (B). 3. Remove the screws, then remove both spacers. 4. While lifting the front portion of the sunshade (A), move the sunshade forward until you can see both sunshade rear hooks (B). Do not damage the sunshade and hooks. 5. Remove the screws, then remove both hooks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Page 6437 6. Remove the sunshade (A). 7. Remove both front sunshade base sliders (A) and both rear sunshade base sliders (B). 8. Install the sunshade in the reverse order of removal, and check the glass height adjustment. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Service and Repair Sunroof / Moonroof Cable Housing: Service and Repair Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. Remove the screws (A, B), then remove the slide stops (C) and cable tube rear brackets (D). Remove the bolts (E) from the cable tube side bracket (F) and the cable tube mounting screws (G) from both sides of the frame (H). 4. Detach the open switch connector clip (I) from the frame. 5. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Service and Repair > Page 6441 6. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). 7. Remove the drain channel slider (A) from the glass bracket (B). 8. Install the slider and cable assembly in the reverse order of removal, and note these items: - Damaged parts should be replaced. - Apply multipurpose grease to the glass bracket (A) and guide rail portion of the frame (B) indicated by the arrows. - Before reinstalling the motor, make sure both link lifters are parallel, and in the fully closed position. - Before reinstalling the motor, install the frame and glass, then check the opening drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6445 123. Moonroof Limit Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6446 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6447 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. Fully closed position adjustment 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the position switch (open/close). - Check that the switch plate contacts the switch bracket (G). Auto-stop position adjustment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6448 5. With the moon roof wrench, operate the glass (A) to the auto-stop position. 6. With an open-end wrench, loosen the auto-stop switch mounting bolts (C). 7. Adjust the auto-stop switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the switch (auto-stop). - Check that the switch plate contacts the switch bracket (G). 8. Check the operation of the glass by operating the moonroof switch: From the tilt-up position to the fully closed position, from the fully open position to the auto-stop position, from the auto-stop position to the fully closed position. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Sunroof / Moonroof Motor: Locations Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 6452 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 6453 49. Moonroof Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 6454 Sunroof / Moonroof Motor: Testing and Inspection Motor Test 1. Remove the headliner. 2. Disconnect the 2P connector from the moonroof motor. 3. Check the motor by connecting power and ground according to the table. 4. If the motor does not run, replace it. NOTE: See closing force check for motor clutch test. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 6455 Sunroof / Moonroof Motor: Service and Repair Motor Replacement 1. Remove the headliner. 2. Put on gloves to protect your hands. Disconnect the connector (A), and remove the bolts, then remove the motor (B). 3. Install the motor in the reverse order of removal, and note these items: - Make sure the connector is plugged in properly. - Check the motor operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 6459 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 6460 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 6461 142. Moonroof Close And Open Relay Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 6462 Sunroof / Moonroof Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 6463 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Switch: Component Locations 95. Front of Roof 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6468 97. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6469 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6470 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 6471 Sunroof / Moonroof Switch: Diagrams 50. Moonroof Auto-stop Switch 144. Moonroof Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement > Page 6474 Sunroof / Moonroof Switch: Testing and Inspection Auto-Stop Switch Test Auto-stop Switch Test 1. Remove the headliner. 2. Disconnect the 2P connector from the moonroof auto-stop switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. - The auto-stop position is about 145 mm (5.75 in.) from fully closed. 4. If the continuity is not as specified, repair or replace the auto-stop switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 6475 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair Wind Deflector Replacement 1. Open the glass fully. 2. Remove the screws (A, B), and release the hooks (C), then remove the wind deflector (D). 3. Install the deflector (A) in the reverse order of removal, and check that the deflector arm base (B) and deflector link pivot base (C) line up with the same alignment lines (D). If necessary, adjust them forward or backward so the edge of the deflector seal (E) touches the roof panel (F) evenly. Each base must be moved the same amount for adjustment. If the deflector seal and roof panel make a rubbing sound, move the deflector backward as necessary to position it properly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel Sunroof / Moonroof Drain: Service and Repair Drain Channel Drain Channel Replacement 1. Remove the moonroof glass. 2. With the moonroof wrench, move both glass brackets (A) to the position where the moonroof normally pivots down, and remove the screws securing the drain channel (B). 3. Release the drain channel (A) from both hooks (B) of the drain channel slider by pulling the drain channel forward. 4. Remove the drain channel (A). 5. Install the channel in the reverse order of removal, and note these items: - Push the drain channel onto the hooks until a faint click is heard. - Check the glass height adjustment. 6. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 6483 Sunroof / Moonroof Drain: Service and Repair Frame and Drain Tube Frame and Drain Tube Replacement 1. Remove these items. - Headliner - Moon roof glass 2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/close-tilt/close switch connector (B), moonroof control unit connector (C), auto-stop switch connector (D), and the drain tubes (E), and remove the moonroof relays (F). 3. Remove the interior harness (G) by detaching the harness clips (H). 4. With an assistant holding the frame (I), remove the bolts, starting at the rear, and release the rear hooks (J) by moving the frame forward, then remove the frame. 5. With the help of an assistant, carefully remove the frame through the passenger's door opening. Take care not to scratch the interior trim and body, or tear the seat covers. 6. To remove a front drain valve (A) from the body, remove the kick panel, left or right. Tie a string to the end of the drain tube, then pull the front drain tube (B) down out of the front pillar. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 6484 7. To remove a rear drain valve (A) from the cargo compartment, remove the rear side trim panel. Detach the clips (B), then remove the drain tube (C). 8. Install the frame and drain tube in the reverse order of removal, and note these items: - Before installing the frame, clear the drain tubes and drain valves using compressed air. - Check the frame seal. - Clean the surface of the frame. - When installing the frame, first attach the rear hooks into the body holes. - Make sure the connectors are plugged in properly. - When connecting the drain tube, slide it over the frame nozzle at least 10 mm (0.39 in.). - Install the tube clip (A) on the drain tube (B) as shown. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 6485 Sunroof / Moonroof Drain: Service and Repair Drain Channel Slider and Cable Assembly Replacement Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. Remove the screws (A, B), then remove the slide stops (C) and cable tube rear brackets (D). Remove the bolts (E) from the cable tube side bracket (F) and the cable tube mounting screws (G) from both sides of the frame (H). 4. Detach the open switch connector clip (I) from the frame. 5. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 6486 6. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). 7. Remove the drain channel slider (A) from the glass bracket (B). 8. Install the slider and cable assembly in the reverse order of removal, and note these items: - Damaged parts should be replaced. - Apply multipurpose grease to the glass bracket (A) and guide rail portion of the frame (B) indicated by the arrows. - Before reinstalling the motor, make sure both link lifters are parallel, and in the fully closed position. - Before reinstalling the motor, install the frame and glass, then check the opening drag. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair Frame and Drain Tube Replacement 1. Remove these items. - Headliner - Moon roof glass 2. Put on gloves to protect your hands. Disconnect the motor connector (A), open/close-tilt/close switch connector (B), moonroof control unit connector (C), auto-stop switch connector (D), and the drain tubes (E), and remove the moonroof relays (F). 3. Remove the interior harness (G) by detaching the harness clips (H). 4. With an assistant holding the frame (I), remove the bolts, starting at the rear, and release the rear hooks (J) by moving the frame forward, then remove the frame. 5. With the help of an assistant, carefully remove the frame through the passenger's door opening. Take care not to scratch the interior trim and body, or tear the seat covers. 6. To remove a front drain valve (A) from the body, remove the kick panel, left or right. Tie a string to the end of the drain tube, then pull the front drain tube (B) down out of the front pillar. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 6490 7. To remove a rear drain valve (A) from the cargo compartment, remove the rear side trim panel. Detach the clips (B), then remove the drain tube (C). 8. Install the frame and drain tube in the reverse order of removal, and note these items: - Before installing the frame, clear the drain tubes and drain valves using compressed air. - Check the frame seal. - Clean the surface of the frame. - When installing the frame, first attach the rear hooks into the body holes. - Make sure the connectors are plugged in properly. - When connecting the drain tube, slide it over the frame nozzle at least 10 mm (0.39 in.). - Install the tube clip (A) on the drain tube (B) as shown. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations 97. Middle of Roof Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 6494 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 6495 143. Moonroof Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 6496 Sunroof / Moonroof Module: Testing and Inspection Moonroof Control Unit Input Test 1. Remove the headliner. 2. Disconnect the 5P connector (A) from the control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the moonroof control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 6497 5. Disconnect the moonroof control unit 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, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Customer Interest for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing Child Seat: Customer Interest Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Customer Interest for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6507 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Customer Interest for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6508 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing Child Seat: All Technical Service Bulletins Restraints - Child Seat Anchor Locating Button Missing 05-016 May 17, 2005 Applies To: See VEHICLES AFFECTED Child Seat Anchor Locating Button Is Missing PROBLEM The small button on the rear seat-back cover that marks the location of each child seat LATCH lower anchor is missing. VEHICLES AFFECTED 2001-05 Accord - ALL 2001-05 Civic - ALL 2003-05 Civic Hybrid - ALL 2002-05 Civic Si - ALL 2001-05 CR-V - ALL 2003-05 Element - ALL 2001-05 Odyssey - ALL 2003-05 Pilot - ALL CORRECTIVE ACTION Replace the button. NOTE: Older vehicles have buttons without a child seat icon. The buttons in newer vehicles and the replacement buttons all have an icon. If your customer requests matching buttons, replace all the buttons at the same time as a set. PARTS INFORMATION Child Seat ISOFIX Button Kit: (Kit contains buttons in nine different colors; 10 buttons of each color.) P/N 070AZ-SHJA190, H/C 7979016 Child Seat ISOFIX Button Kit Replacement Parts: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6514 NOTE: For color information, refer to PIB A05-0005, Child Seat Anchor Buttons. Click PARTS, then click PARTS LIBRARY, then click Parts Bulletins. Select Child Seat Anchor Buttons from the list. (Each part contains fabric washers, button posts, and back portions.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: 82123-SDA-305ZA Defect Code: 07801 Symptom Code: 03220 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the rear seat-back cover just enough to allow access to the opening where the button will be attached: ^ Refer to Section 20, Rear Seat-back Cover Replacement, in the appropriate service manual, or ^ Online, enter keyword SEAT COVER, and select the appropriate Rear Seat-back Cover Replacement procedure from the list. 2. Select the appropriate button from the Child Seat Anchor Service Set. 3. Attach the button to the rear seat-back cover: ^ Place a fabric washer over the button post. ^ Insert the post through the opening in the cover. ^ Snap the back portion onto the post. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6515 4. Repeat steps 2 and 3 as needed for additional buttons. 5. Install the seat-back cover in the reverse order of removal. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Page 6516 Child Seat: Description and Operation Attachment points are provided for a rear seat mounted child restraint system which uses a top tether. The attachment points are located on the rear shelf, just behind the rear seat-back. When using a child seat with a top tether, install the child seat anchor plates securely. WARNING: Do not use the child seat anchor plate for any other purpose; it is designed exclusively for installation of a child seat. Additional information at Restraint Systems / Seat Belt Systems / Child Restraint. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Upholstery Wrinkle Information Seat Cover: Technical Service Bulletins Interior - Fabric Upholstery Wrinkle Information Use a Steamer to Smooth Out Fabric Upholstery A garment steamer and a stiff-bristle brush make a great team for removing those nasty wrinkles, lines, or impressions in fabric upholstery. You can buy an inexpensive, small, hand-held garment/ fabric steamer from a number of different manufacturers. Some of these units even come with a handy built-in brush. Once you've got your steamer, follow the manufacturer's instructions to get it ready for use. Then apply a generous amount of steam to the problem area. Keep the steamer moving slowly over the area until it's hot and moist. A Word of Caution: Go easy on the steam if you're cleaning the front passenger seat in a vehicle with side airbags. Moisture can adversely affect or damage the OPDS sensors in the seatback. While the area is hot and moist, use a stiff-bristle brush, or the built-in brush if your steamer has one, to work the fabric back and forth and up and down. Stubborn areas might need more steam and brushing, so be patient and stay with it. It's worth the effort. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover Seat Cover: Service and Repair Front Seat Cover Front Seat Cover Replacement For some models: SRS components are located in this area. Review the SRS component locations and the precautions and procedures in the SRS section before performing repairs or service. NOTE: - Take care not to tear the seams or damage the seat covers. - On the passenger's seat with side airbag, do not touch the OPDS sensor in the seat-back pad, and keep it away from oil. Oil can corrode the sensor causing it to fail. - Put on gloves to protect your hands. Seat-back Cover 1. Remove the front seat. 2. With side airbag: From under the seat cushion, detach the side airbag connector clip (A), and on the passenger's seat, detach the OPDS unit connector clip (B). Release the hook springs (C) from the seat cushion frame spring (D), then pull the guide cover (E) back, and remove the wire ties (F). The passenger's seat is shown, the driver's seat is symmetrical except it has no OPDS unit connector. 3. Fold the seat-back forward. 4. Release the hooks (A), and unzip the seat-back cover (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6523 5. Release the hooks (A) and hook springs (B), then loosen the seat-back cover (C). Pull the side airbag harness (D) and the OPDS harness (E) (passenger's seat) out through the guide cover (F) and holes (G). Take care not to bend the cable. 6. With side airbag. Remove the side airbag, and release the hooks (A) from the airbag module holder (B). 7. Pull back the seat-back cover (A) all the way around, and release the clips (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6524 8. Using a flat-tip screwdriver wrapped with protective tape, insert it into the hook portions (seven places) of the headrest rear trim (A) from the headrest front trim side. Pry up the hooks (B) to release the labs (C) of the headrest front trim (D) while pulling the headrest front trim forward, and remove the trim. 9. Unzip the headrest portion of the seat-back cover (A), then remove the zipper (B), and remove the cover. 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 until the hooks snap into place. - To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the clips, hooks, and hook springs. - Make sure the side airbag harness, OPDS harness (passenger's seal), and rear seal access cable (passenger's seat) are routed properly. - If necessary, reinitialize the OPDS control unit. Seat Cushion Cover 1. Remove the front seat. 2. Remove these items from the front seat: - Recline cover, driver's seat passenger's seat - Front seat belt buckle (see step 4 of Front Seat Belt Replacement). 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 spring, then pull the guide cover back, and remove the wire ties. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6525 4. Release the hooks (A). 5. Release the seat-back cover (A) from the cushion frame spring (B), and release the hooks (C) from under the seat cushion. 6. Remove the seat cushion cover (A) with the seat cushion pad from the seat cushion frame. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6526 7. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove the seat cushion cover (B). 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 before securing the clips and hooks. - Make sure the side airbag harness and OPDS harness (passenger's seat) are routed properly. - Replace any clips you removed with new ones (A). Install them with commercially available upholstery ring pliers (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6527 Seat Cover: Service and Repair Rear Seat-Back Cover Rear Seat-back Cover Replacement NOTE: - Take care not to tear the seams or damage the seal covers. - Put on gloves to protect your hands. 1. Remove the seat-back. 2. Remove the headrest. 3. Pull up the latch cover (A) to release the clips, then remove it. 4. Pull up the outside edge of the latch lever cover (A) to release the clips, and release the cover from the pivot pins (B) of the latch lever (C) while pulling the latch lever. 5. On right seat-back: Using a Torx T30 bit, remove the bolts, then remove the belt holder trim (A), and remove the trim from the center belt (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6528 6. Release the hook (A), and unzip the seat-back cover (B). The right seat-back is shown, the left seat-back is similar. 7. Pull back the edge of the seat-back cover (A), and release the clips (B). 8. Pull back the edge of the seat-back cover, and pull out the seat-back frame (A) from the seat-back pad (B), then pull out the headrest guide (C) while pinching the end of the guides, and remove them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6529 9. Remove the seat-back cover (A) from the seat-back pad (B). On right seat-back with center 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-back cover, make sure the material is stretched evenly over the pad before securing the hooks and clips. - On right seat-back: When installing the seat-back frame to the pad, slip the center belt through the hole in the seat-back cover and pad. - Replace any clips you removed with new ones. Install them with commercially available upholstery ring pliers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 6530 Seat Cover: Service and Repair Rear Seat Cushion Cover Rear Seat Cushion Cover Replacement 1. Remove the rear seat cushion. 2. Release all the clips (A) from under the seat cushion, and fold back the seat cushion cover (B). 3. Pull back the edge of the seat cushion cover all the way around, and release the clips (A), then remove the seat cushion cover. 4. Install the cover in the reverse order of removal, and note these items: - To prevent wrinkles, make sure the material is stretched evenly over the pad before securing the clips. - Replace any clips (A) you removed with new ones. Install them with commercially available upholstery ring pliers (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair Rear Seat-back Latch Replacement 1. Remove the seat-back. 2. Remove the seat-back cover. 3. Remove the seat-back pad (A) from the seat-back frame (B). On right seat-back with center shoulder belt, pass the center belt (C) through the hole in the seat-back pad. 4. Remove the bolts, then remove the seat-back latch (A) from the seat-back frame (B), and release the pivot pin (C) of the latch lever (D) from the seat-back frame. 5. Install the latch in the reverse order of removal, and make sure the seat-back locks and unlocks properly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Heated Mirror Switch > Component Information > Locations Power Mirrors - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Heated Mirror Switch > Component Information > Locations > Page 6538 Heated Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations 86. Driver's Door (Passenger's Similar) 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6542 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6543 Power Door Lock Switch: Diagrams 98. Door Lock Knob Switch, Driver's 99. Door Lock Switch, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Test Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Disconnect the 3P connector from the actuator. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the door lock knob switch is in the LOCKED position. - There should be no continuity when the door lock knob switch is in the UNLOCKED position. 4. Check for continuity between the No. 2 and No. 3 terminals. - There should be continuity when the door lock knob switch 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. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Door Lock Knob Switch Test > Page 6546 Power Door Lock Switch: Testing and Inspection Door Lock Switch Test Door Lock Switch Test 1. Remove the driver's door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when the door lock switch is in the LOCKED position and no continuity in the neutral position. - There should be continuity between the No. 2 and No. 3 terminals when in the door lock switch is in the UNLOCKED position and no continuity in the neutral position. 4. If the continuity is not as specified, replace the door lock switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 6550 171. Power Mirror Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 6551 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test 1. Remove the driver's pocket. 2. Reach through the pocket opening, and push out the power mirror switch (A). 3. Disconnect the 13P connector (B) from the switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the power mirror switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6558 123. Moonroof Limit Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6559 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test 1. Remove the headliner. 2. Disconnect the 4P connector from the moonroof limit switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. 4. If the continuity is not as specified, replace the moonroof limit switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6560 Sunroof / Moonroof Limit Switch: Adjustments Limit Switch Adjustment 1. Remove the headliner. Fully closed position adjustment 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the limit switch mounting bolts (C). 4. Adjust the limit switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the position switch (open/close). - Check that the switch plate contacts the switch bracket (G). Auto-stop position adjustment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 6561 5. With the moon roof wrench, operate the glass (A) to the auto-stop position. 6. With an open-end wrench, loosen the auto-stop switch mounting bolts (C). 