Chevrolet - CR-V 4wd - Workshop Manual - 2004 - 2004

Factory Workshop Manual Make Honda Model Cr-v 4wd Engine and year L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 for Alarm Module: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 for Alarm Module: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 for Alarm Module: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 for Alarm Module: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 35. In Steering Column Cover 45. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 23 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 24 Alarm Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 25 Alarm Module: Service and Repair Immobilizer Control Unit-Receiver Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 7P connector (A) from the immobilizer control unit-receiver (B). 4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (C). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with a Honda PGM Tester, then check the immobilizer system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 29 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 30 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 35 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 36 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay (Canada: EX-L) And A/F Sensor Relay ('02) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Page 40 Seat Heater Relay: Testing and Inspection Seat Heaters Relay Test 1. Remove the front seat. 2. Disconnect the 6P connector from the seat heater relay (A). 3. Check for continuity between the No.6 and No.5 terminals, and No.6 and No.4 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. 4. Check for continuity between the No.1 and No.6 terminals, and No.3 and No.4 terminals when power and ground are connected to the No.6 and No.5 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. Seat Heater Main Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations 41. Under left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 44 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 45 Sunroof / Moonroof Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Moonroof Open Relay Moonroof Close Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 50 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. - Take care 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. Disconnect negative cable from the battery. 3. Pull up the lock (A) of the ABS control unit 47P connector (B), then disconnect the connector. 4. Disconnect the six brake lines. 5. Remove the ABS modulator-control unit /bracket (C/D) from the body. 6. Remove the two 6 mm shoulder bolts and 6 mm bolt from the bracket, then remove the ABS modulator-control unit from the bracket. Installation 1. Install the ABS modulator-control unit on the bracket, then tighten the two 6 mm shoulder bolts and 6 mm bolt. 2. Install the ABS modulator-control unit/bracket on the body. 3. Align the connecting surface of the ABS control unit 47P connector. 4. Push in the lock of the ABS control unit 47P connector, then connect the connector. 5. Connect the six brake lines. 6. Bleed the brake system, starting with the front wheels. 7. Start the engine, and check that the ABS indicator and brake system indicator go off. 8. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 55 Radiator Cooling Fan Motor Relay: Testing and Inspection 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. Radiator Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 60 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 65 Blower Motor Relay: Testing and Inspection 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. Blower Motor Relay Blower Motor Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 69 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 70 Compressor Clutch Relay: Testing and Inspection 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. A/C Compressor Clutch Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Condenser Fan Motor Relay: Testing and Inspection 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. Condenser Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 78 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 82 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test (Canada) 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 83 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations 39. Left Kick Panel (USA: P/N 08V31-S9A-11O Honda Acc.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 90 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. 6. Install the switch in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 104 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 105 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 106 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 107 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 108 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 109 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 111 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 112 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 113 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 114 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 115 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 116 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 117 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 118 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 119 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 120 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 121 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 122 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 123 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 124 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 125 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 126 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 127 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 128 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 129 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 130 Interior Lighting Module: Electrical Diagrams Diagram 115-0 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 131 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 132 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 5. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 133 6. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the underdash 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams > Page 137 Low Beam Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Low Beam Cut Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 146 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 147 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 148 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 149 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 151 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 152 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 153 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 156 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 163 DTC P0A94 thru P0157 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 164 DTC P0158 thru P0400 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 165 DTC P0401 thru P0562 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 166 DTC P0563 thru P0748 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 167 DTC P0750 thru P0977 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 168 DTC P0979 thru P1193 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 169 DTC P1253 thru P1459 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 170 DTC P1486 thru P1585 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 171 DTC P1586 thru P1678 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 172 DTC P1679 thru P1860 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 173 DTC P1861 thru P2238 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 174 DTC P2240 thru U0073 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 175 DTC U0100 thru U1288 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 176 Engine Control Module: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 177 82. Behind Glove Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 180 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview Engine Control Module: Initial Inspection and Diagnostic Overview How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 183 Engine Control Module: Pinout Values and Diagnostic Parameters ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 184 ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 185 ECM/PCM Inputs And Outputs At Connector B (24P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 186 PCM Inputs And Outputs At Connector C (22P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 187 PCM Inputs And Outputs At Connector D (17P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 188 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 189 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove the ECM/PCM and test it: 1. Disconnect the negative cable from the battery. 2. Remove glove box. 3. Disconnect the gray 20P ECM/PCM wire harness connector, and remove it from the ECM/PCM mounting bracket. Disconnect the 7 P mode control motor connector. Remove PGM-FI main relay 2 (A). Remove the ECM/PCM mounting bolt (B) and the bracket. 4. Remove the nuts, then remove the ECM/PCM (C). 5. Install the ECM/PCM in the reverse order of removal. 6. Reconnect the negative cable to the battery. 7. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 192 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the HDS does not require you to do the idle learn procedure. - Replace the throttle body. - Replace the idle air control (IAC) valve. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 BATTERY (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fusel relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 193 Engine Control Module: Service and Repair ECM/PCM Updating and Substitution for Testing ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) E0S05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - You can not update an ECM/PCM with the program it already has. It will only accept a new program. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, 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/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the Honda interface module (HIM) to the data link connector (DLC) (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label. If the software in the ECM/PCM is the latest, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS again. 5. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 194 Engine Control Module: Service and Repair ECM Reset How to Reset the ECM/PCM You can reset the ECM/PCM in either of two ways: NOTE: After resetting the ECM/PCM, do the ECM/PCM idle learn procedure. Reset the ECM/PCM with the Scan Tool or the HDS 1. Turn the ignition switch ON (II). Do not start the engine. 2. Use the scan tool or the HDS to clear the DTC. NOTE: For the specific operations, refer to the user's manual that came with the scan tool or the HDS. Reset the ECM/PCM by removing the fuse 1. Turn the ignition switch OFF. 2. Remove the No.6 ECU (ECM/PCM) (15A) fuse (A) from the under-hood fuse/relay box (B) for 10 seconds. How to End a Troubleshooting Session (required after any troubleshooting) 1. Reset the ECM/PCM as described above. 2. Do the ECM/PCM idle learn procedure. 3. Turn the ignition switch OFF. 4. Disconnect the scan tool or the HDS from the DLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a different immobilizer code. To start the engine, you must rewrite the immobilizer code with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 198 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 199 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 200 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 201 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 202 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 203 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 207 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 208 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 213 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 214 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 218 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 219 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 220 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 221 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 222 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 223 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations 73. Under Middle of Dash 93. In Front Passenger's Seat (Side Airbag) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 228 Air Bag Control Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 229 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 230 Air Bag Control Module: Service Precautions Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 231 Air Bag Control Module: Description and Operation SRS Unit The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag and front passenger's airbag. Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the airbag inflators (and seat belt tensioners). 3. The inflators must ignite and deploy the airbags (and activate the tensioners). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 232 Air Bag Control Module: Service and Repair 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 5 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. Remove the right heater unit duct (A). 7. Pull down the carpet on the right side, then remove the Torx bolt (A) and the harness clip (B) from the SRS unit. 8. Pull down the carpet on the left side, then disconnect the connectors. Remove the Torx bolt (A), loosen the Torx bolt (B), then pull out the SRS unit from the right side. 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. Install the right heater unit duct. 3. Reinstall the dashboard center lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 233 4. Reconnect the driver's and front passenger's airbag connectors. 5. Reconnect the side airbag connectors. 6. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 7. Reconnect the battery negative cable. 8. Initialize the OPDS unit. 9. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 242 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 243 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 244 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 245 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 246 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 247 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 248 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 249 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 250 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 251 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 252 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 258 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 259 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 260 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 261 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 262 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 263 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 264 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 265 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 266 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 267 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 268 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 273 Starter Relay: Testing and Inspection 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. Starter Cut Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 279 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Window Control Module: Component Tests and General Diagnostics Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Loss of battery power - Loss of power from the No.6 (7.5A) and/or the No.23 (20A) fuses in the under-dash fuse/relay box. - Open circuit caused by disconnecting the 20P connector from the power window master switch - Removal of the regulator, glass, or glass run channel 1. Make sure the glass is installed properly. 2. Close the driver's door. 3. Turn the ignition switch OFF. 4. Remove the No.23 (20A) fuse in the under-dash fuse/relay box. 5. Turn the ignition switch ON (II). 6. After 1 second, turn the ignition switch OFF. 7. After 5 seconds, install the No.23 (20A) fuse to the under-dash fuse/relay box. 8. Make sure the driver's window does not work in AUTO with the ignition switch ON (II). 9. Start the engine. 10. Move the driver's window all the way down using the manual DOWN function of the driver's power window switch. 11. Move the driver's window all the way up using the manual UP function of the driver's power window switch, and hold it for 1 second after the window reaches the closed position. 12. If the window does not work in AUTO, repeat steps 2 through 12. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 288 Power Window Control Module: Programming and Relearning Power Window Control Unit Reset Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5A) and/or the No. 23 (20A) fuses from 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 by holding the driver's switch firmly down; when the window reaches the bottom, hold the driver's window switch firmly down for 2 seconds. 3. Move the driver's window all the way up by holding the driver's switch firmly up; when the window reaches the top, hold the driver's window switch firmly up for 2 seconds. 4. If the window does not work in AUTO, turn the ignition switch OFF and repeat Step 1 through 3. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations 103. Right Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 299 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 302 Wiper Control Module: Testing and Inspection Rear Wiper Control Unit Input Rear Wiper Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 12P 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. Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 303 Part 2 4. Reconnect the connector and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. 5. Disconnect the connector, and make these input tests at the connector. - If all the input tests prove OK, the control unit must be faulty; replace the rear wiper control unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 309 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 315 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 319 107. Driver's Door 109. Driver's Door 111. Front Passenger's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 320 Power Door Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch Power Door Lock Switch: Testing and Inspection Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 323 Power Door Lock Switch: Testing and Inspection Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 324 Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Identify the type of door lock actuator. 3. Disconnect the 3P connector from the actuator. 4. Check for continuity between the No.1 [No. 2] and No.3 [No. 1] 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. [] : Mitsui Type 5. Check for continuity between the No.1 [No. 2] and No.2 [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. [] : Mitsui Type 6. If the continuity is not as specified, replace the driver's door lock actuator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 325 Power Door Lock Switch: Testing and Inspection Door Lock Switch Door Lock Switch Test 1. Remove the door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the No.1 and No.2 terminals: - There should be continuity when the door lock switch is in the LOCKED position. - There should be no continuity when the door lock 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 switch is in the UNLOCKED position. - There should be no continuity when the door lock switch is in the LOCKED position. 