7. Adjust the auto-stop switch (D): - Move the switch plate (E) a little at a time, then secure it at the position where you hear a faint click when the switch cam (F) pushes the switch (auto-stop). - Check that the switch plate contacts the switch bracket (G). 8. Check the operation of the glass by operating the moonroof switch: From the tilt-up position to the fully closed position, from the fully open position to the auto-stop position, from the auto-stop position to the fully closed position. 9. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Switch: Component Locations 95. Front of Roof 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6566 97. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6567 Moonroof - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 6568 96. Middle of Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 6569 Sunroof / Moonroof Switch: Diagrams 50. Moonroof Auto-stop Switch 144. Moonroof Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement Sunroof / Moonroof Switch: Testing and Inspection Switch Test/Replacement Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Switch Test/Replacement > Page 6572 Sunroof / Moonroof Switch: Testing and Inspection Auto-Stop Switch Test Auto-stop Switch Test 1. Remove the headliner. 2. Disconnect the 2P connector from the moonroof auto-stop switch. 3. Check for continuity between the terminals in each switch position according to the table. NOTE: Turn the motor by hand with the wrench. - The auto-stop position is about 145 mm (5.75 in.) from fully closed. 4. If the continuity is not as specified, repair or replace the auto-stop switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Testing and Inspection > Page 6573 Sunroof / Moonroof Switch: Service and Repair Switch Test/Replacement 1. Carefully pry the moonroof switch (A) out of the headliner. 2. Disconnect the 5P connector (B) from the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the moonroof switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations Trunk / Liftgate Switch: Component Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 6578 Interior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 6579 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Component Locations > Page 6580 111. Middle of Hatch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 6581 41. Hatch Latch Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 6582 Trunk / Liftgate Switch: Testing and Inspection Hatch Latch Switch Test 1. Open the hatch. 2. Remove the hatch lower trim panel. 3. Disconnect the 2P connector (A) from the hatch latch (B), 4. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the hatch open. - There should be no continuity with the hatch closed. 5. If the continuity is not as specified, replace the hatch latch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Hatch Spoiler Replacement NOTE: Put on gloves to protect your hands. 1. Remove the hatch upper trim. 2. Remove the high mount brake light. 3. From inside the hatch, remove the bolts (A) and nuts (B). 4. From inside the hatch, release the clips, while pulling the hatch spoiler (A) away, and release the fasteners (B), then remove the spoiler. Take care not to scratch the body. 5. Install the spoiler in the reverse order of removal, and note these items: - Replace any damaged clips. - Replace any damaged fasteners. - Before installing the fastener to the spoiler, clean the spoiler bonding surface with a sponge dampened in alcohol. Attach the fastener to the spoiler with adhesive tape. Adhesive tape: Thickness 0.8 mm (0.031 in.) Width 24 mm (0.94 in.) - Push the clips and fasteners into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair Removal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 6590 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse, and leave the transmission mount bracket attached to the front side frame. - Check the wheelhouse upper extension and damper housing position, and check for damage. If necessary, remove the wheelhouse upper member, and replace the damper housing and wheelhouse upper extension as an assembly. If possible. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 6591 - Replace the wheelhouse upper extension, damper housing and damper housing extension as an assembly. - Check the transmission mount bracket position, and check for damage. If necessary, replace it. Installation 1. Set the new damper housing assembly, front wheelhouse and front bulkhead into position, and measure the front compartment diagonally. Check the body dimensions. 2. Tack weld the clamped position. 3. Temporarily install the front subframe, and check the front side frame position. 4. Temporarily install the hood, front fender, headlight, and front bumper, and check for differences in level and clearance. Make sure the body lines flow smoothly. 5. Do the main welding. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 6592 - Weld the damper housing and front side frame. - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, damper housing extension and wheelhouse upper extension. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 6593 - From the dashboard upper side, plug weld the holes in the damper housing. - Weld the front wheelhouse, damper housing, and front side frame. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 6594 - Weld the wheelhouse upper member. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Tailgate Lock Cylinder: Customer Interest Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6604 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6605 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6606 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6607 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6608 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6609 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6610 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6611 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6612 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6613 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6619 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6620 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6621 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6622 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6623 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6624 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6625 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6626 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6627 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind Tailgate Lock Cylinder: All Technical Service Bulletins Body - Door Lock Cylinders Bind 03-068 October 29, 2004 Applies To: See VEHICLES AFFECTED Door Lock Cylinder Binds (Supersedes 03-068, dated April 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM The key will not go into the door lock cylinder, or if it goes in, it will not turn. PROBABLE CAUSE The door lock tumblers are damaged or worn. VEHICLES AFFECTED CORRECTIVE ACTION Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6632 PARTS INFORMATION REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 72185-S9A-003 H/C 6896716 Defect Code: 00503 Symptom Code: 07902 Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6633 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made. 2. Use the chart shown to write down the numbers found in the key code book. 3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel. 4. Remove the plastic cover as necessary. 5. Raise the window glass fully. 6. Remove the lock cylinder. ^ For Civic, go to step 7. ^ For CR-V, go to step 8. ^ For Element, go to step 11. 7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6634 8. Release the clip, detach the hook, and remove the lock rod protector. 9. Disconnect the outer handle rod and cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6635 10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14. 11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward. 12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6636 13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14. 14. With the door lock cylinder out of the door handle remove the E-clip and the arm. 15. Try to insert the key into the cylinder and turn it. ^ If you can insert and turn the key, go to step 18. ^ If you cannot insert the key or turn it, go to step 16. 16. Carefully remove the spring and plastic retainer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6637 17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20. 18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6638 19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs. 20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.* NOTE: ^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J." ^ Cavity "E" is empty on all cylinders. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6639 ^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity. ^ Do not use the old inner cylinder, springs, or tumblers. ^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations. NOTE: If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6640 21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder. 22. Install the arm with a new cylinder rod clip and a new E-clip. 23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Lock Cylinder: > 03-068 > Oct > 04 > Body - Door Lock Cylinders Bind > Page 6641 24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place. 25. Civic: Reconnect the cylinder rod. 26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector. 27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel. 28. Reinstall the plastic covering, and lower the window glass. Install the door panel. 29. Check that the door lock and handle operate smoothly. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys Technical Service Bulletin # 01-077 Date: 060419 Ignition/Locks - Cutting Sidewinder-Type Keys 01-077 April 19, 2006 Applies To: Models With Sidewinder-Type Keys - All Cutting Sidewinder-Type Keys With the MATRIX H Key Cutting Machine (Supersedes 01-077, dated January 12, 2005) Updated information is noted by asterisks. MATRIX H Key Cutting Machine, manufactured by Silca and supplied by Kaba Ilco Corporation, is a portable, power-operated tool that cuts sidewinder-type automotive keys exclusively. The machine lets you cut these keys either by copying or by code. The code function is designed and built to meet the Honda code requirements. No other similar machine has this capability. This service bulletin gives you information for ordering and servicing this special tool, and guides you through the entire key cutting process from setting up the machine to cutting the key blank. TOOL INFORMATION Order through the Honda Tool and Equipment Program: MATRIX H Key Cutting Machine: Model No. ILCMATRIXSH Cutter Bit: Model No. ILCF3O Fixed Jaw: Model No. ILCMTX-H Mobile Jaw (Right Side): Model No. ILCRTMTX-H Mobile Jaw (Left Side): Model No. ILCLTMTX-H *Remanufactured Clamp Unit: Model No. ILCMATRIXHCR* PARTS INFORMATION *For some models, there are two choices for sidewinder-type key blanks: ^ T-5 sidewinder key blanks ^ Honda sidewinder key blanks For other models, only Honda sidewinder key blanks can be used. See DETERMINING WHICH KEY TO USE to determine which key blank you should choose. Ordering T-5 key blanks through the Honda Tool and Equipment Program: T-5 Programmable Key Blank (Master): P/N ILC-35111-T-5H T-5 Programmable Key Blank (Valet): P/N ILC-35112-T-5H Practice Key Blanks (five per pack): ILC-35111DEMO* NOTE: Do not use practice key blanks for replacement purposes. Practice keys do not have an immobilizer chip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6647 *T-5 Sidewinder Key Applications ^ 2003-05 Civic ^ 2004-05 Civic Hybrid ^ 2003-05 Civic GX (CNG) ^ 2004-05 S2000 ^ 2002-06 CR-V ^ 2003-06 Element ^ 2003-04 Odyssey ^ 2003-04 Pilot Ordering Honda key blanks through normal parts ordering channels: Refer to the parts catalog for correct key(s) for your application. PROGRAMMING KEYS Depending on the type of key blank you use, do this: ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), you must code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). ^ If you have used a Honda key blank, add the* transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ORDERING INFORMATION *To order the MATRIX H Key Cutting Machine, replacement cutter bits, fixed jaws and mobile jaws, T-5 programmable key blanks, and practice key blanks, contact the Honda Tool and Equipment Program by calling 888-424-6857 or using the fax order form provided in your Honda Tool and Equipment Program Catalog.* Order Honda key blanks through normal parts ordering channels. WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. *DETERMINING WHICH KEY TO USE T-5 keys require less time to program and should be the first choice. They can be used as long as the following requirements are met: ^ Do you have the customer's operating key? ^ Does the vehicle fall within the T-5 Sidewinder Key Applications? ^ Does your dealership have an Ilco Immobilizer Key Code Duplicator? If the answer to all three questions on the above is yes, the 1-5 key option is the easier procedure. If you answered no to any of the questions, you should order the key(s) from the parts catalogue, and program it using the HDS.* BEFORE YOU START CUTTING 1. Get the original key or the key number from your customer or from the iN. 2. Get the applicable key blank. 3. If cutting by code, look up the applicable 9-digit cutting code for the key number. Refer to the code book Honda High Security key Codes that comes with the machine. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6648 NOTE: You need to make the corrections listed in CODE BOOK CORRECTIONS at the end of this service bulletin. TRACER AND CUTTER BIT INSTALLATION 1. Turn the power switch on the back of the machine to ON. (This turns on the built-in work light.) 2. Use the Allen wrench from the built-in tool drawer to loosen the setscrew on the left sleeve of the vertical carriage. Slide the tracer all the way into the sleeve, and tighten the screw. 3. Turn the plastic shield on the right sleeve of the vertical carriage so you can access the setscrew on the sleeve. Use the Allen wrench to loosen the screw. Slide the cutter bit all the way into the sleeve, and tighten the screw. Turn the plastic shield so the open side is in the back. MACHINE COMPONENTS Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6649 Disclaimer Cutting Procedure - By Copying 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it all the way to the left until it stops. Turn the lever to the right to lock the clamp unit in place. 3. Use the clamp carriage lever to position the clamp unit so the tracer and cutter bit are centered directly over the base of the center and right jaws. 4. Pull the vertical carriage lever toward you until the tracer and the cutter bit just touch the base of each fixed jaw. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the arrow on the right of the keypad lights red, the tracer is not touching the fixed jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right three clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer three clicks lower than the cutter bit has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the setscrew, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. Tighten both the lateral and spring tension adjustment knobs. 8. Make sure the center and right jaws are free of any metal shavings or debris. (A soft-bristle toothbrush is ideal for this purpose.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6650 9. Open the jaws with the jaws knob, and slide the original key with its flat side down into the center jaw up to the key stop. Slide the key blank with its flat side down into the right jaw up to the key stop. Close the jaws with the jaws knob to lock the keys into place. Visually inspect both keys for proper alignment in the jaws. 10. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. With the clamp carriage lever, adjust the clamp carriage to position the tracer and the cutter bit over the middle of the two locked key blades. Tighten only the spring tension knob when done. NOTE: The clamp carriage has a spring system that puts lateral pressure on the tracer and cutting bit to make it easier to cut sidewinder-type keys. Do not tighten the lateral tension adjustment knob. This knob should be left loose. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6651 12. Pull the vertical carriage lever toward you while you position the tracer on the right edge of the original key at its head, using the clamp carriage lever. Let the cutter bit cut into the key blank, then stop. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 13. Use the clamp carriage lever and the tracer to follow the contours of the original key. (The cutter bit cuts the same contours into the key blank.) Working from right to left, follow the right edge of the original key from head to tip, then the left edge of the key from tip to head. Turn off the cutter motor. 14. Reposition the tracer on the right edge of the original key at its head, using the clamp carriage lever. Turn on the cutter motor. Retrace the key from head to tip, then from tip to head. (This retracing cleans up the cuts on the key.) Turn off the cutter motor. 15. Release the vertical carriage lever. Open the jaw and remove only the new key. Make sure the jaw is free of any metal shavings or debris, then turn the new key over and slide the key with its blank side up into the jaw up to the key stop. Close the jaw to lock the key into place. 16. Turn on the cutter motor, and repeat steps 12 thru 14 to cut both edges of the other side of the key. 17. When you are finished making the required cuts, turn off the cutter motor, and release the vertical carriage lever. Open the jaws, and remove the keys. 18. Use a wire brush to smooth the cut surfaces on the new key. 19. Make sure the key works in the ignition switch and all the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key blank you have used, do this: ^ If you have used a Honda key blank, add the transponder code of the new key to the immobilizer system with the Honda Diagnostic System (HDS). ^ If you have used a T-5 programmable key blank ("T-5" stamped on the shank), code the key's transponder with the Ilco Immobilizer Key Code Duplicator (see S/B 99-053, Ilco Immobilizer key Code Duplicator). Cutting Procedure - By Code 1. Press the ON/OFF button in the middle of the setting unit keypad. (This powers up the keypad.) 2. Turn the clamp unit lock lever to the left to release the clamp unit, and slide it to the right until the bottom left side is flush with the base edge. Turn the lever to the right to lock the clamp unit in place. Loosen the lateral and spring tension adjustment knobs on the clamp carriage. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6652 3. Use the clamp carriage lever to position the clamp unit so the tracer is directly over the flat surface of the code device, just ahead of the cam blades. 4. Pull the vertical carriage lever toward you until the tracer just touches the flat surface ahead of the cam blades. Watch the arrows on the keypad: ^ If the double-headed arrow in the middle of the keypad lights green, the tracer and cutter bit are properly aligned. ^ If the arrow on the left of the keypad lights red, the cutter bit is not touching the jaw. Turn the micrometric ring nut above the tracer to the left until the double-headed arrow lights green. ^ If the vertical arrow on the right of the keypad lights red, the tracer is not touching the jaw. Turn the micrometric ring nut above the tracer to the right until the double-headed arrow lights green. *5. Turn the micrometric ring nut to the right five clicks so the cutter bit is slightly higher than the tracer. The arrow on the left should light red. Raise the vertical carriage. NOTE: Setting the tracer five clicks lower than the cutter bit at this point has the effect of making the cutter bit cut the duplicated key a little shallower. This will protect the locking jaws from being damaged.* 6. Optional: Loosen the set screw, and adjust the hand rest to a comfortable position. Tighten the screw. 7. Pull the clamp carriage lever toward you until the clamp carriage clicks into its end-of-run position. 8. Clean any metal shavings or debris out of the center jaw. (A soft-bristle toothbrush is ideal for this purpose.) Then open the jaws with the jaws knob, and slide the key blank with its flat side down into the jaw up to the key stop. Close the jaw with the jaws knob to lock the key blank into place. Visually inspect the key for proper alignment in the jaw. 9. Set and lock the cam sets on the code device. ^ Starting with the left cam set, make sure the lock pin is pulled all the way out. (This releases the cams.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6653 ^ Going from front to back, use the middle lock pin to set the first cam to the appropriate key code number in the code book. (The cam is properly set when the number on the cam lines up with the red scribe mark on the clamp unit.) ^ Slide the lock pin through the notch in the cam. (This locks the cam in place.) ^ Keep doing this for each of the remaining cams in the set until all the cams are set and locked, then push the lock pin all the way in. Repeat this process to set and lock the cams for the right cam set. NOTE: Make sure you set the MIS cam in the right cam set for the type of key you are cutting. For a master key, set the cam to M; for a valet key, set it to S. When you are done, push all the cam blades to the left until they touch the cams in the left cam set. 10. Pull the vertical carriage lever toward you until the tracer touches the flat surface on the right side at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 11. Turn on the cutter motor with the motor start switch. [NOTICE] ^ To avoid damaging the locking jaws while cutting, keep your hand off the vertical carriage lever. Pressure on the lever will change the cutting depth. * ^ To avoid breaking the cutter bit, never back up while cutting.* ^ Wear proper eye protection (safety glasses, goggles, etc.) 12. Use the clamp carriage lever and the tracer to follow the contours of the cam blades from front to back. (The cutter bit cuts the same contours into the right edge of the key blank, from head to tip.) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6654 13. After completing the right edge, push all of the cam blades to the right until they touch the cams, then trace the cam blades from back to front. (The cutter bit cuts the same contours into the left edge of the key from tip to head.) Turn off the cutter motor. 14. Release the vertical carriage lever. Push all the cam blades to the left until they touch the cams. Pull the vertical carriage lever towards you until the tracer touches the flat surface on the right side, at the front of the cams. Gently twist the lever clockwise to lock the vertical carriage at this height. Do not overtighten the lever. 15. Turn on the cutter motor, then retrace the cam blades from front to back. Push all the cam blades to the right until they touch the cams, and then retrace the cam blades from back to front (retracing cleans up the cuts on the key). Turn off the cutter motor. 16. Release the vertical carriage lever. Open the jaw and remove the key. Make sure the jaw is free of any metal shavings or debris. Turn the key over so the blank side is up, then slide it into the jaw up to the key stop. Close the jaw to lock the key in place. 17. Push all the cam blades to the left until they touch the cams. Repeat steps 10 through 15 to cut both edges on the other side of the key. 18. When you are done making the required cuts, release the vertical carriage lever. Open the jaw and remove the key. 19. Make sure the key works in the ignition switch and the locks. If the key does not work, recut the key, and try it again. 20. Depending on the type of key, code the key transponder. Equipment Service and Warranty To service the MATRIX H Key Cutting Machine, refer to section 7 of the MATRIX H Operating Manual. It tells you how to replace parts that commonly wear out such as the drive belt, the work light bulb, and the tension spring on the vertical carriage. It also covers checking and replacing fuses and replacing the printed circuit board for the setting unit keypad. If you have technical questions on the equipment, contact the Ilco Technical Assistance Department. Mail: Kaba Ilco Technical Assistance Department 400 Jeffreys Road Rocky Mount, NC 27804 Phone: 800-452-6872 Ext: 200, 384, 323, 398, 356 Fax: 252-446-4702 The MATRIX H Key Cutting Machine comes with a 3-year limited warranty. This warranty does not cover the cutter bit or the work light bulb. CODE BOOK CORRECTIONS In the code book Honda High Security key Codes, correct these errors: Pages 4 thru 51, code headings: ^ Incorrect: J H G F Z X E D C B M/S X ^ Correct: J H G F A X E D C B M/S X Page 2, last paragraph: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate Lock Cylinder: > 01-077 > Apr > 06 > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6655 ^ Incorrect: "If a Master Key is to be cut, put a five (5) in the blank space. Use a two (2) if a valet key is needed." ^ Correct: "If a Master Key is to be cut, put an M in the blank space. Use an S if a valet key is needed." Page 2, legend at the bottom: ^ Incorrect: "C. If a Master key is desired, then the number five (5) should be placed in the M/S position. Place the number two (2) in the M/S column if a Sub (Valet) key is needed." ^ Correct: "C. If a Master Key is desired, then an M should be placed in the M/S position. Place an S in the MIS column if a Sub (Valet) key is needed." Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Cowl Cover Replacement 1. Remove the windshield wiper arms. 2. Remove the windshield side trim from both sides. 3. Pull the hood rear seal (A) away from the cowl covers, then remove it, and using a clip remover, detach the clips (B) from the cowl covers. Take care not to scratch the cowl covers. 4. Detach the clips (C, D, E) by carefully pulling the passenger's cowl cover (F) upward, to release the hooks (G), and pull the cover forward to release the hooks (H), then remove the cover. Take care not to scratch the body. 5. Detach the clips (C, D, E) by carefully pulling the driver's cowl cover (I) upward, then pull the cover forward to release the hooks (J), and remove the cover. Take care not to scratch the body. 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the A-pillar, remove the door stop mounting bolt (A). 2. Detach the clips (B, C), then remove the door weatherstrip (D). 3. Install the weatherstrip in the reverse order of removal and note these items: - Replace any damaged clips. - Make sure the weatherstrip is installed in the holder (E) securely. - Apply liquid thread lock to door stop mounting bolt before installation. - Check for water leaks (see step 7 of Door Glass Adjustment). - Test-drive and check for wind noise. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair 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. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Hatch Weatherstrip Replacement 1. Remove the hatch weatherstrip (A) by pulling out on it. 2. Locate the painted alignment mark (B) 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 in the direction shown. Make sure there are no wrinkles in the weatherstrip. 3. Check for water leaks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 6678 Clutch Switch: Diagrams 28. Clutch Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 6679 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations 66. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 6683 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 6684 177. Cruise Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Cruise Control Servo: Locations 25. Under Right Side of Cowl Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6688 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6689 Cruise Control Servo: Diagrams 121. Cruise Control Actuator Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6690 Cruise Control Servo: Testing and Inspection Cruise Control Actuator Test 1. Disconnect the 4P connector (A) from the cruise control actuator (B). 2. Remove the cover (A), and check the output linkage (B) for smooth movement. 3. Connect battery power to the No. 2 terminal and ground to the No. 1 terminal. 4. Check for a clicking sound from the magnetic clutch. The output linkage should be locked. 5. If the output linkage is not locked, replace the cruise control actuator assembly. 6. Check the operation of the actuator motor in each output linkage position according to the table. You should hear the motor. 7. If the actuator motor does not operate as specified, replace the cruise control actuator assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6691 Cruise Control Servo: Service and Repair Cruise Control Actuator/Cable Replacement 1. Fully open the cruise control link by hand, then remove the cruise control cable (A) from the link. Loosen the locknut (B), and remove the cable from the bracket. 2. Disconnect the 4P connector, and remove the three bolts securing the cruise control actuator. 3. Remove the actuator cover (A), then remove the actuator cable (B) from the cruise control actuator. 4. Install in the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments Cruise Control Actuator Cable Adjustment 1. Check that the actuator cable (A) moves smoothly with no binding or sticking. 2. Start the engine. 3. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase. At first, the output linkage should be located at the fully closed position (C). The free play (D) should be 3.75 ± 0.5 mm (0.15 ± 0.02 in.). 4. If the free play is not within specs, loosen the locknut (E), and turn the adjusting nut (F) until the free play is as specified, then retighten the locknut. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 6695 Cruise Control Servo Cable: Service and Repair Cruise Control Actuator/Cable Replacement 1. Fully open the cruise control link by hand, then remove the cruise control cable (A) from the link. Loosen the locknut (B), and remove the cable from the bracket. 2. Disconnect the 4P connector, and remove the three bolts securing the cruise control actuator. 3. Remove the actuator cover (A), then remove the actuator cable (B) from the cruise control actuator. 4. Install in the reverse order of removal, and adjust the free play at the throttle linkage after connecting the actuator cable. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 79. Inside Steering Wheel 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6699 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6700 Cruise Control Switch: Diagrams 122. Cruise Control Set/Resume/Cancel Switch 136. Cruise Control Main Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch Cruise Control Switch: Testing and Inspection Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch > Page 6703 Cruise Control Switch: Testing and Inspection Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch Cruise Control Switch: Service and Repair Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch > Page 6706 Cruise Control Switch: Service and Repair Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations 66. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 6711 Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 6712 177. Cruise Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations 65. Under Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 6720 Clutch Switch: Diagrams 28. Clutch Pedal Position Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 6721 Clutch Switch: Testing and Inspection Clutch Pedal Position Switch Test 1. Disconnect the 2P connector from the clutch pedal position switch (A). 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch pedal position switch. - If OK, install the clutch pedal position switch, and adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 79. Inside Steering Wheel 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6725 Cruise Control - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6726 Cruise Control Switch: Diagrams 122. Cruise Control Set/Resume/Cancel Switch 136. Cruise Control Main Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch Cruise Control Switch: Testing and Inspection Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Testing and Inspection > Cruise Control Master Switch > Page 6729 Cruise Control Switch: Testing and Inspection Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch Cruise Control Switch: Service and Repair Cruise Control Master Switch Cruise Control Master Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Release the clips of the cruise control master switch and push the cruise control master switch (A) out of the panel, then disconnect the 5P connector (B) from the cruise control master switch. 3. Check for continuity between the terminals in each switch position according to the table. If the continuity is not as specified, replace illumination bulbs (C) or the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Cruise Control Master Switch > Page 6732 Cruise Control Switch: Service and Repair Cruise Control Set/Decel, Resume/Accel, Cancel Switch Cruise Control Set/decel, Resume/Accel, Cancel Switch Test/Replacement 1. Remove the two screws, then remove the switch. 2. Check for continuity between the terminals in each switch position according to the table. - If there is continuity, and it matches the table, but switch failure has occurred during the cruise control unit input test, check and repair the switch circuit. - If there is no continuity in one or both positions, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Brake Warning Indicator: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Brake System Indicator Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Cigarette Lighter: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 27. Cigarette Lighter (Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Cigarette Lighter: Electrical Diagrams Diagram 155-0 Diagram 155-1 (Honda Accessory) Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6813 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6814 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 6818 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 6819 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 6820 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6824 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6825 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07AAA-S0XA100 NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel (A) from the floor. 6. Disconnect the fuel pump 5P connector (B). 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is as specified, go to step 8. - If the voltage is not as specified, check for: an open in the YEL/BLK or BLK wire. - poor ground (G 551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6826 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer does not indicate "F", replace the gauge. - If the pointer indicates "F", inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6827 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the above readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6828 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07AAA-S0XA100 See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions 1. Relieve the fuel pressure.See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 6829 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install the fuel tank unit in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming General Precautions Please read the following precautions carefully before performing airbag system service. Observe the instructions described, or the airbags could accidentally deploy and cause damage or injuries, - Except when performing electrical inspections, always turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning work. NOTE: The SRS memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. - Use replacement parts which are manufactured to the same standards and quality as the original parts. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. - Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks, or deformation. - Before removing any SRS parts (including the disconnection of connectors), always disconnect the SRS connector. - Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. - Do not put objects on the front passenger's airbag. - The original radio has a coded theft protection circuit. Be sure to get the customer's radio code and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable. - Before returning the vehicle to the customer, enter the radio code, then enter the customer's radio station presets, and set the clock. Do the engine control module (ECM) idle learn procedure. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6835 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Spring-loaded Lock Connector Some SRS system connectors have a spring-loaded lock. Front Airbag Connectors Disconnecting To release the lock, pull the spring-loaded sleeve (A) toward the stop (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector. Connecting 1. To reconnect, hold the pawl-side connector, and press on the back of the sleeve-side connector in the direction shown. As the two connector halves are pressed together, the sleeve (A) is pushed back by the pawl (C). Do not touch the sleeve. 2. When the connector halves are completely connected, the pawl is released, and the spring-loaded sleeve locks the connector. Side Airbag Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 6836 Disconnecting To release the lock, pull the spring-loaded sleeve (A) and the slider (B) while holding the opposite half of the connector. Then pull the connector halves apart. Be sure to pull on the sleeve and not on the connector half. Connecting Hold both connector halves, and press them firmly together until the projection (C) of the sleeve-side connector clicks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Gauge Bulb Replacement Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations 72. In Steering Column Cover Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 6843 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 6844 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations > Page 6845 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch, the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the multiplex control unit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed from the ignition switch. 4. If the continuity is not as specified, replace the ignition switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection Low Fuel Indicator Test 1. Do the fuel gauge sending unit test. - If the system is OK, go to step 2. - If the system has any malfunction, repair it. 2. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 30 seconds, then reinstall it. 3. Turn the ignition switch ON (II) with the float at the E (EMPTY) 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 and check the circuit. 4. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 30 seconds, then reinstall it. 5. Lift the float above the LOW position. - If the low fuel indicator goes off, the system is OK. - If the low fuel indicator is still on, refer to the low fuel indicator Circuit Diagram, and check the circuit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Resetting the Maintenance Required Indicator How to Reset Push and hold the trip/reset button, turn the ignition switch ON (II), and continue to hold the button for more than 10 seconds. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Indication (In relation to Readiness Codes) The vehicle has certain "readiness codes" that are part of the on-board diagnostics for the emissions systems. If the vehicle's battery has been disconnected or gone dead, if the DTCs have been cleared, or if the ECM has been reset, these codes are set to incomplete. In some states, part of the emissions; testing is to make sure these codes are set to complete. If all of them are not set to complete, the vehicle may fail the test or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are set to complete. If it blinks several times, on 2 or more readiness codes are not set to complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6855 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect the HDS or a scan tool. 2. Turn the ignition switch ON (II) and read the HDS or a scan tool. Does the HDS or a scan tool communicate with the ECM? YES - Go to step 3. NO - Go to troubleshooting "DLC Circuit Troubleshooting". 3. Check the HDS or a scan tool for DTCs. Are any DTCs indicated? YES - Go to the DTC Troubleshooting Index. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions NO - Go to step 4. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON (II) and watch the malfunction indicator lamp (MIL). Does the MIL come on and stay on for more than 20 seconds after turning the ignition switch ON (II)? YES - If the MIL always comes on and stays on, go to step 76. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM (E29) and the data link connector (DLC). - An intermittent short in the wire between the ECM (E31) and the gauge assembly. NO - If the MIL is always off, go to step 6. But if the MIL sometimes works normally, first check for these problems. A loose No.10 METER (7.5A) fuse in the under-dash fuse/relay box. - A loose No.20 IG (40A) (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 connection at ECM terminal E31. - An intermittent open in the GRN/ORN wire between the ECM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM (A21) and the manifold absolute pressure (MAP) sensor. - An intermittent short in the wire between the ECM (A20) and the throttle position (TP) sensor. - An intermittent short in the wire between the ECM (E5) and the fuel tank pressure (FTP) sensor. 6. Turn the ignition switch OFF. 7. Turn the ignition switch ON (II). Is the low oil pressure light on? YES - Go to step 10. NO - Go to step 8. 8. Inspect the No.10 METER (7.5A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 9. NO - Repair short in the wire between No.10 METER (7.5A) fuse and the gauge assembly. Also replace the No.10 METER (7.5A) fuse. 9. Inspect the No.20 IG1 (40A) (Canada: 50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (40A) (Canada: 50A) fuse and the gauge assembly. If the wire is OK, test the ignition switch. NO - Repair short in the wire between No.20 IG (40A) (Canada: 50A) fuse and the under-dash fuse/relay box. Also replace the No.20 IG (40A) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6856 (Canada: 50A) fuse. 10. Try to start the engine. Does the engine start? YES - Go to step 11. NO - Go to step 14. 11. Turn the ignition switch OFF. 12. Connect ECM connector terminal E31 to body ground with a jumper wire. 13. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Check for an open in the wire between the ECM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 14. Turn the ignition switch OFF. 15. Inspect the No.6 ECU (ECM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 16. 16. Remove the blown No.6 ECU (ECM) (15A) fuse from the under-hood fuse/relay box. 17. Remove the glove box and PGM-FI main relay 1. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6857 18. Check for continuity between body ground and PGM-FI main relay 14P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM) (15A) fuse and the PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or the connectors below, one at a time, and check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM connector A (31P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft Position (CMP) sensor B 3P connector - Crankshaft position (CKP) sensor 3P connector Is there continuity? YES - Go to step 20. NO - Replace the component that made continuity to body ground go away when disconnected. If the item is the ECM, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Also replace the No.6 ECU (ECM) (15A) fuse. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM connector A (31P) - Injectors - Idle air control (IAC) valve - Camshaft Position (CMP) sensor B - Crankshaft position (CKP) sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6858 21. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM) (15A) fuse. NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse from the under-dash fuse/relay box. 24. Disconnect ECM connector E (31P). 25. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 26. Remove the PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6859 27. Check for continuity between ECM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9), or between the No.17 FUEL PUMP (15A) fuse and the PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 28. 28. Remove the rear seat cushion. 29. Remove the access panel from the floor. 30. Disconnect the fuel pump 5P connector. 31. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Repair short in the wire between the fuel pump and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 32. 32. Reinstall PGM-FI main relay 2 (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6860 33. Check for continuity between fuel pump 5P connector terminal No.5 and body ground. Is there continuity? YES - Replace PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Check the fuel pump, and replace it if necessary. Also replace the No.17 FUEL PUMP (15A) fuse. 34. Disconnect ECM connector E (31P). 35. Turn the ignition switch ON (II). 36. Measure voltage between ECM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 37. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM (E9). 37. Measure voltage between ECM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 42. NO - Go to step 38. 38. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6861 39. Remove PGM-FI main relay 1 (A). 40. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 41. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 41. Check for continuity between PGM-FI main relay 1 4P connector terminal No.3 and ECM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (E7). 42. Reconnect ECM connector E (31P). 43. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6862 44. Measure voltage between body ground and ECM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 51. NO - Go to step 45. 45. Turn the ignition switch OFF. 46. Remove PGM-FI main relay 1 (A). 47. Turn the ignition switch ON (II). 48. Measure voltage between PGM-FI main relay 14P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 49. NO - Repair open in the wire between the No.6 ECU (ECM) (15A) fuse and PGM-FI main relay 1. 49. Turn the ignition switch OFF. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6863 50. Check for continuity between PGM-FI main relay 14P connector terminal No.1 and ECM connector terminals A2 and A3 individually. Is there continuity? YES - Replace PGM-FI main relay 1. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM (A2, A3). 51. Measure voltage between body ground and ECM connector terminals A4, A5, A23, and A24 individually. Is there more than 1.0 V? YES - Go to step 52. NO - Repair open in the wire(s)that had more than 1.0 V between G101 and the ECM (A4, A5, A23, A24). 52. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Go to step 60. NO - Go to step 53. 53. Turn the ignition switch OFF. 54. Disconnect the manifold absolute pressure (MAP) sensor 3P connector. 55. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6864 56. Measure voltage between body ground and ECM connector terminal A21. Is there about 5 V? YES - Replace the MAP sensor. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect ECM connector A (31P). 59. Check for continuity between ECM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A21) and the MAP sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 60. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 61. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6865 61. Turn the ignition switch OFF. 62. Disconnect the throttle position (TP) sensor 3P connector. 63. Turn the ignition switch ON (II). 64. Measure voltage between body ground and ECM connector terminal A20. Is there about 5 V? YES - Replace the throttle body (the TP sensor is not available separately). NO - Go to step 65. 65. Turn the ignition switch OFF. 66. Disconnect ECM connector A (31P). 67. Check for continuity between ECM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM (A20) and the TP sensor, or repair short in the wire between the ECM (A8) and the knock sensor. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. 68. Measure voltage between body ground and ECM connector terminal E5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6866 Is there about 5 V? YES - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). 72. Measure voltage between body ground and ECM connector terminal E5 Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF 74. Disconnect ECM connector E (31P). 75. Check for continuity between ECM connector terminal E5 and body ground Is there continuity? YES - 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. If the symptom/indication goes away with a known good ECM, replace the original ECM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 6867 78. Measure voltage between ECM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM connector E (31P). 81. Check for continuity between ECM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the data link connector (DLC) and the ECM (E29). NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. 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 (31P). 84. Turn the ignition switch ON (II). Does the MIL stay on? YES - Repair short in the wire between the gauge assembly and the ECM (E31). If the wire is OK, replace the gauge assembly. NO - Update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the symptom/indication goes away with a known-good ECM, replace the original ECM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Recalls: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension Odometer: Recalls Campaign - Vehicle Warranty Mileage Extension 06-085 May 9, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: Vehicle Warranty Mileage (Supersedes 06-085, dated January 22, 2008, to update the information marked by asterisks) BACKGROUND On December 29, 2007, a federal court provided final approval of the settlement of a class action lawsuit alleging that the odometers on certain 2002 through 2006 Honda models, and some 2007 Fit models, were overstating mileage. As part of the settlement, American Honda is extending the mileage-based coverage period of all warranties, Honda Care Service Contracts, and Honda Certified Used Vehicles by 5 percent on the above referenced vehicles. The time limits for all warranties are unchanged. VEHICLES AFFECTED The vehicles affected by this settlement include certain 2002 through 2006 Honda models and some 2007 Fit models purchased or leased between April 13, 2002, and November 7, 2006. The affected region is the United States (including the District of Columbia, Puerto Rico, and the U.S. Virgin Islands). Affected vehicles registered to customers with a military or a NATO address are also included in this settlement. The most effective way to check a vehicle's warranty coverage is by a VIN status inquiry. CUSTOMER NOTIFICATION American Honda notified affected customers by mail or publication. The notices were sent to original registered purchasers, informing them of the terms of the settlement. Notice was also published in a national newspaper. To view the content of the mailed notice, as well as other documents regarding the settlement, or for additional information, please refer to these sources: Website: www.odosettlementinfo.com Information Center: (888) 888-3082 CORRECTIVE ACTION *On affected vehicles, the settlement requires you to honor a 5 percent increase in the mileage coverage period for all warranties, all Honda Certified Used Vehicles, and those Honda Care Service Contracts purchased only by the original owners.