5. If the continuity is not as specified, replace the door lock switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch Power Door Lock Switch: Service and Repair Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch > Page 328 Power Door Lock Switch: Service and Repair Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 332 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 333 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 334 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 335 Power Mirror Switch: Service and Repair Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations 108. Driver's Door 125. Middle of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 339 Power Trunk / Liftgate Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams (Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 343 Seat Heater Switch: Testing and Inspection Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 344 Seat Heater Switch: Service and Repair Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Limit Switch: Component Locations Moonroof Component Location Index 121. Middle of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations > Page 349 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 350 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 351 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test: 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, adjust the limit switch, and recheck. 7. If the continuity is still not as specified, replace the moonroof motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 352 Sunroof / Moonroof Limit Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 357 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 358 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 359 Sunroof / Moonroof Switch: Testing and Inspection Moonroof Switch Test 1. Remove the dashboard lower cover. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the bulb (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 360 Sunroof / Moonroof Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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 (F). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moon roof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 364 Front Door Component Location Index Openers Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations 23. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 369 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 370 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations 46. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 374 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 375 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 376 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. 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. At the insulator cutout, measure the pedal height (B) from the middle of the pedal pad (C). 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 377 4. 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 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. 5. Check the brake pedal free play. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 381 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 382 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel sensor Standard Front/Rear 0.5 - 1.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 386 Wheel Speed Sensor: Locations 138. Left Side of Engine Compartment 143. Right Side of Engine Compartment 145. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 387 148. Under Right Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 388 Wheel Speed Sensor: Diagrams (EX; Canada: EX-L) (EX; Canada: EX-L) (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 389 (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 390 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. The wheel sensors detect changing of magnetic polarity on the magnetic encoder. The ABS control unit calculates the wheel speed based on signals received from the wheel sensor. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 391 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Remove the appropriate front driveshaft or rear driveshaft. 2. Check the magnetic encoder after cleaning the encoder. If necessary, replace the encoder. 3. Measure the air gap between the wheel sensor and the magnetic encoder all the way around while rotating the encoder. Standard: Front/Rear: 0.5 - 1.5 mm (0.02 - 0.06 inch) Note: - Install the wheel brearing with the magnetic encoder (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Be carful not to damage the encoder surface when you insert them wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 392 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 397 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 402 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 403 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 404 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F Turns OFF Subtract 5 - 15 deg F from actual ON temperature Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 408 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 409 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 410 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 411 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then 2. Install the radiator fan switch with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 31. Left Side of Dash 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 416 Cruise Control Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 421 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 426 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 427 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 431 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations 51. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 439 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 440 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 441 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor clockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 446 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 452 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 453 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 454 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 456 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 457 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 459 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 460 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Dimmer Switch: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 463 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 464 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 465 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 466 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 467 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 468 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 469 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 470 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 471 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 472 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 473 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 474 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 475 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 476 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 477 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 478 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 479 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 480 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Dimmer Switch: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 482 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 486 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 490 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from the 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 correctly, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 OK, go to step 8. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fusel relay box for at least 30 seconds, then reinstall it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 491 9. Install a 2 Ohm resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicate "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom 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 locknut (A), and remove the fuel tank unit from the fuel tank. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 492 15. Measure resistance between the No.1 and No.2 terminals with the float at E(EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting. Otherwise, it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 493 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 494 8. Remove the locknut (A) and the fuel tank unit. 9. 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). Be sure to check these items: - When connecting the wire harness, make sure the connection is secure and the connectors (K) are firmly locked into 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 it excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 503 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 504 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 509 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 513 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Remove the driver's dashboard lower cover. 2. Disconnect the 4P connector (A) from the brake pedal position switch (B). 3. 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. 4. Check for continuity between No.3 and No.4 terminals (with cruise control). - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 5. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 517 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations 34. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 521 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 522 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 523 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 527 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 531 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: Customer Interest Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 540 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-064 > Nov > 04 > Lighting Glove Box Lamp Stays ON Glove Box Lamp Switch: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-064 > Nov > 04 > Lighting Glove Box Lamp Stays ON > Page 546 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 552 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 553 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 554 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 560 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 561 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Glove Box Lamp Switch: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 562 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations 59. Center of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 566 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 570 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 583 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 584 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 585 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement > Page 588 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 592 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 593 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 594 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 598 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 599 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 600 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 609 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 610 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 611 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 612 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 618 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 619 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 620 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 621 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 622 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 623 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 624 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Locations Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Locations > Page 628 146. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Locations > Page 629 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 633 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 634 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 635 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the clip (A) and the IAT sensor (B). 3. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 639 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 640 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 641 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 645 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 646 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor convents manifold absolute pressure into electrical signals to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 651 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 652 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: Customer Interest Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 661 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: All Technical Service Bulletins Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 667 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 670 144. Middle Underside of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 671 Oxygen Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM which varies the duration of fuel injection accordingly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 674 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/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The ECM/PCM compares the HO2S output with the A/F sensor output to determine catalyst efficiency. The secondary HO2S is installed in the TWC. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 677 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YAB875, 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 681 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 682 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 683 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 684 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 685 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 694 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 700 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 701 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 702 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 703 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 712 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 713 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 719 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 720 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 726 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 727 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 728 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 734 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 735 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 736 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 737 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 738 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 739 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 740 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 741 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 742 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 743 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 747 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 752 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 753 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 754 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) (M/T) 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 755 Vehicle Speed Sensor: Service and Repair VSS Replacement M/T only: 1. Remove the air cleaner. 2. Disconnect the 3P connector from the vehicle speed sensor (VSS). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 760 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 769 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 775 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > Page 776 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > Page 777 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Technical Service Bulletins > Page 778 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations Variable Induction Position Sensor: Locations Intake Air System - Component Location Index 6. Right Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 782 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 783 Variable Induction Position Sensor: Description and Operation Intake Manifold Runner Control (IMRC) Valve Position Sensor The IMRC position sensor is a potentiometer connected to the IMRC valve shaft. As the IMRC valve position changes, the sensor varies the signal voltage to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 784 Variable Induction Position Sensor: Service and Repair IMRC Valve Position Sensor Replacement 1. Remove the two screws (A) and the IMRC position sensor (B). 2. Install the sensor with a new O-ring (C), and make sure the projection (D) inside the IMRC valve matches up with the groove (E) in the sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 789 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 790 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 791 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement > Page 794 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 798 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 799 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 800 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 806 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 807 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 808 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 809 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 810 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 811 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 812 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 813 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 814 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 815 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 819 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 820 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 821 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 96. Left B-Pillar (Right Similar) 130. Behind Right Side of Front Bumper 135. Behind Left Side of Front Bumper Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 826 Impact Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 827 Impact Sensor: Service Precautions SRS Unit, Front Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF. - During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit, front sensors, and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. - Do not disassemble the SRS unit or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit and side impact sensors are installed securely, with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit or the side impact sensors, and keep them away from dust. - Store the SRS unit and the side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 828 Impact Sensor: Service and Repair 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 and the B-pillar lower trim panel. 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 (1) to the side impact sensor (B). 2. Reconnect the negative battery 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. Front Sensor Replacement Removal 1. Disconnect the negative battery 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 829 4. Disconnect the engine compartment wire harness 2P connector (1), and remove the two Torx bolts (A) using a Torx T30 bit, then remove the front sensor (B). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (1) to the front sensor (B). 2. Reconnect the negative battery cable. 