* WARRANTY CLAIM INFORMATION Use the chart as a reference for converting most standard warranty mileage limits to the extended mileage coverage. Use the chart as a reference to all service bulletins affected by the extended mileage coverage. In addition to the 5 percent mileage increase in warranty coverage, any repair performed after warranty expiration may be eligible for goodwill Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Recalls: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension > Page 6876 consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. WARRANTY MILEAGE CONVERSION NOTE: Follow normal warranty claim coding when submitting a claim. SERVICE BULLETINS AFFECTED BY EXTENDED MILEAGE COVERAGE Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension Odometer: All Technical Service Bulletins Campaign - Vehicle Warranty Mileage Extension 06-085 May 9, 2008 Applies To: See VEHICLES AFFECTED Warranty Extension: Vehicle Warranty Mileage (Supersedes 06-085, dated January 22, 2008, to update the information marked by asterisks) BACKGROUND On December 29, 2007, a federal court provided final approval of the settlement of a class action lawsuit alleging that the odometers on certain 2002 through 2006 Honda models, and some 2007 Fit models, were overstating mileage. As part of the settlement, American Honda is extending the mileage-based coverage period of all warranties, Honda Care Service Contracts, and Honda Certified Used Vehicles by 5 percent on the above referenced vehicles. The time limits for all warranties are unchanged. VEHICLES AFFECTED The vehicles affected by this settlement include certain 2002 through 2006 Honda models and some 2007 Fit models purchased or leased between April 13, 2002, and November 7, 2006. The affected region is the United States (including the District of Columbia, Puerto Rico, and the U.S. Virgin Islands). Affected vehicles registered to customers with a military or a NATO address are also included in this settlement. The most effective way to check a vehicle's warranty coverage is by a VIN status inquiry. CUSTOMER NOTIFICATION American Honda notified affected customers by mail or publication. The notices were sent to original registered purchasers, informing them of the terms of the settlement. Notice was also published in a national newspaper. To view the content of the mailed notice, as well as other documents regarding the settlement, or for additional information, please refer to these sources: Website: www.odosettlementinfo.com Information Center: (888) 888-3082 CORRECTIVE ACTION *On affected vehicles, the settlement requires you to honor a 5 percent increase in the mileage coverage period for all warranties, all Honda Certified Used Vehicles, and those Honda Care Service Contracts purchased only by the original owners.* WARRANTY CLAIM INFORMATION Use the chart as a reference for converting most standard warranty mileage limits to the extended mileage coverage. Use the chart as a reference to all service bulletins affected by the extended mileage coverage. In addition to the 5 percent mileage increase in warranty coverage, any repair performed after warranty expiration may be eligible for goodwill Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension > Page 6882 consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. WARRANTY MILEAGE CONVERSION NOTE: Follow normal warranty claim coding when submitting a claim. SERVICE BULLETINS AFFECTED BY EXTENDED MILEAGE COVERAGE Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Updating Control Units And Modules 01-023 April 10, 2010 Applies To: Honda Vehicles With Programmable Control Units/Modules Updating Control Units/Modules (Supersedes 01-023, dated May 15, 2009, to revise the information marked by the black bars and asterisks) REVISION SUMMARY *^Under REQUIRED TOOLS AND EQUIPMENT, the MVCI was added. ^ Under UPDATING TIPS AND PRECAUTIONS MVCI information was added. ^ UPDATING WITH THE MVCI was added.* The procedures in this service bulletin are used and referenced in other service bulletins. Most 2002 and later Hondas have reprogrammable control units/modules. To update (reprogram) any of these control units/modules, you need the vehicle you're working on and one of these systems: *^MVCI unit with latest control module (CM) update software installed* ^ GNA600 gateway device and an iN workstation with the latest HDS software installed ^ HDS Tablet with the latest HDS software installed ^ HDS Pocket Tester with the latest HDS software installed ^ HIM and an iN workstation with the latest HDS software installed ^ A compatible J2534 device and a PC with Honda's J2534 software installed This service bulletin describes these subjects: ^ Who to contact for questions or problems when using Honda-supplied updating equipment or the iN. ^ Required Tools and Equipment - MVCI - GNA600 - HDS Tablet - HDS Pocket Tester - HIM ^ Updating Tips and Precautions ^ Updating with the MVCI ^ Updating with the GNA600 - GNA6OO Updating in Pass-Thru Mode - GNA6OO Updating in Storage Mode ^ Updating with the HDS Tablet and the HDS Pocket Tester Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6888 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6889 *MVCI: (Available through the Honda Tool and Equipment Program)* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6890 GNA600: (No longer available for purchase) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6891 HDS Tablet: HDS Pocket Tester: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6892 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6893 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6894 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6895 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6896 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6897 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6898 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6899 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6900 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6901 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6902 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6903 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6904 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6905 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6906 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6907 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6908 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6909 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6910 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Vehicle Won't Move/MIL ON/DTC P0730 04-036 January 7, 2005 Applies To: See VEHICLES AFFECTED Vehicle Does Not Move in Drive; MIL Comes On or D Indicator Blinks With A/T DTC P0730 (Supersedes 04-036, dated September 24, 2004) SYMPTOM The vehicle does not move when you select Drive. The MIL comes on ('01-03 models) or the D indicator blinks ('04 models) with "A" DTC P0730 (shift control system) set. PROBABLE CAUSE Excessive wear in the 2nd clutch. VEHICLES AFFECTED CORRECTIVE ACTION Replace the A/T. Use the Honda Interface Module (HIM) to update the PGM software ('01-03 models only). TOOL INFORMATION To do the repair procedure, you need these items: ^ Interactive Network (iN) CD (July '04 or later) ^ iN Workstation ^ Honda Interface Module (HIM): T/N EQS05A35570 ^ PC Interface Cable (RS232): T/N VET-02002832 [This is the same cable you use to connect the PCM Tester to the iN workstation when updating software or when downloading DTCs to American Honda. The cable is blue with an attached adapter.] ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N VET-02002426 (This is the same adapter used by the PGM Tester.) To order additional HIMs, interface cables, or A/C adapters, call the Honda Tool and Equipment Program or use the fax order form provided in your Honda Tool and Equipment Program Catalog. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m., Central Time. You can also order through the iN. Click on SERVICE, Service Bay, and then Tool and Equipment, or click on eMail and then Tool and Equipment Program. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 6915 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 6916 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6922 ^ Updating with the HIM - HIM Updating in Pass-Thru Mode - HIM Updating in Storage Mode - Diagnosing HIM Error Codes - HIM Self-Test NOTE: Whenever you install a new, reprogrammable control unit/module, check that it has the latest software, and update it if needed. WARRANTY CLAIM INFORMATION Skill Level: Repair Technician Refer to the specific service bulletin for the symptom you are repairing. QUESTIONS ABOUT THE UPDATING EQUIPMENT OR THE INTERACTIVE NETWORK For questions about the Honda-supplied updating equipment, call American Honda's Special Tools hotline. For questions about the iN, call the iN Support Center. REQUIRED TOOLS AND EQUIPMENT NOTE: Updating for most control units/modules can be done with any of the following tools. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6923 *MVCI: (Available through the Honda Tool and Equipment Program)* Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6924 GNA600: (No longer available for purchase) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6925 HDS Tablet: HDS Pocket Tester: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6926 HIM: UPDATING TIPS AND PRECAUTIONS ^ If you're updating a control module/unit on a new vehicle, make sure all its fuses were installed at PDI. ^ To prevent control unit/module damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, etc.) during the update. ^ Make sure the HDS Tablet, the HDS Pocket Tester, or the iN workstation has the latest version of HDS software. The HDS version number is on the HDS start-up screen. To find the latest HDS software information on ISIS, select Search by Vehicle, select Technical Library, expand the ServiceNews branch, select Keyword (All Models), enter keywords HDS VERSION, then select the latest article. NOTE: The screen is from an iN workstation. The HDS tablet and pocket tester screens are similar. *^Make sure the Database Update listed in a Honda service communication (service bulletin, product update, iN message, etc.) is the same or earlier than the ones listed on the Reprogramming screen of the MVCI (on the MVCI, select CM Update Mode, then select Reprogramming), or on the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6927 Updating Honda Control Modules screen on the HDS tablet, the HDS pocket tester, or the iN workstation. MVCI:* iN Workstation: NOTE: The HDS tablet and pocket tester screens are similar. *^If the Database Update listed in the service bulletin is later than that shown by the software, please see the the procedures for software installation in the following documents in Tool Information on ISIS (go to General Publications, then Tool Information): - MVCI User Guide (see HDS MVCI Firmware Update section) - Honda Diagnostic System (HDS) Tablet Setup Instructions - Installation Instructions for HDS ( see PC Software for the GNA600, HIM or Pocket Tester ID)* ^ Do not connect an additional power supply to the updating equipment when it is connected to the vehicle; power is supplied through the DLC. ^ To ensure that the control module/unit is not permanently damaged during updating, vedfy that the vehicle's 12-volt battery is fully charged before starthg an update. NOTE: If the vehicle's 12-volt battery drops below 10 volts during the update, the programming status bar may go past 100 percent, or the updating tool may display an error message. ^ If you have a problem during an update (D4/ immobilizer indicator flashes, update tool freezes, etc.), you can minimize the chances of damaging the control unit/module by doing one or more of these actions: - CRITICAL: Keep the ignition switch in ON (II). - Connect a jumper battery (DO NOT connect a battery charger). - Disconnect the updating tool from the vehicle's DLC. - Reboot the updating tool. - Reconnect the updating tool to the vehicle's DLC, and retry the updating procedure. *UPDATING WITH THE MVCI Make sure you have the latest control module (CM) Update software loaded from your HDS PC to your MVC I. For loading instructions and other Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6928 details, refer to the MVCI User Guide on ISIS. The Database Update version appears when you select Reprogramming, then press ENTER. 1. Connect the DLC cable to the MVCI and to the vehicle's DLC. 2. Turn the ignition switch to ON (II). The MVCI automatically boots up. 3. Press the ENTER button on the MVCI to see the User Config menu. Select CM Update Mode. 4. Select Reprogramming, then press ENTER. NOTE: Use these MVCI default settings: Setting 1Destination: USA Language: American English Setting 2 - Auto Detect: Yes Continuous Mode: No For more information on these settings, refer to the MVCI User Guide. 5. The CM Update software information appears. Press ENTER to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6929 NOTE: If the Database Update is an earlier version than the one listed in a Honda service communication (service bulletin, product update, iN message, etc.), press ESC, then update your MVCI before continuing. 6. Wait for the MVCI to check the vehicle for reprogrammable systems. This may take up to 90 seconds. 7. If there are multiple reprogrammable systems that need to be updated, select the applicable system. Press ENTER to continue, or press ESC to exit. 8. The current program ID, the recommended update, and other details appear. Press ENTER to continue, or press ESC to exit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6930 9. Wait for the MVCI to copy the data for updating the vehicle. 10. After the MVCI has copied the files, a confirmation screen appears. Press ENTER to update the control unit/module, or press ESC to exit. 11. Wait for the MVCI to update the control unit/module. 12. After the MVCI finishes updating the control uniti module, turn the ignition switch to LOCK (0) when directed by the MVCI. 13. Turn the ignition switch back to ON (II) within 60 seconds to complete the updating procedure. NOTE: The MVCI has a countdown timer. If you do not turn the ignition switch to ON (II) within 60 seconds, the MVCI sets an error code. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6931 14. After finishing the updating procedure, the MVCI gives you the option of updating the same system on another vehicle. For more information on updating several vehicles, see the MVCI User Guide. 15. If an error occurs during the updating procedure, an error message appears. Keep the ignition switch in ON (II). Press ENTER to display the error code. Refer to the CM Update Error Code Table in the MVCI User Guide for more information about the code and its solutions.* UPDATING WITH THE GNA600 NOTE: For more information on the GNA6OO, refer to the GNA600 User's Guide. This guide is on ISIS, under the Tool Information heading. Two modes of updating can be used with the GNA600: Pass-Thru mode and Storage mode. Use Pass-Thru mode when the GNA6OO can be connected to an iN workstation and the vehicle at the same time. Use Storage mode when the GNA6OO cannot be connected to the iN workstation and the vehicle at the same time. GNA600 Updating in Pass-Thru Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6932 NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-th ru-Mode. 5. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6933 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 9. Click on the check mark to begin the control uniti module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control uniti mod ule has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. GNA600 Updating in Storage Mode 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the ISIS publication Installation Instructions for HDS PC Software. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6934 NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the Tools button on the right side of the screen, and make sure the interface device is set to GNA600. 4. Return to the Updating Honda Control Modules main screen, then click on Storage Mode and follow the on-screen instructions. 5. Take the GNA600 to the vehicle. Connect the DLC cable to the GNA600 and to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA6OO stays on. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. 7. Connect the USB PC interface cable to the iN workstation and to the GNA6OO. Connect the power supply unit and power supply cord to the GNA600. The GNA600 does a self-check and, after about 30 seconds, its yellow No.1 and green No.2 LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6935 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the GNA600. 10. Disconnect the GNA600 from the USB PC interface cable, then connect the trigger switch adapter block (yellow) and the trigger switch to the GNA600 as shown below. (The DLC cable should still be connected to the GNA600.) 11. Reconnect the DLC cable to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.2 LED on the GNA600 stays on. Press and release the trigger switch button. 13. The yellow No.1 LED blinks, and the green No.2 LED stays on. This indicates that the control uniti module is being updated. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6936 NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the No.1 LED stays on and the No.2 LED goes off, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the No.1 and No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the DLC cable from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. UPDATING WITH THE HDS TABLET AND THE HDS POCKET TESTER NOTE: This procedure explains how to update with the HDS tablet. Updating with the HDS pocket tester is similar, but the user interface is modified to fit its smaller screen. 1. If not already done, load the latest HDS PC sofiware onto your HDS tablet or HDS pocket tester. Refer to the instructions included with the HDS Installation Disc. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. On the HDS Switchboard screen, click on the CM update icon. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6937 3. Turn the ignition switch to ON (II), and connect the DLC cable to the vehicle's DLC. In the Updating Honda Control Modules screen, click on the check mark. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the Systems one at a time. 4. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6938 5. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HDS tablet. 6. In the HDS Tablet Programming screen, click on the check mark after programming is completed. 7. In the Updating Honda Control Modules screen, click on the check mark. NOTE: To avoid permanent control module damage, do not turn the ignition switch to LOCK (0) during the update. 8. When updating is complete, follow the screen prompts to turn the ignition switch to LOCK (0), and then to ON (II). To update another system, return to the Updating Honda Control Modules screen by clicking on the exit button on the right side of the screen. UPDATING WITH THE HIM Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6939 Two updating modes can be used with the HIM: Pass-Thru mode and Storage mode. Pass-Thru mode is used when the HIM can be connected to an iN workstation and the vehicle at the same time. Storage mode is used when the HIM cannot be connected to the iN workstation and the vehicle at the same time. HIM Updating in Pass-Thru Mode NOTE: If the red No.3 LED on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC Software on ISIS. NOTE: If the latest software is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Connect the PC interface cable to the iN workstation and to the HIM. 4. Return to the Updating Honda Control Modules main screen, and click on Pass-thru-Mode. 5. Connect the HIM to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Click on the check mark to continue. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6940 NOTE: Update the systems one at a time. 7. Verify that the Program ID and the Program Part No. are for the vehicle you are updating, then click on the check mark. 8. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update sofiware loads the program file onto the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6941 9. Click on the check mark to begin the control unit/module update. NOTE: To avoid control unit/module damage, do not interrupt the update. 10. Within 60 seconds of update completion, turn the ignition switch to LOCK (0) and then back to ON (II). 11. Once the software verifies that the control unit/module has been successfully updated, click on Yes to update another identical vehicle, or click on No to exit the update program. HIM Updating in Storage Mode NOTE: If the red No.3 on the HIM comes on or flashes during the update, go to Diagnosing HIM Error Codes. 1. If not already done, load the latest HDS PC software onto your iN workstation. For loading instructions, refer to the Tool Information publication Installation Instructions for HDS PC So ftware on ISIS. NOTE: If the latest sofiware is not loaded and you do a control unit/module update, the software may indicate the vehicle has the latest update when it doesn't. Updates not done with the latest software are not covered under warranty. 2. From the iN workstation desktop, select CM Update (ECU Rewrite). 3. Click on the tools button on the right side of the screen, and make sure the interface device is set to HIM. 4. Return to the Updating Honda Control Modules main screen, then select Storage Mode and follow the on-screen instructions. 5. Take the HIM to the vehicle, and connect it to the vehicle's DLC. 6. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Turn the ignition switch to LOCK (0), and disconnect Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6942 the HIM from the vehicle. 7. Connect the PC interface cable to the iN workstation and to the HIM. Connect the power supply unit and power supply cord to the HIM. After several seconds, the green and yellow LEDs flash. Each updatable vehicle system is checked to make sure it is current. Any systems needing an update are listed on the screen. Highlight the system you want to update, then click on the check mark to continue. NOTE: Update the systems one at a time. 8. Verify that the Program ID and the Program Part No. are correct, then click on the check mark. 9. Confirm the control module update by Program ID and Program Part No. Make sure this corresponds with any information provided in the service bulletin for the update you are doing. Click on Yes to continue. Within a few seconds, the CM Update software loads the program file onto the HIM. 10. Disconnect the HIM from the PC interface cable. 11. Reconnect the HIM to the vehicle's DLC. 12. Turn the ignition switch to ON (II), and wait until the green No.1 LED on the HIM stays on. Press and release the ENTER button on the HIM. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6943 13. The green No.1 LED stays on, and the yellow No. 2 LED blinks. This indicates that the control uniti module is being updated. NOTE: To avoid control unit/module damage, do not interrupt the update. 14. When the yellow No.2 LED stays on, turn the ignition switch to LOCK (0). 15. Turn the ignition switch to ON (II). When the green No.1 and the yellow No.2 LEDs stay on, the control unit/module is updated. 16. Turn the ignition switch to LOCK (0), and disconnect the HIM from the vehicle. To do the same update on an identical vehicle, repeat steps 11 thru 16. Diagnosing HIM Error Codes If the red No.3 LED on the HIM came on or was flashing during the update, do this: 1. Leave the ignition switch in ON (II) while you disconnect the HIM from the vehicle's DLC. 2. If not already done, load the latest HDS sofiware onto the iN workstation. 3. Connect the HIM to the iN workstation. Connect the small end of the PC interface cable to the PC port on the HIM. 4. If not already done, connect the PC end of the blue PC interface cable to the 9P serial port on the iN workstation. 5. Connect the 110 VACIl 2 VDC power supply to the HIM and to a wall outlet. 6. Restart the CM Update application on the iN workstation. 7. On the right side of the screen, click on the view error button. 8. Click on View Error at the bottom of the screen to display the problem encountered while the HIM was connected to the vehicle. ^ If you get a Code 40 error message (usually caused by a communication error between the HIM and the workstation), do this: - Do the HIM self-test procedure (see HIM Self-Test). - Move the blue PC interface cable to another communication port on the back of the computer. - If one of the communication ports on the back of the computer has another cable connected to it, disconnect that cable, leave it disconnected during the HIM procedure, and connect the blue PC interface cable to that port. - Connect the HIM to another computer. (Some iN workstations require an internal communication port setup procedure. For help, call the iN Support Center) ^ If you get a Code 50 error message (usually caused by a communications error between the HIM and the vehicle's DLC), do this: - Diagnose and clear any DTCs. (The control unit/module must be free of DTCs before you can update it.) - Make sure there's a good connection between the HIM and the DLC. - Retry the update using the procedures in this service bulletin or on the back of the HIM. - If needed, call Tech Line for further help. HIM Self-Test If you suspect there's a problem with the HIM, review the instructions in this service bulletin to make sure you are using it correctly. If you still think there's a problem, do this self-test: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 6944 1. If not already done, load the latest HDS software onto the iN workstation. 2. Restart the CM Update application on the iN workstation. 3. On the right side of the screen, click on the tools button. 4. Click on HIM Self-Test Procedure. 5. Follow the on-screen instructions to run the HIM self-test. 6. If the self-test indicates a problem with the HIM, call the Special Tools hotline for repair instructions. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 6949 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Replace the A/T. See S/B 98-061, Automatic Transmission In-Warranty Exchange Program, for detailed requirements of the A/T ordering, removal, and installation process. 2. '01-03 models only: Make sure you have the iN CD (July '04 or later) loaded into your iN master terminal. If not, load the CD using the instructions that come with it. Also, make sure the vehicle's battery is fully charged. [Low voltage or turning the ignition switch to LOCK (0) can permanently damage the PCM.] 3. '01-03 models only: Use the Honda Interface Module (HIM) to update the PCM software. Refer to S/B 01-023, Using the Honda Interface Module to Update Control Units/Modules. 4. Use the Honda Diagnostic System (HDS) with version 1.012.023 or later software to clear the DTC. 5. Do the idle learn procedure: ^ Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are off. ^ Start the engine, and let it reach normal operating temperature (cooling fans cycle twice). ^ Let the engine idle with the throttle closed for 10 minutes. 6. 2001 Civic 2-door EX, LX models from VIN 1HGEM2... 1L000001 thru 1HGEM2... 1L016502: Do the cruise control learn procedure: ^ Drive the vehicle, and set the cruise control above 40 miles per hour. ^ Keep driving the vehicle for 5 to 10 minutes. NOTE: You can use a smog/chassis dynamometer to do this step instead of driving the vehicle. Do not do this step with the vehicle on a lift. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-036 > Jan > 05 > A/T - Vehicle Won't Move/MIL ON/DTC P0730 > Page 6950 Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations 15. Lower Right Rear of Engine Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6954 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6955 8. Oil Pressure Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6956 Oil Pressure Sender: Testing and Inspection Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (B). 2. Check for continuity between the positive terminal (C) and the engine (ground). There should be continuity with the engine stopped. There should be no continuity with the engine running. 3. If the switch fails to operate, check the engine oil level. If the engine oil level is OK, check the engine oil pressure. If the oil pressure is OK, replace the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 6957 Oil Pressure Sender: Service and Repair Oil Pressure Switch Replacement 1. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 2. Apply liquid gasket to the oil pressure switch threads, then install the oil pressure switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 6961 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 6962 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 6963 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 6968 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 6969 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 6970 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations Fuel Supply System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6974 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6975 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07AAA-S0XA100 NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from minimum to maximum position and then returns to the minimum position, the gauge is OK. Go to step 3. - If the fuel gauge needle does not sweep from minimum to maximum position position and then return to the minimum position, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Remove the rear seat cushion. 5. Remove the access panel (A) from the floor. 6. Disconnect the fuel pump 5P connector (B). 7. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage. - If the voltage is as specified, go to step 8. - If the voltage is not as specified, check for: an open in the YEL/BLK or BLK wire. - poor ground (G 551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6976 9. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer does not indicate "F", replace the gauge. - If the pointer indicates "F", inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level. 11. Relieve the fuel pressure. 12. Remove the fuel fill cap. 13. Disconnect the quick-connect fittings from the fuel pump. 14. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6977 15. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the above readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (7.5A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6978 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07AAA-S0XA100 See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions 1. Relieve the fuel pressure.See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the fuel fill cap. 3. Remove the seat cushion. 4. Remove the access panel (A) from the floor. 5. Disconnect the fuel pump 5P connector (B). 6. Disconnect the quick-connect fitting (C) from the fuel tank unit. 7. Using the special tool, loosen the fuel tank unit locknut (A). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 6979 8. Remove the locknut (A) and the fuel tank unit. 9. Remove the stopper (O). Release the hook (P) and remove the fuel filter (B), the fuel gauge sending unit (C), the case (D), the wire harness (E), and the fuel pressure regulator (F). 10. When connecting the fuel tank unit, make sure the connection is secure and the suction filter (G) is firmly connected to the fuel pump (H). 11. Install the fuel tank unit in the reverse order of removal with a new base gasket (I) and new O-rings (J), then check these items: - When connecting the wire harness, make sure the connection is secure and the connector (K) is firmly locked into the place. - When installing the fuel gauge sending unit, make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist the connector excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Key Reminder Switch: Locations 72. In Steering Column Cover Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 6983 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 6984 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations > Page 6985 Key Reminder Switch: Testing and Inspection Ignition Key Switch Test NOTE: For more key-in beeper information, refer to the circuit diagram and input test. When the ignition key is in the ignition switch, the multiplex control unit senses ground through the closed ignition key switch. When you open the driver's door, the multiplex control unit senses ground through the closed door switch and sounds the beeper. 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity with the key in the ignition switch. - There should be no continuity with the key removed from the ignition switch. 4. If the continuity is not as specified, replace the ignition switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations 91. Middle of Floor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 6989 Gauges - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 6990 9. Parking Brake Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 6991 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the rear console. 2. Disconnect the connector (A) from the switch (B). 3. Check for continuity between the switch terminal and body ground: ^ With the brake lever up, there should be continuity. ^ With the brake lever down, there should be no continuity. 4. Reconnect the connector from the switch. 5. Reinstall the rear console. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection Speedometer Head: Testing and Inspection Vehicle Speed Signal Circuit Troubleshooting Special Tools Required Test harness 07LAJ-PT3020A Before testing, inspect the No. 4 (10 A) and No. 10 (7.5 A) fuses in the under-dash fuse/relay box. 1. Disconnect the 3P connector from the vehicle speed sensor (VSS) (A). 2. Connect the test harness only to the engine wire harness. 3. Connect the RED test harness clip (B) to the positive probe of an Ohmmeter. Cover the white (0 and green (D) test harness leads with protective tape (E). 4. Check for continuity between the RED test harness clip and body ground. Is there continuity? YES - Go to step 5. NO - Repair open in the BLK wire between the VSS andG101. 5. Connect the WHT test harness clip (B) to the positive probe of a voltmeter, and connect the RED test harness clip (C) to the negative probe. 6. Connect the test harness to the VSS. 7. Turn the ignition switch ON (II). Is there battery voltage? YES - Go to step 8. NO - Repair open in the BLK/YEL or BLK/ORN wire between the VSS and the under-dash fuse/relay box, repair ground or open in BLK wire between VSS and G101. 8. Disconnect the WHT test harness clip (B). 9. Disconnect the test harness from the VSS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > Page 6995 10. Connect the GRN test harness clip (D) to the positive probe of a voltmeter. Is there 5 V or more? YES - Go to step 11. NO - Repair short or open in the BLU/WHT or WHT7 GRN wire between the VSS and the cruise control unit, the gauge assembly or the ECM. 11. Turn the ignition switch OFF. 12. Connect the other test harness connector (A) to the VSS (B). 13. Raise the front of the vehicle, and make sure it is securely supported. 14. Put the vehicle in neutral with the ignition switch ON (II). 15. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5V? YES - Go to step 16. NO - Replace the VSS. 16. Disconnect the 22P connector "B" from the gauge assembly. 17. Connect the positive probe of a voltmeter to the BLU/WHT wire and the negative probe to ground. 18. Slowly rotate one wheel with the other wheel blocked. Does voltage pulse from 0 to about 5V? YES - Replace the speedometer assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > Page 6996 NO - Repair open in the BLU/WHT wire between the VSS and the speedometer. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Tachometer Connector > Component Information > Diagrams 73. Test Tachometer Connector Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection Coolant Temperature Gauge Circuit Troubleshooting Before testing, check the No. 9 (10 A) fuse in the under-hood fuse/relay box and the No. 10 (7.5 A) fuse in the under-dash fuse/relay box. 1. Start the engine, and check the malfunction indicator lamp (MIL). Does the MIL come on? YES - Troubleshoot the cause of the ECM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshoot the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self-diagnostic function. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM. Check for an open in the WHT/GRN wire (gauge connector terminal B13). If no open is found, go to step 5. NO - Go to step 4. 4. Do the gauge drive circuit check with the self-diagnostic function. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM and recheck. Did the symptom/indication go away? YES - Replace the ECM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Testing and Inspection Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations 11. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7012 20. Back-up Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7013 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 2P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the back-up light switch. Apply liquid gasket (P/N 08718-0001), and install it on the transmission housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Brake Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 Brake Lamp: Connector Views 109. Brake Light/Taillight, Left 110. Brake Light/Taillight, Right Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Brake Lamp: Electrical Diagrams Wiring Diagrams Diagram 110-12 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Exterior Lights - Circuit Diagram (Brake Lights) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7055 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7056 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No. 3 and No. 4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Cargo Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 25. Cargo Area Light Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Cargo Lamp: Electrical Diagrams Diagram 114-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 7094 Cargo Lamp: Testing and Inspection Cargo Area Light Test/Replacement 1. Open the hatch. 2. Carefully pry out the cargo area light (A). 3. Disconnect the 2P connector (B) from the light. 4. Check for continuity between the No. 1 (+) and No. 2 (-) terminals. There should be continuity. If there is no continuity, check the bulb. If the bulb is OK, replace the cargo area light. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 7095 Cargo Lamp: Service and Repair Cargo Area Light Test/Replacement 1. Open the hatch. 2. Carefully pry out the cargo area light (A). 3. Disconnect the 2P connector (B) from the light. 4. Check for continuity between the No. 1 (+) and No. 2 (-) terminals. There should be continuity. If there is no continuity, check the bulb. If the bulb is OK, replace the cargo area light. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams 43. High Mount Brake Light Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 7099 Center Mounted Brake Lamp: Service and Repair High Mount Brake Light Replacement 1. Open the hatch. 2. Remove the plastic trim. 3. Disconnect the 2P connector (A) from the high mount brake light (B). 4. Carefully remove the high mount brake light. 5. Install the light in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Locations Interior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Courtesy Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 Interior Lights - Circuit Diagram Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7141 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7142 178. DRL Control Unit (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7143 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. It should go off when you turn on the headlight switch and release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard under cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7144 4. Make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, go to step 5 5. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, the control unit must be faulty Replace it '04-05 models 6. Make these input tests at the connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7145 - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 7. 7. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Diagrams 206. DRL Diode Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 7152 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 7153 141. Low Beam Cut ('02-'03 Canada) And DRL Relay (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 7154 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 7155 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 Dome Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 Dome Lamp: Connector Views 95. Ceiling Light, Rear 120. Ceiling Light/Spotlights Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Dome Lamp: Electrical Diagrams Diagram 114-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Testing and Inspection > Ceiling Light/Spotlight Dome Lamp: Testing and Inspection Ceiling Light/Spotlight Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screw driver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Testing and Inspection > Ceiling Light/Spotlight > Page 7195 Dome Lamp: Testing and Inspection Rear Ceiling Light Rear Ceiling Light Test/Replacement 1. Turn the light switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 3P connector (B) from the housing (C). 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the rear ceiling light. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Ceiling Light/Spotlight Dome Lamp: Service and Repair Ceiling Light/Spotlight Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screw driver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Ceiling Light/Spotlight > Page 7198 Dome Lamp: Service and Repair Rear Ceiling Light Rear Ceiling Light Test/Replacement 1. Turn the light switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two mounting screws. 4. Disconnect the 3P connector (B) from the housing (C). 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the rear ceiling light. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7202 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7203 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 7204 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations 74. Left Kick Panel (USA) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7209 137. Fog Light Relays 1 & 2 (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 7213 138. Fog Light Switch (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Testing and Inspection Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7221 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 7222 Hazard Warning Flasher: Application and ID PLEASE NOTE: The flasher function for this vehicle is provided by the Turn Signal/Hazard Relay. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7226 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7227 163. Hazard Warning Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7228 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 7229 Hazard Warning Switch: Service and Repair Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Bulb Replacement Headlight (high beam) ('04-05 models) 1. Disconnect the 2P connector (A) from the headlight. 2. Turn the high beam bulb socket (B) 45° counterclockwise to remove it from the headlight. 3. Install a new bulb in the reverse order of removal. Headlight (low beam) ('04-05 models) 1. Disconnect the 2P connector (A) from the headlight. 2. Turn the low beam bulb socket (B) 45° counterclockwise to remove it from the headlight. 3. Install a new bulb in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7237 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7238 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 7239 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Check Relay > Component Information > Locations Low Beam Check Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Check Relay > Component Information > Locations > Page 7243 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Check Relay > Component Information > Locations > Page 7244 Low Beam Check Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Check Relay > Component Information > Locations > Page 7245 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations > Page 7249 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations > Page 7250 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Five-terminal type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations > Page 7251 Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7256 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7257 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7258 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations 79. Inside Steering Wheel Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7262 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7263 4. Horn Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7264 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector No. 2 terminal to body ground. - If the horns sound, go to step 4. - If the horns do not sound, check these items: Horn relay - No. 7 (15 A) fuse in the under-hood fuse/relay box - Horns. - An open in the wire 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horns sound, go to step 6. - If the horns do not sound, replace the cable reel. 6. Reconnect the horn switch positive 1P connector. 7. Using a jumper wire, connect the steering wheel to body ground. 8. Close the contacts between the horn plate and the contact plate. - If the horns sound, replace the steering column. - If the horns do not sound, replace the horn and contact plate. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Interior Lighting Module: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7297 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7298 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7299 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7301 Interior Lighting Module: Electrical Diagrams Entry Lights Control System - Circuit Diagram Wiring Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Diagram 115-0 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Diagram 115-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 7304 Interior Lighting Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. 5. With the connectors still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 7305 6. Reconnect the connectors to the under-dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake then make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty-Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations 72. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations > Page 7309 151. Ignition Key Switch/Key Light Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations > Page 7310 Key Cylinder Lamp: Testing and Inspection Ignition Key Light Test 1. Remove the steering column upper and lower covers. 2. Disconnect the 6P connector. 3. The LED should come on when power is connected to the No. 6 terminal and ground is connected to No. 5 terminal. 4. If the LED does not come on, replace the ignition switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > Customer Interest for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. License Plate Lamp: Customer Interest Lighting - Inner Tail Lamps/License Plate Lamps Inop. 08-094 December 12, 2008 Applies To: 2004-05 Civic 2-Door VIN starts with 1HGEM or 2HGEM 2004-05 Civic 4-Door VIN starts with 1HGES or 2HGES Inner Taillights and License Plate Lights Flicker or Don't Work SYMPTOM The inner taillights (on the trunk lid) and the license plate lights don't work, or they flicker when the trunk lid is opened or closed. PROBABLE CAUSE A splice in the rear wire harness near the right side trunk hinge is damaged or broken. CORRECTIVE ACTION Repair and relocate the splice in the rear wire harness. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the right side trunk trim panel: ^ Refer to pages 20-87 and 20-88 of the 20012005 Civic Service Manual, or ^ Online, enter keywords TRUNK TRIM, and select Interior Trim Removal/Installation - Trunk Area from the list. 2. Cut and remove the trunk lid wire harness clips near the splice. One clip is on the underside of the rear shelf near the right side trunk hinge. The other clip is near the sharp bend in the trunk hinge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > Customer Interest for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7319 3. Use a utility knife to carefully cut the tape wrapped around the harness protective tubing between the clip locations, and 100 mm past each clip location. 4. Open the protective tubing, pull out the RED/YEL wires, and find the splice in the wires. NOTE: The RED/YEL wire splice may be wrapped in tape. 5. Cut the three body side RED/YEL wires at the splice as shown. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > Customer Interest for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7320 6. Cut the trunk lid RED/YEL wire 50 mm past the hinge harness clip location as shown. 7. Cut 100 mm from the ends of two of the three body side RED/YEL wires. 8. Strip 7 mm of insulation from the ends of the RED/ YEL wires, and from the 300 mm wire in the splice repair kit. 9. Insert the two shortened body side wires into one side of the blue splice connector, then insert the 300 mm wire and the longer body side wire into the other side of the connector. Crimp both ends of the connector. 10. Insert the other end of the 300 mm wire into one side of the red splice connector, then insert the trunk lid RED/YEL wire into the other side. Crimp both ends of the connector. 11. Use a heat gun to shrink the insulation on the splice connectors until sealant comes out from the ends of the connectors. NOTE: Use a non-flammable insulating material to protect the other wires from heat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > Customer Interest for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7321 12. Make sure that the license plate lights and the inner taillights work properly. 13. Reinstall the wires in the protective tubing, and wrap the tubing with electrical tape. 14. Reattach the harness to the rear shelf and the trunk hinge using the new harness clips in the splice repair kit. 15. Reinstall all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. License Plate Lamp: All Technical Service Bulletins Lighting - Inner Tail Lamps/License Plate Lamps Inop. 08-094 December 12, 2008 Applies To: 2004-05 Civic 2-Door VIN starts with 1HGEM or 2HGEM 2004-05 Civic 4-Door VIN starts with 1HGES or 2HGES Inner Taillights and License Plate Lights Flicker or Don't Work SYMPTOM The inner taillights (on the trunk lid) and the license plate lights don't work, or they flicker when the trunk lid is opened or closed. PROBABLE CAUSE A splice in the rear wire harness near the right side trunk hinge is damaged or broken. CORRECTIVE ACTION Repair and relocate the splice in the rear wire harness. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the right side trunk trim panel: ^ Refer to pages 20-87 and 20-88 of the 20012005 Civic Service Manual, or ^ Online, enter keywords TRUNK TRIM, and select Interior Trim Removal/Installation - Trunk Area from the list. 2. Cut and remove the trunk lid wire harness clips near the splice. One clip is on the underside of the rear shelf near the right side trunk hinge. The other clip is near the sharp bend in the trunk hinge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7327 3. Use a utility knife to carefully cut the tape wrapped around the harness protective tubing between the clip locations, and 100 mm past each clip location. 4. Open the protective tubing, pull out the RED/YEL wires, and find the splice in the wires. NOTE: The RED/YEL wire splice may be wrapped in tape. 5. Cut the three body side RED/YEL wires at the splice as shown. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7328 6. Cut the trunk lid RED/YEL wire 50 mm past the hinge harness clip location as shown. 7. Cut 100 mm from the ends of two of the three body side RED/YEL wires. 8. Strip 7 mm of insulation from the ends of the RED/ YEL wires, and from the 300 mm wire in the splice repair kit. 9. Insert the two shortened body side wires into one side of the blue splice connector, then insert the 300 mm wire and the longer body side wire into the other side of the connector. Crimp both ends of the connector. 10. Insert the other end of the 300 mm wire into one side of the red splice connector, then insert the trunk lid RED/YEL wire into the other side. Crimp both ends of the connector. 11. Use a heat gun to shrink the insulation on the splice connectors until sealant comes out from the ends of the connectors. NOTE: Use a non-flammable insulating material to protect the other wires from heat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for License Plate Lamp: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7329 12. Make sure that the license plate lights and the inner taillights work properly. 13. Reinstall the wires in the protective tubing, and wrap the tubing with electrical tape. 14. Reattach the harness to the rear shelf and the trunk hinge using the new harness clips in the splice repair kit. 15. Reinstall all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 License Plate Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 47. License Plate Light Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 License Plate Lamp: Electrical Diagrams Diagram 110-13 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Diagram 110-14 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 7366 License Plate Lamp: Service and Repair License Plate Light Replacement 1. Remove the hatch lower trim panel. 2. Pull the license plate light assembly out, and disconnect the 2P connector (A) from the light. 3. Separate the lens (B) and housing (C), then remove the bulb. 4. Install the light in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions Map Light: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 Map Light: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 120. Ceiling Light/Spotlights Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 Map Light: Electrical Diagrams Diagram 114-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 7404 Map Light: Testing and Inspection Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screw driver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 7405 Map Light: Service and Repair Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screw driver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 Marker Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 Marker Lamp: Connector Views 65. Side Marker Light, Left Front 66. Side Marker Light, Left Rear 67. Side Marker Light, Right Front Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 68. Side Marker Light, Right Rear Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Marker Lamp: Electrical Diagrams Diagram 110-13 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 Diagram 110-14 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 7445 Marker Lamp: Service and Repair Side Marker Light Replacement 1. Carefully pry the light (A) out of the front or rear bumper, and disconnect the 2P connector (B) from the light. Be careful not to damage the rear bumper. 2. Remove the bulb socket (C) by turning it 45° counterclockwise, then replace the bulb. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair Front Turn Signal Light, Parking Light 1. Remove the inner fender. 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 45° counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Testing and Inspection Backup Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7457 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7458 178. DRL Control Unit (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7459 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test Canada The DRL indicator light in the gauge assembly will come on when you turn the ignition switch to ON (II) with the headlight switch off and the parking brake set. It should go off when you turn on the headlight switch and release the parking brake. If it comes on at any other time, do the control unit input test. NOTE: When the daytime running lights are on, the high beam indicator will glow at half its normal intensity. 1. Remove the driver's dashboard under cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7460 4. Make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, go to step 5 5. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector - If any test indicates a problem, find and correct the cause then recheck the system - If all the input tests prove OK, the control unit must be faulty Replace it '04-05 models 6. Make these input tests at the connector. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 7461 - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 7. 7. Reconnect the 14P connector to the daytime running lights control unit, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 7465 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 7466 141. Low Beam Cut ('02-'03 Canada) And DRL Relay (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 7467 Daytime Running Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 7468 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations 74. Left Kick Panel (USA) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7472 137. Fog Light Relays 1 & 2 (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Testing and Inspection Hazard Flasher Relay: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7479 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7480 Headlamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 7481 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7485 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7486 Horn Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7487 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7493 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7494 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7495 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7496 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7497 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7498 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7499 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7500 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7501 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7502 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7503 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7504 Interior Lighting Module: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7505 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7506 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7507 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 Interior Lighting Module: Electrical Diagrams Entry Lights Control System - Circuit Diagram Wiring Diagrams Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 Diagram 115-0 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Diagram 115-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 7527 Interior Lighting Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 5. 5. With the connectors still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 7528 6. Reconnect the connectors to the under-dash fuse/relay box, turn the ignition switch ON (II) to keep the system awake then make these input tests at the appropriate connectors on the under-dash fuse/relay box. If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty-Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations Low Beam Check Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 7532 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 7533 Low Beam Check Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Five-terminal type Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Check Relay > Component Information > Locations > Page 7534 - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Low Beam Relay: Locations Relay and Control Unit Location - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 7538 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 7539 Low Beam Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. NOTE: For the turn signal/hazard relay input test. Five-terminal type Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations > Page 7540 Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 5 terminals. - There should be continuity between the No. 1 and No. 4 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 7544 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 7545 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 7546 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 7550 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations 11. Transmission Housing Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 7555 20. Back-up Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 7556 Backup Lamp Switch: Testing and Inspection Back-Up Light Switch Test 1. Disconnect the back-up light switch (A) connector. 2. Check for continuity between the back-up light switch 2P connector No. 1 and No. 2 terminals. There should be continuity when the shift lever is in reverse. 3. If necessary, replace the back-up light switch. Apply liquid gasket (P/N 08718-0001), and install it on the transmission housing. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7560 Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM when the brake pedal is pressed. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7561 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Disconnect the 4P connector (A) from the brake pedal position switch (B). 2. Check for continuity between the No. 1 and No. 2 terminals. - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 3. Check for continuity between the No. 3 and No. 4 terminals (with cruise control). - There should be no continuity when the brake pedal is pressed. - There should be continuity when the brake pedal is released. 4. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7565 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7566 181. Combination Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7567 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 7568 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 108. Left B-Pillar (Right Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7572 Entry Lights Control System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7573 Keyless/Power Door Lock System - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 7574 Door Switch: Diagrams 2. Door Switch, Driver's 3. Door Switch, Passenger's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations 82. Left Side of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 7578 138. Fog Light Switch (USA: Honda Accessory) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7582 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7583 163. Hazard Warning Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7584 Hazard Warning Switch: Testing and Inspection Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 7585 Hazard Warning Switch: Service and Repair Hazard Warning Switch Test/Replacement 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the bulb (D) or the hazard warning switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations 79. Inside Steering Wheel Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7589 Horns - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7590 4. Horn Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7591 Horn Switch: Testing and Inspection Horn Switch Test 1. Remove the steering column covers. 2. Disconnect the dashboard wire harness B 5P connector (A) from the cable reel (B). 3. Using a jumper wire, connect the dashboard wire harness B 5P connector No. 2 terminal to body ground. - If the horns sound, go to step 4. - If the horns do not sound, check these items: Horn relay - No. 7 (15 A) fuse in the under-hood fuse/relay box - Horns. - An open in the wire 4. Reconnect the dashboard wire harness B 5P connector (A), and disconnect the horn switch positive 1P connector (B). 5. Using a jumper wire, connect the horn switch positive 1P connector (B) to ground. - If the horns sound, go to step 6. - If the horns do not sound, replace the cable reel. 6. Reconnect the horn switch positive 1P connector. 7. Using a jumper wire, connect the steering wheel to body ground. 8. Close the contacts between the horn plate and the contact plate. - If the horns sound, replace the steering column. - If the horns do not sound, replace the horn and contact plate. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions Spot Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7599 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7600 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7601 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7602 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7603 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7604 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7605 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7606 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7607 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7608 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7609 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 Spot Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7619 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7620 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7621 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7622 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7623 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7624 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7625 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7626 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7627 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7628 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7629 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7630 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7631 Spot Lamp: Electrical Diagrams Diagram 114-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7632 Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Page 7633 Spot Lamp: Testing and Inspection Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Page 7634 Spot Lamp: Service and Repair Ceiling Light/Spotlight Test/Replacement 1. Turn the ceiling light/spotlights switch OFF. 2. Carefully pry off the lens (A) with a small screwdriver. Ceiling Light: 5 W Spotlight: 5 W x 2 3. Remove the two screws and the housing (B). 4. Disconnect the 4P connector (C) from the housing. 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, check the bulb. If the bulb is OK, replace the ceiling light/spotlights. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > Customer Interest for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. Tail Lamp Pigtail Assembly: Customer Interest Lighting - Inner Tail Lamps/License Plate Lamps Inop. 08-094 December 12, 2008 Applies To: 2004-05 Civic 2-Door VIN starts with 1HGEM or 2HGEM 2004-05 Civic 4-Door VIN starts with 1HGES or 2HGES Inner Taillights and License Plate Lights Flicker or Don't Work SYMPTOM The inner taillights (on the trunk lid) and the license plate lights don't work, or they flicker when the trunk lid is opened or closed. PROBABLE CAUSE A splice in the rear wire harness near the right side trunk hinge is damaged or broken. CORRECTIVE ACTION Repair and relocate the splice in the rear wire harness. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the right side trunk trim panel: ^ Refer to pages 20-87 and 20-88 of the 20012005 Civic Service Manual, or ^ Online, enter keywords TRUNK TRIM, and select Interior Trim Removal/Installation - Trunk Area from the list. 2. Cut and remove the trunk lid wire harness clips near the splice. One clip is on the underside of the rear shelf near the right side trunk hinge. The other clip is near the sharp bend in the trunk hinge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > Customer Interest for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7644 3. Use a utility knife to carefully cut the tape wrapped around the harness protective tubing between the clip locations, and 100 mm past each clip location. 4. Open the protective tubing, pull out the RED/YEL wires, and find the splice in the wires. NOTE: The RED/YEL wire splice may be wrapped in tape. 5. Cut the three body side RED/YEL wires at the splice as shown. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > Customer Interest for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7645 6. Cut the trunk lid RED/YEL wire 50 mm past the hinge harness clip location as shown. 7. Cut 100 mm from the ends of two of the three body side RED/YEL wires. 8. Strip 7 mm of insulation from the ends of the RED/ YEL wires, and from the 300 mm wire in the splice repair kit. 9. Insert the two shortened body side wires into one side of the blue splice connector, then insert the 300 mm wire and the longer body side wire into the other side of the connector. Crimp both ends of the connector. 10. Insert the other end of the 300 mm wire into one side of the red splice connector, then insert the trunk lid RED/YEL wire into the other side. Crimp both ends of the connector. 11. Use a heat gun to shrink the insulation on the splice connectors until sealant comes out from the ends of the connectors. NOTE: Use a non-flammable insulating material to protect the other wires from heat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > Customer Interest for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7646 12. Make sure that the license plate lights and the inner taillights work properly. 13. Reinstall the wires in the protective tubing, and wrap the tubing with electrical tape. 14. Reattach the harness to the rear shelf and the trunk hinge using the new harness clips in the splice repair kit. 15. Reinstall all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. Tail Lamp Pigtail Assembly: All Technical Service Bulletins Lighting - Inner Tail Lamps/License Plate Lamps Inop. 08-094 December 12, 2008 Applies To: 2004-05 Civic 2-Door VIN starts with 1HGEM or 2HGEM 2004-05 Civic 4-Door VIN starts with 1HGES or 2HGES Inner Taillights and License Plate Lights Flicker or Don't Work SYMPTOM The inner taillights (on the trunk lid) and the license plate lights don't work, or they flicker when the trunk lid is opened or closed. PROBABLE CAUSE A splice in the rear wire harness near the right side trunk hinge is damaged or broken. CORRECTIVE ACTION Repair and relocate the splice in the rear wire harness. PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the right side trunk trim panel: ^ Refer to pages 20-87 and 20-88 of the 20012005 Civic Service Manual, or ^ Online, enter keywords TRUNK TRIM, and select Interior Trim Removal/Installation - Trunk Area from the list. 2. Cut and remove the trunk lid wire harness clips near the splice. One clip is on the underside of the rear shelf near the right side trunk hinge. The other clip is near the sharp bend in the trunk hinge. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7652 3. Use a utility knife to carefully cut the tape wrapped around the harness protective tubing between the clip locations, and 100 mm past each clip location. 4. Open the protective tubing, pull out the RED/YEL wires, and find the splice in the wires. NOTE: The RED/YEL wire splice may be wrapped in tape. 5. Cut the three body side RED/YEL wires at the splice as shown. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7653 6. Cut the trunk lid RED/YEL wire 50 mm past the hinge harness clip location as shown. 7. Cut 100 mm from the ends of two of the three body side RED/YEL wires. 8. Strip 7 mm of insulation from the ends of the RED/ YEL wires, and from the 300 mm wire in the splice repair kit. 9. Insert the two shortened body side wires into one side of the blue splice connector, then insert the 300 mm wire and the longer body side wire into the other side of the connector. Crimp both ends of the connector. 10. Insert the other end of the 300 mm wire into one side of the red splice connector, then insert the trunk lid RED/YEL wire into the other side. Crimp both ends of the connector. 11. Use a heat gun to shrink the insulation on the splice connectors until sealant comes out from the ends of the connectors. NOTE: Use a non-flammable insulating material to protect the other wires from heat. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Pigtail Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tail Lamp Pigtail Assembly: > 08-094 > Dec > 08 > Lighting - Inner Tail Lamps/License Plate Lamps Inop. > Page 7654 12. Make sure that the license plate lights and the inner taillights work properly. 13. Reinstall the wires in the protective tubing, and wrap the tubing with electrical tape. 14. Reattach the harness to the rear shelf and the trunk hinge using the new harness clips in the splice repair kit. 15. Reinstall all removed parts. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations > Page 7658 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations > Page 7659 Tail Lamp Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations > Page 7660 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7665 Exterior Lights - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7666 181. Combination Light Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7667 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 7668 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. 6. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7672 Turn Signal Flasher: Application and ID PLEASE NOTE: The flasher function for this vehicle is provided by the Turn Signal/Hazard Relay. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 7673 Turn Signal Flasher: Testing and Inspection Turn Signal/Hazard Relay Input Test 1. Remove the turn signal/hazard relay (A) from the under-dash fuse/relay box (B). 2. Inspect the relay and fuse/relay box socket terminals to be sure they are all making good contact. - If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 3. 3. Make these input tests at the fuse/relay box. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the turn signal/hazard relay must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Front Turn Signal Light, Parking Light 1. Remove the inner fender. 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 45° counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 7681 Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal/Hazard Flasher - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Wire Color Abbreviations Wire Color Codes Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 Wires Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Connectors - "C" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Splices Components Ground - "G" Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 Terminals - "T" Shielding Switches Fuses Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Diodes Light Emitting Diode (LED) Motor Pressure Sensor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Resistor Variable Sensor Solenoid Transistors How to Identify Connector Terminals How to Identify Connector Terminals Cavity Numbering System Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 The cavities (and wire terminals) in each connector are numbered starting from the upper left, looking at the male terminals from the terminal side (or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same.) All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is # 6. Circuit Schematics Circuit Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 Each schematic represents one circuit. A circuit's wires and components are arranged to show current flow, from power at the top, to ground at the bottom. Shared Circuits Other circuits may share power or ground terminals or wiring with the circuit shown. A wire that connects one circuit to another, for example, is cut short and has an arrowhead at the end of it pointing in the direction of current flow. Next to the arrowhead is the name of the circuit or component which shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo that shows the connector's location on the car. The VIEW number refers to an illustration that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector. Except for the DLC (data link connector), disregard any numbers molded into the connector housing. Wires Wires are identified by the abbreviated names of their colors; the second color is the color of the stripe. Wires are also identified by their location in a connector. The number "2" next to the male and female wire terminals at C554, for example, means those terminals join in cavity 2 of connector C554. Symbols A complete description of schematic symbols begins in Wire Color Abbreviations. Power Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution diagram set to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 Vanity Lamp: Diagnostic Aids Five-Step Troubleshooting Five-Step Troubleshooting 1. Verify The Complaint Turn on all the components in the problem circuit to check the accuracy of the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area. 2. Analyze The Schematic Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground. Also, trace circuits that share wiring with the problem circuit. The names of circuits that share the same fuse, ground, or switch, and so on, are referred to in each circuit schematic. Try to operate any shared circuits you didn't check in step 1. If the shared circuits work, the shared wiring is OK, and the cause must be in the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse or ground is a likely cause. Based on the symptoms and your understanding of the circuit's operation, identify one or more possible causes. 3. Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make tests at points that are easily accessible. 4. Fix The Problem Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures. 5. Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on that fuse. Make sure no new problems turn up and the original problem does not recur. Test Equipment Test Equipment CAUTION: Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Test Light and DVOM On circuits without solid-state devices, use a test light to check for voltage. A test light is made up of a 12 volt bulb with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present. The bulb will go on if there is voltage at the point being tested. If you need to know how much voltage is present, use a digital volt/ohmmeter (DVOM). Self-Powered Test Light and DVOM Use a self-powered test light to check for continuity. This tool is made up of a light bulb, battery, and two leads. To test it, touch the leads together: the light should go on. Use a self-powered test light only on an unpowered circuit. First, disconnect the battery, or remove the fuse that feeds the circuit you are working on. Select two points in the circuit between which you want to check continuity. Connect one lead of the self-powered test light to each point. If there is continuity, the test light's circuit will be completed, and the light will go on. If, in addition, you need to know exactly how much resistance there is between two points, use a digital volt/ohmmeter (DVOM). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 In the "OHMS" range, the DVOM will measure resistance between two points along a circuit. Low resistance means good continuity. Diodes and solid-state devices in a circuit can make a DVOM give a false reading. To check a reading, reverse the leads, and take a second reading. If the readings differ, the component is affecting the measurement. Jumper Wire Use a jumper wire to bypass an open circuit. A jumper wire is made up of an in-line fuse holder connected to a set of test leads. It should have a five ampere fuse. Never connect a jumper wire across a short circuit. The direct battery short will blow the fuse. Short Finder (Short Circuit Locater) Short finders are available to locate shorts to ground. The short finder creates a pulsing magnetic field in the shorted circuit which you can follow to the location of the short. To order any test equipment shown above, contact your local tool supplier. For a list of suppliers and tool numbers, refer to Honda Required Special Tools and Equipment Service Bulletin. Troubleshooting Precautions Troubleshooting Precautions Before Troubleshooting 1. Check the main fuse and the fuse box. 2. Check the battery for damage, state of charge, and clean and tight connections. CAUTION: - Do not quick-charge a battery unless the battery ground cable has been disconnected, or you will damage the alternator diodes. - Do not attempt to crank the engine with the ground cable disconnected or you will severely damage the wiring. While You're Working 1. Make sure connectors are clean, and have no loose terminals or receptacles. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 2. Make sure that connectors without wire seals are packed with dielectric (silicone) grease. Part Number: 08798-9001. 3. When connecting a connector, push it until it "clicks" into place. CAUTION: - Do not pull on the wires when disconnecting a connector. Pull only on the connector housings. - Most circuits include solid-state devices. Test the voltages in these circuits only with a 10-megaohm or higher impedance digital multimeter. Never use a test light or analog meter on circuits that contain solid-state devices. Damage to the devices may result. Troubleshooting Tests Testing for Voltage When testing for voltage at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Connect one lead of the test light to a known good ground, or, if you're using a digital volt ohmmeter (DVOM), place it in the appropriate DC volts range, and connect its negative lead to ground. 2. Connect the other lead of the test light or DVOM to the point you want to check. 3. If the test light glows, there is voltage present. If you're using a DVOM, note the voltage reading. It should be within one volt of measured battery voltage. A loss of more than one volt indicates a problem. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for Continuity When testing for continuity at a connector without wire seals, you do not have to separate the two halves of the connector. Instead, probe the connector from the back. Always check both sides of the connector because dirty, corroded, and bent terminals can cause problems (no electrical contact = an open). 1. Disconnect the negative cable from the car battery. If you're using a DVOM, place it in the lowest OHMS" range. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 2. Connect one lead of a self-powered test light or DVOM to one end of the part of the circuit you want to test. 3. Connect the other lead to the other end. 4. If the self-powered test light glows, there is continuity. If you're using a DVOM, a low reading or no reading (zero), means good continuity. Testing for Voltage Drop Wires, connectors, and switches are designed to conduct current with a minimum loss of voltage. A voltage drop of more than one volt indicates a problem. 1. Place the digital volt/ohmmeter (DVOM) in the appropriate DC volts range. Connect the positive lead to the end of the wire (or to the connector or switch) closest to the battery. 2. Connect the negative lead to the other end of the wire (or the other side of the connector or switch). 3. Turn on the components in the circuit. 4. The DVOM will show the difference in voltage between the two points. A difference, or drop, of more than one volt indicates a problem. Check the circuit for loose, dirty, or bent terminals. Testing for a Short with a Test Light or DVOM 1. Remove the blown fuse and disconnect the load. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. How to Replace Connector Terminals Terminal Replacement Procedure HOW TO REPLACE CONNECTOR TERMINALS The terminal repair kits provide necessary tools and materials (terminals, wire seals, and splice connectors) to repair many damaged or faulty connector terminals. However, not all terminals for all connectors are available. Refer to the labels on the lids of the repair kits for replacement terminal availability. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. Before you begin, inspect the wire you are about to repair for damage and length. Make sure the wire will be long enough to make a terminal repair without stretching it when you reinstall the terminal in the connector. If the wire is too short, or if access to the connector is too restricted to make a terminal repair, you may need to install a pigtail terminal (a short length of wire with a factory-crimped terminal on it). Refer to HOW TO INSTALL PIGTAIL TERMINALS. Removing the Terminal Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 Use the tools from Pin Tool Set. First, check the connector that you are about to repair. - If it has a secondary terminal lock, go to Connectors With a Secondary Lock. A secondary lock, found on most connectors on some models, is an additional locking device on the connector housing as a backup for the primary lock on the terminal. - If the connector does not have a secondary lock, go to Connectors Without a Secondary Lock. Connectors With a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of the secondary terminal locks; however, the connector you are repairing may vary in size. Identify the connector by the type of secondary lock, not by the number of terminal cavities. EXAMPLE A: 1. Release the secondary lock. 2. Remove the terminal. 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 1. Remove the secondary lock from the male terminal half. 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 1. Remove the secondary lock. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: 1. Remove the secondary locks. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the secondary locks. 2. Remove the terminal (same procedure for male and female). 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 1. Remove the secondary locks. 2. Remove the terminal from the female half. 3. Remove the terminal from the male half. 4. Go to HOW TO INSTALL NEW TERMINALS. Connectors Without a Secondary Lock All examples are shown with the connector lock facing up. The illustrations are examples of connector terminals without a secondary lock; however, the connector you are repairing may vary in size and shape. EXAMPLE A: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 EXAMPLE D: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE E: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE F: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE G: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. How to Install New Terminals HOW TO INSTALL NEW TERMINALS 1. Carefully match the old terminal with a new one from the terminal repair kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. NOTE: If the replacement terminal quantities are low, reorder them by using the terminal part number listed on the inside lid of the terminal repair kit. Replacement terminals are available through your parts department using normal parts ordering procedures. 2. Depending on the size of the wire you are repairing, use the proper size slot in the crimping tool. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 3. Strip the insulation off the end of the wire so the wire fits in the new terminal as shown. (If the wire has a wire seal, replace it with a new one from the kit.) NOTE: After stripping the end of the wire, make sure you did not cut any wire strands. If you did, cut the wire off even with the insulation, and strip it again. 4. Position the terminal in the crimping tool slot with the solid portion of the terminal toward the anvil and the open section toward the former. 5. Insert the wire in the terminal to the position shown in step 3. 6. Squeeze the tool with both hands until the stops make contact. 7. Crimp the insulation crimp. -If you do not have a wire seal, then use the next larger size crimp slot. Position the crimping tool over the insulation crimp section of the terminal, then squeeze the tool with both hands until the stops make contact. If you have a wire seal, position the insulation crimp in the 5.5 crimping slot, then carefully squeeze the crimp closed until its ends are touching and making a full-circle shape. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 8. Inspect the quality of the wire crimp. If it has any of the following NO GOOD crimps, cut it off and start over. 9. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector. Lightly pull on the wires to make sure the terminal is locked into place. 10. Close or insert the secondary terminal lock, if applicable, and reconnect the connector. How to Install Pigtail Terminals HOW TO INSTALL PIGTAIL TERMINALS Pigtail terminals (short pieces of wire with a factory crimped terminal) are used when the wire is too short or when access to the connector is too restricted to make a terminal repair. NOTE: To replace just a connector terminal, go to How to Replace Connector Terminals. IMPORTANT SAFETY INFORMATION: On some models, the SRS wires are in a separate harness. If the SRS harness is damaged, replace the harness; do not repair it. On other models, wire harnesses include yellow SRS wires. If any SRS wire is damaged, replace the entire harness; do not repair it. 1. Remove the damaged or faulty terminal from the connector. Use the proper removal tool from Pin Tool Set. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 2. Cut off the wire about an inch back from where it connects to the damaged or faulty terminal, then strip about half of the insulation off that piece. This will be used to size the wire end of the replacement pigtail terminal. NOTE: If you are not sure of the wire size, start with a large enough hole on the stripper that will not nick or cut off any strands of wires. 3. Select a pigtail terminal that matches the original wire at both ends (same kind of terminal and same diameter bare wire). 4. Select the smallest splice connector (yellow, pink, or blue) that will fit onto the stripped end of the original wire. 5. Insert the pigtail terminal into the connector cavity; push it in until it locks in place. 6. Lay the pigtail and the original wire side-by-side, and cut off both ends at once. If you are making more than one splice, do not cut each pigtail at the same location; the resulting "lump" of splice connectors would interfere with rewrapping the harness. Instead, cut the first pigtail close enough to the terminal so you will have room to make each remaining cut about 20 mm (3/4 inch) farther down on the next pigtail. 7. If you are using a yellow splice connector, strip about 6 mm (1/4 inch) of insulation off the ends of both wires. If you are using a pink or blue splice connector, strip off about 8 mm (5/16 inch) of insulation. NOTE: If you nick or cut off any strands of wire, try again with the next larger size hole on the stripper. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 8. Put the splice connector in the proper size slot in the Crimper Tool, slide it to one end (where the flare begins), and close the crimper handles far enough to hold it in place. To release the ratchet mechanism at any point after the first click, squeeze the handles slightly and push the release lever, then let the handles open. 9. Insert one of the bare wires into the splice connector end that is in the crimper jaws. Push the wire all the way into the splice connector, and squeeze the crimper handles. Keep squeezing until the jaws touch, and hold it at that position until the ratchet clicks again. 10. Crimp the other wire in the same way into the other end of the splice connector. 11. After crimping, gently pull on the wires in the opposite directions to make sure they are secure in the connector. 12. Separate the other wires in the harness from the repaired wire(s), and shield them with nonflammable material. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 13. Plug in the heat gun, and turn it on. Start at the middle of the splice connector, and move the gun toward the ends as the tube shrinks. Apply heat evenly by rotating the curved heat spreader around the splice connector. Shrinking is complete when a small amount of sealant appears at each end of the tube. NOTE: Be careful when working with the high heat produced by the heat gun. Pigtail Terminal Selection Chart PIGTAIL TERMINAL SELECTION CHART Select the proper size pigtail terminal by matching the replacement terminal part number and the wire size being repaired to the corresponding pigtail terminal part number. Then use the color (size) splice connector listed. In some instances you may also have to match the wire seal style to select the proper pigtail terminal. Pigtail terminals are available through your parts department, in quantities of 10, using normal parts ordering procedures. Checking For Poor Fit of Terminals CHECKING FOR POOR FIT OF TERMINALS Loose terminal fit can cause a number of intermittent problems in electrical circuits. By using the Terminal Inspection Feeler Tool Set you can inspect the terminal fit between the two matching connectors without removing the terminals from the connector body. 1. Find the terminal tool that best matches the male terminal in the mating connector. 2. Insert the terminal tool into the female terminal, and then remove the terminal tool. NOTE: Make sure you do not select a terminal tool that is larger than the mating male terminal because it would spread the female terminal and cause a loose fit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 3. Compare the drag to the other terminals in the connector. If the drag is less, replace the terminal with a replacement terminal from the appropriate terminal repair kit. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 Vanity Lamp: Electrical Diagrams Diagram 114-0 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 Diagram 114-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7727 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7728 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 7729 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 7733 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations > Page 7734 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Switch > Component Information > Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay And Control Unit Locations - Engine Compartment Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7743 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7744 Heated Glass Element Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 7745 Normally-open type B Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection Power Window Control Module: Testing and Inspection Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5 A) and/or the No. 23 (20 A) fuses in the under-dash fuse/relay box. - Disconnecting the driver's door wire harness. 1. Turn the ignition switch ON (II). 2. Move the driver's window all the way down holding the driver's switch in the AUTO DOWN position; when the window reaches the bottom, hold the driver's window switch in the AUTO DOWN position for 2 seconds. 3. Move the driver's window all the way up holding the driver's switch in the AUTO UP position; when the window reaches the top, hold the driver's window switch in the UP position for 2 seconds. 4. If the window does network in AUTO, repeat steps 1 through 3. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 7752 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 7753 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 7754 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 7759 Rear Window Defogger - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations > Page 7760 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Locations 80. Center of Dash Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Safety Switch > Component Information > Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Safety Switch > Component Information > Locations > Page 7767 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7771 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7772 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 7773 Power Window Switch: Diagrams 146. Power Window Switch, Passenger's 179. Power Window Master Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test 1. Remove the power window master switch. 2. Disconnect the 14P connector from the switch (A). 3. Check for continuity between the terminals in each switch position according 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. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7776 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the Power window master switch (A). 2. Disconnect the 14P connector (B) from the master switch. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. With the connector still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7777 5. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch '04-05 models 6. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7778 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test 1. Remove the switch panel. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the passenger's power window switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7779 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Window Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the connector, and using a back probe, make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. 5. Disconnect the 5P connector, and make these input tests. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7780 6. If all the tests prove OK, the switch must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Replacement 1. Remove the door grip. 2. Remove the power window master switch (A) from the door panel. 3. Disconnect the 14P connector (B) from the switch. 4. Remove the three screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 7783 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Passenger's Window Switch Replacement 1. Remove the door grip. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the switch, 4. Remove the two screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Testing and Inspection Power Window Control Module: Testing and Inspection Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5 A) and/or the No. 23 (20 A) fuses in the under-dash fuse/relay box. - Disconnecting the driver's door wire harness. 1. Turn the ignition switch ON (II). 2. Move the driver's window all the way down holding the driver's switch in the AUTO DOWN position; when the window reaches the bottom, hold the driver's window switch in the AUTO DOWN position for 2 seconds. 3. Move the driver's window all the way up holding the driver's switch in the AUTO UP position; when the window reaches the top, hold the driver's window switch in the UP position for 2 seconds. 4. If the window does network in AUTO, repeat steps 1 through 3. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Component Locations Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Component Locations > Page 7793 84. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Page 7794 Front Door Window Motor: Diagrams 55. Power Window Motor, Passenger's 124. Power Window Motor, Driver's Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay And Control Unit Locations - Dashboard Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 7798 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 7799 Power Window Relay: Testing and Inspection Power Relay Test Use this chart to identify the type of relay, then do the test listed for it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 7800 Normally-open type A Check for continuity between the terminals. - There should be continuity between the No. 1 and No. 2 terminals when power and ground are connected to the No. 3 and No. 4 terminals. - There should be no continuity between the No. 1 and No. 2 terminals when power is disconnected. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Safety Switch > Component Information > Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Safety Switch > Component Information > Locations > Page 7804 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations 83. Driver's Door (Passenger's Similar) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7808 Relay And Control Unit Locations - Door And Seat Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7809 Power Windows - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 7810 Power Window Switch: Diagrams 146. Power Window Switch, Passenger's 179. Power Window Master Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement Power Window Switch: Testing and Inspection Master Switch Test/Replacement Master Switch Test 1. Remove the power window master switch. 2. Disconnect the 14P connector from the switch (A). 3. Check for continuity between the terminals in each switch position according 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. If the tests are normal, the driver's switch must be faulty. 4. If the switch is faulty, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7813 Power Window Switch: Testing and Inspection Master Switch Input Test Master Switch Input Test NOTE: The power window control unit is built into the power window master switch, and it only controls the driver's window operations. 1. Remove the Power window master switch (A). 2. Disconnect the 14P connector (B) from the master switch. 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. With the connector still disconnected, make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5 ('02-03 models) or step 6 ('04-05 models). '02-03 models Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7814 5. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch '04-05 models 6. Reconnect the 14P connector to the switch, and perform the following input tests - If any test indicates a problem, find and correct the cause, then recheck the system - If all the input tests prove OK, the control unit must be faulty, replace the power window master switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7815 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test 1. Remove the switch panel. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the passenger's power window switch. 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7816 Power Window Switch: Testing and Inspection Passenger's Window Switch Input Test Passenger's Window Switch Input Test 1. Remove the switch panel. 2. Disconnect the 5P connector (A) from the switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the connector, and using a back probe, make these input tests at the connector. If any test indicates a problem, find and correct the cause, then recheck the system. 5. Disconnect the 5P connector, and make these input tests. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 7817 6. If all the tests prove OK, the switch must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement Power Window Switch: Service and Repair Master Switch Replacement Master Switch Replacement 1. Remove the door grip. 2. Remove the power window master switch (A) from the door panel. 3. Disconnect the 14P connector (B) from the switch. 4. Remove the three screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 7820 Power Window Switch: Service and Repair Passenger's Window Switch Replacement Passenger's Window Switch Replacement 1. Remove the door grip. 2. Remove the power window switch (A) from the door panel. 3. Disconnect the 5P connector (B) from the switch, 4. Remove the two screws and the switch from the switch panel. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair Rear Window Replacement NOTE: - Put on gloves to protect your hands. - Wear eye protection while cutting the glass adhesive with piano wire. - Use seat covers to avoid damaging any surfaces. - Do not damage the rear window defogger grid lines and terminals. 1. Remove these items: - Hatch lower trim panel - Hatch spoiler 2. Remove these items: - High mount brake light - Rear window wiper motor 3. Disconnect the rear window defogger connectors (A). 4. If the old rear window will 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 a hole through the adhesive from inside the vehicle at the corner portion of the rear window. Push the piano wire through the hole, and wrap each end around a piece of wood. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 7825 6. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the rear window (B) as possible to prevent damage to the hatch, and carefully cut through the adhesive (C) around the entire rear window. 7. Carefully remove the rear window. 8. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the fasteners from the tailgate. 9. Clean the hatch bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 10. If the old rear window will be reinstalled, use a putty knife to scrape off all of the old adhesive, the fasteners and the rubber dams from the rear window. Clean the inside face and the edge of the rear window with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease. 11. Attach the side upper fasteners (A), side lower fasteners (B), upper rubber dams (C), and lower rubber dam (D) with adhesive tape to the inside Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 7826 face of the rear window (E) as shown. Before installing the lower rubber dam, apply primer to the areas between the alignment marks (F), then attach the rubber dam on. If necessary, attach the spoiler fasteners (G) with adhesive tape to the outside face of the rear window. Be sure the side upper fasteners, and upper rubber dams line up with alignment marks (H, I). - Be sure both ends of the lower rubber dam line up with the edge of the glass. - Be sure the spoiler fasteners line up with alignment marks (J). - Be careful not to touch the rear window where adhesive will be applied. 12. Attach the side upper fasteners (A) and side lower fasteners (B) with adhesive tape to the hatch as shown. 13. Set the rear window in the opening, and center it. Align the clips (A) of the rear window with the holes in the opening flange. Make alignment marks (B) across the rear window, hatch, and body with a grease pencil at the four points shown. Be careful not to touch the rear window where adhesive will be applied. 14. Remove the rear window. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 7827 15. With a sponge, apply light coat of glass primer along the edge of the rear window (A), upper rubber dams (B), and lower rubber dam (C) as shown, then lightly wipe it off with gauze or cheesecloth: With the printed dots (D) on the rear window as a guide, apply the glass primer to both side portions of the rear window. - Do not apply body primer to the rear window, and do not get body and glass primer sponges mixed up. - Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. - Keep water, dust, and abrasive materials away from the primed surfaces. 16. With a sponge, carefully apply a light coat of body primer to any exposed paint around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do NOT apply body primer to any remaining original adhesive on the flange. - Be careful not to mix up the body and glass primer sponges. - Never touch the primed surface with your hands. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 7828 17. Cut a "V," in the end of the nozzle (A) on the adhesive cartridge as shown. 18. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rear window (B) as shown. With the glass primer (C) you applied in step 15 as a guide, apply the adhesive to both side portions of the rear window. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 19. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 13, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 20. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with alcohol. 21. Let the adhesive dry for at least 1 hour, then spray water over the rear window and check for leaks. Mark the leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 22. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. - Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair 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. 2. Starting at the front, pry the door glass outer weatherstrip (A) up to detach the clips (B), and release the weatherstrip from the door sash trim (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations Glass Component Location Index Part 2 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7836 Quarter Window Glass: Service and Repair Quarter Glass Replacement NOTE: - Put on gloves to protect your hands. - Wear eye protection while cutting the glass adhesive with piano wire. - Use seat covers to avoid damaging any surfaces. 1. Remove the C-pillar trim. If necessary, remove the rear side trim panel and B-pillar upper trim. 2. Remove the front seal (A) from the front edge of the glass (B). If necessary, cut the seal with a utility knife. 3. Apply protective tape along the inside and outside edges of the body. Using an awl, make a hole through the adhesive from inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood. 4. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the quarter glass (B) as possible to prevent damage to the body, and carefully cut through the adhesive (C) around the entire quarter glass. 5. Carefully remove the quarter glass. 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 scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the clips from the body. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7837 7. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 8. If the old quarter glass will be reinstalled, use a putty knife to scrape off all of the old adhesive and the rubber dam from the glass. Clean the inside face and the edge of the glass with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil, and grease. 9. Set the quarter glass (A) in the opening, and center it. From inside the vehicle, use a grease pencil to make an alignment mark (B) where the rear clip will be installed on the quarter glass. Be careful not to touch the glass where adhesive will be applied. 10. Remove the quarter glass. 11. Align the upper clip (A) and lower clip (B) with the edge of the quarter glass (C), then attach them with adhesive tape to the inside face of the quarter glass, and align the center of the rear clip (D) with the alignment mark (E) you made in step 9, and attach it with adhesive tape to the inside face of the quarter glass as shown. Be careful not to touch the glass where the adhesive tape will be applied. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7838 12. First attach the front seal (A) with adhesive tape, and attach the rubber dam (B) with adhesive tape to the inside face of the quarter glass (C) as shown. Before installing the front seal and rubber dam, apply primer to the inside face of the glass, then attach the seal on: Be sure the front seal lines up with the bottom and front edges of the glass. - Be careful not to touch the glass where adhesive will be applied. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7839 13. With a sponge, apply a light coat of glass primer along the edge of the rubber dam (A) and front seal (B) as shown, then lightly wipe it off with gauze or cheesecloth: With the printed dots (C) on the quarter glass (D) as a guide, apply the glass primer to the upper and lower corner portions of the quarter glass. - Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. - Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the quarter glass properly, causing a leak after the quarter glass is installed. - Keep water, dust, and abrasive materials away from the primed surfaces. 14. With a sponge, carefully apply a light coat of body primer to any exposed paint around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: Do NOT apply body primer to any remaining original adhesive on the flange. - Be careful not to mix up the body and glass primer sponges. - Never touch the primed surface with your hands. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7840 15. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown. 16. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the rubber dam (B) as shown. With the glass primer (C) you applied in step 13 on the quarter glass (D) as a guide, apply the adhesive to the upper and lower corner portions of the quarter glass. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 17. Use suction cups (A) to hold the quarter glass over the opening, align it with the clips (B) and set it down on the adhesive. Lightly push on the Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Locations > Page 7841 quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 18. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, 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, then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 20. Reinstall all remaining removed parts. NOTE: Advise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. - Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary 2. Carefully raise the glass (A) until you can see the bolts, then remove them. Carefully pull the glass out through the window slot. Take care not to drop the glass inside the door. 3. Disconnect and detach the connector (Al and harness clip (B) from the door. 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 the regulator (A) where shown. 6. Install the glass and regulator in the reverse order of removal, and note these items: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 7846 - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks (see step 7 of Door Glass Adjustment). - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed Windshield Moulding / Trim: Customer Interest Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 7856 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body - Windshield Moulding Warped/Deformed > Page 7857 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body Windshield Moulding Warped/Deformed Windshield Moulding / Trim: All Technical Service Bulletins Body - Windshield Moulding Warped/Deformed 00-064 March 17, 2009 Applied Vehicles Deformed Windshield Molding (Supersedes 00-064, dated November 13, 2007, to update the information marked by the black bars) REVISION SUMMARY SYMPTOM The windshield molding is warped or deformed. PROBABLE CAUSE The inner lip is folded, causing a poor fit against the body. CORRECTIVE ACTION Remove the entire inner lip, and fill the channel between the molding and the body with silicone sealant. REQUIRED MATERIALS WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 831004 Flat Rate Time: 0.7 hour Failed Part: P/N 73150-S84-A01 H/C 5443387 Defect Code: 00401 Symptom Code: 00101 Template ID: 00-064A Skill Level: Repair Technician Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body Windshield Moulding Warped/Deformed > Page 7863 Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS Pull up the outer edge of the windshield molding. Check if the inner lip is folded over anywhere. ^ If the inner lip is folded over, go to REPAIR PROCEDURE. ^ If the inner lip is not folded, disregard this bulletin, and look for other possible causes. REPAIR PROCEDURE 1. Protect the roof by applying a strip of 2-inch-wide masking tape along the outer edge of the windshield molding. 2. Pull up the outer edge of the molding, and use scissors or an X-Acto knife to remove its entire inner lip. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 00-064 > Mar > 09 > Body Windshield Moulding Warped/Deformed > Page 7864 3. Using an O-ring pick or similar tool, pull up the outer edge of the molding, and apply 3M Black Super Silicone Sealant under it, along the A-pillars and the upper edge of the windshield. 4. Push down on the molding, and smooth it out until it sits flush with the roof. 5. Wait 5 minutes, then remove the masking tape. 6. Clean up any excess sealant with 3M General Purpose Adhesive Cleaner. Disclaimer Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Testing and Inspection Windshield Washer Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations 106. Rear of Cargo Area Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7873 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7874 184. Rear Window Wiper Intermittent Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test Wiper Control Module: Testing and Inspection Control Unit Input Test Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 7877 Wiper Control Module: Testing and Inspection Rear Window Wiper Intermittent Control Unit Input Test Rear Window Wiper Intermittent Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 20P connector (A) from the rear window wiper intermittent control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the 20P connector to the rear window intermittent control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 7878 5. Disconnect the 20P connector from the rear window wipe intermittent control unit, make these input tests at the connector. - If any test indicates a problem, find and correct the cause,then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7883 85. Washer Fluid Level Switch (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7884 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7885 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7889 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7890 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7891 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7895 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7896 180. Wiper/Washer Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7897 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7898 Wiper Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7902 85. Washer Fluid Level Switch (Canada) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7903 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 7904 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch Test/Replacement Canada 1. Partially remove the right inner fender. 2. Disconnect the 2P connector (A) from the washer level switch. 3. Remove the washer fluid level switch from the reservoir. NOTE: Fluid may flow out the opening. 4. Check for continuity between the terminals in each float (B) position according to the table. 5. If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Testing and Inspection Windshield Washer Control Module: Testing and Inspection Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Washer Tube Replacement 1. Remove the right inner fender. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 7911 2. Remove the washer nozzles and clips, then remove the tubes. 3. Install in the reverse order of removal Take care not to pinch the washer tubes Check the washer operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations 33. Right Front of Vehicle (Bumper Removed) Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7915 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7916 Windshield Washer Motor: Diagrams 58. Rear Window Washer Motor 90. Windshield Washer Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 7917 Windshield Washer Motor: Testing and Inspection Washer Motor Test 1. Partially remove the right inner fender. 2. Disconnect the 2P connectors (A) from the washer motors (B). 3. Test the washer motor by connecting battery power and ground according to the table. 4. If the motor does not run, replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair Washer Reservoir Replacement 1. Partially remove the right inner fender. 2. Disconnect the 2P connectors (A) from the washer motors (B) and level switch (Canada). 3. Disconnect the tubes (C) from the washer motors. 4. Remove the three bolts (A) and the washer reservoir (B). Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7924 Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7925 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 7926 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Windshield Wipers - Blade Care & Replacement Wiper Blade: Technical Service Bulletins Windshield Wipers - Blade Care & Replacement SOURCE: Honda Service News TITLE: Windshield Wiper Blade Care and Replacement APPLIES TO: All models SERVICE TIP: A buildup of road film, oil, or grease on the windshield or the wiper blades can cause the wiper blades to smear, streak, or chatter when being used. If your customers complain of this problem, and their wiper blades are less than 6 months old, try doing this before you replace the blades: - Use Glass Cleaner or equivalent, to thoroughly clean the windshield. Make sure you clean it well enough so that water slides off of it, not just beads up. - Use Windshield Washer Concentrate Cleaner & Antifreeze straight from the bottle on a soft cloth to clean the wiper blades. This stuff contains a wetting agent that conditions the blade rubber. If the wiper blades still smear, streak, or chatter after you've cleaned the windshield and the blades, then blade replacement is in order. When you remove the old blade from its holder, make sure you grab the locking end of the blade on its top and bottom (use your thumb and index finger for this). Tug on the blade until it releases, then slide it off the holder. Don't grab the locking end from the sides. The metal rails could come loose and you could also wind up with a nasty cut. If the new blades don't have rails, make sure you install the rails from the old blades on the new blades like this: If the old rails are curved: - Install them on the new driver's-side wiper blade with the ends bowing away from the windshield. This makes the blade press harder against the middle of the windshield, providing a clear center of vision for the driver. - Install them on the new passenger's side wiper blade with the ends bowing toward the windshield. This makes the blade press harder against the edges of the windshield to clear off any water at the upper and lower ends of each wiper pass. If the old rails lie flat: Install them on either new wiper blade. If one of the new blades is shorter than the other (this is common on many vehicles), just install the shorter blade on the driver's side. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Windshield Wipers - Blade Care & Replacement > Page 7931 Slide the new blade into the holder, and push from behind with your thumb until you feel the tabs snap into place. Make sure the blade is locked in place before you reinstall the blade assembly. If it's not, the blade could come off during use and the blade assembly could scratch the windshield. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations 106. Rear of Cargo Area Relay And Control Unit Locations - Rear And Roof Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7935 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 7936 184. Rear Window Wiper Intermittent Control Unit Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test Wiper Control Module: Testing and Inspection Control Unit Input Test Control Unit Input Test 1. Before testing, troubleshoot the multiplex control system. 2. Remove the driver's dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, G, J, X and Y. NOTE: All connectors are wire side of female terminals. 4. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals are OK, go to step 5. 5. Reconnect the connectors, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty. Replace the under-dash fuse/relay box assembly. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 7939 Wiper Control Module: Testing and Inspection Rear Window Wiper Intermittent Control Unit Input Test Rear Window Wiper Intermittent Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 20P connector (A) from the rear window wiper intermittent control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. 4. Reconnect the 20P connector to the rear window intermittent control unit 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, go to step 5. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 7940 5. Disconnect the 20P connector from the rear window wipe intermittent control unit, make these input tests at the connector. - If any test indicates a problem, find and correct the cause,then recheck the system. - If all the input tests prove OK, the control unit must be faulty. Replace it. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations Wiper Motor: Component Locations 23. Under Left Side of Cowl Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations > Page 7945 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations > Page 7946 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations > Page 7947 112. Middle of Hatch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Wiper Motor: Connector Views 125. Rear Window Wiper Motor 148. Windshield Wiper Motor Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7950 Wiper Motor: Testing and Inspection Wiper Motor Test Windshield 1. Open the hood, and carefully remove the cap nuts and the wiper arms. Make sure they do not touch the hood. 2. Remove the hood seal and cowl cover. 3. Disconnect the 5P connector (A) from the motor (B). 4. Test the motor by connecting battery power and ground according to the table. If the motor does not run or fails to run smoothly, replace it. 5. Test the wiper motor park switch by connecting an analog voltmeter between 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 1. Open the hatch, and remove the hatch trim panel. 2. Disconnect the 4P connector (A) from the motor (B). 3. Test the motor by connecting battery power and ground according to the table. If the motor does not run or fails to run smoothly, replace it. 4. Test the wiper motor park switch by connecting an analog voltmeter between the No. 4 (+) terminal and ground, and run the motor. The voltmeter should indicate 12 V and 4 V or less alternately. If it does not, replace the motor. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor Windshield Wiper Motor Replacement 1. Open the hood. Remove the nuts (A) and the windshield wiper arms (B). 2. Remove the hood seal and cowl cover. 3. Disconnect the 5P connector (A) from the wiper motor (B). 4. Remove the bolts (C), move windshield wiper linkage assembly (D) toward the passenger's side of the vehicle until it slides off of the pin (E), then remove the assembly. 5. Scribe a line (A) across the link and windshield wiper linkage to show the original adjustment. Separate the windshield wiper linkage (B) from the wiper motor (C). 6. Install in the reverse order of removal, and note these items. - Apply multipurpose grease to the moving parts. - Before reinstalling the wiper arms, turn the wiper switch ON, then OFF to return the wiper shafts to the park position. - If necessary, replace any damaged clips. - Check the wiper motor operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 7953 Wiper Motor: Service and Repair Rear Window Wiper Motor Rear Window Wiper Motor Replacement 1. Open the hatch, and remove the hatch trim panel. 2. Remove the mounting nut (A), the wiper arm (B) and the special nut (C). 3. Disconnect the 4P connector (A), remove the three mounting bolts (B), then remove the rear window wiper motor (C). 4. Install in the reverse order of removal, and note these items. - Apply multipurpose grease to the moving parts. - Before reinstalling the wiper arm, turn the wiper switch ON, then turn OFF to return the wiper shaft to the park position. - If necessary, replace any damaged clips. - Check the wiper motor operation. Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations 73. In Steering Column Cover Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7957 Wipers/Washers - Component Location Index Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7958 180. Wiper/Washer Switch Honda Civic Si Workshop Manual (L4-2.0L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 7959 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover, and under cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. 5. Inspect the connector terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, check for continuity between the terminals in each switch position according to the tables. - If the continuity is not as specified, replace the switch.