3. After installing the front 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 90. Under Driver's Seat 91. Under Front Passenger's Seat Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 833 Seat Belt Buckle Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 842 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 843 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 844 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 845 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 846 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 847 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 848 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 849 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 850 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 851 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 852 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 858 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 859 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 860 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 861 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 862 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 863 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 864 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 865 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 866 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 867 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 868 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations 43. Under Left Side of Dash (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 873 Clutch Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 874 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector (A). 2. Remove the clutch interlock switch (B). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 880 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 881 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 882 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 883 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 884 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 885 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 886 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 887 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 888 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 889 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 893 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 899 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 900 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 901 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 902 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 903 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 909 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 910 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 914 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 917 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 921 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 922 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 926 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 927 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 928 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 929 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 930 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 931 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 949 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 950 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 951 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 952 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 953 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 954 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 955 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 960 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 964 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 965 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 966 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 967 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 977 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 978 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 984 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 985 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 994 Rear Door Component Location Index 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 995 111. Front Passenger's Door 114. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 996 Power Window Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 997 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1001 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 switch panel from the door panel. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1002 4. Reconnect the 20P 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, go to step 5. 5. Disconnect the 20P connector from the switch 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 the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1003 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1004 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Test/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1007 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1008 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1009 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 1014 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test (Canada) 1. Remove the left inner fender. 2. Disconnect the 2P connector (A) from the washer fluid level switch (B). 3. Check for continuity between the No.1 and No.2 terminals in each float position (C). - There should be continuity when the float is down. - There should be no continuity when the float is up. 4. If the continuity is not as specified, replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1018 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1019 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1020 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1024 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1025 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1026 Wiper Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1042 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1043 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 06-068 > May > 09 > Steering/Suspension - Vehicle Pulls Left/Right > Page 1044 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1056 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1057 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1058 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1063 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1069 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1070 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1071 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1072 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1073 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1074 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1075 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1076 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1077 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1078 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1079 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1080 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1081 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1082 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1083 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1084 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1085 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1086 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1087 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1088 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1089 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Alignment: Specifications Wheel alignment Camber Front 0 deg 00' +/- 45' Rear -1 deg 00' +/- 45' Caster Front 1 deg 45' +/- 1 deg Total Toe Front 0 +/- 2 mm Rear IN 2 [+2/-1] mm Front wheel turning angle Inside wheel 39 deg 45' +/- 2 deg Outside wheel 32 deg 30' (Reference) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment > Page 1092 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1093 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: Front/rear: 205/70R15 95S Tire pressure: Front/rear: 180 kPa (1.8 kgf/cm2, 26 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 manufacture's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: 1°45' ± 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: 0°00' ± 45' Front Camber Adjustment The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1094 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 nuts 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 make sure it is securely supported. 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 it, 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: -1°00'± 45' NOTICE: Do not loosen the special bolts on the trailing arm. Front Toe Inspection/Adjustment 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 ± 2 mm (0 ± 0.08 inch) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1095 3. Loosen the locknut (A) while holding the tie-rod end (B). 4. Turn the tie-rod arm (C) until the toe is correct. NOTE: Adjust both the right and left wheels at the same time by the same amount in opposite directions to obtain the correct toe and to keep the steering wheel straight. 5. After adjusting, tighten the locknut while holding the tie-rod arm. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in: 2 [+2 -1] mm (0.08 [+0.08 -0.04] inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the trailing arm. 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. 5. Turn the adjusting bolt until the toe is correct. Rear toe-in: 2 [+2 -1] mm (0.08 [+0.08 -1] 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1096 1. Turn the steering wheel fully to the right and left while applying the brakes, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................................... 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 psi) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1101 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1102 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment 07VAJ-0040100 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A) at the fuel rail. 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. 7. Remove the fuel pulsation damper from its fitting, and attach the fuel pressure gauge attachment. 8. Attach the fuel pressure gauge. 9. Start the engine and let it idle. - If the engine starts, go to step 11. - If the engine does not start, go to step 10. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1103 10. 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 (II). If the pump runs, go to step 11. - If the pump does not run, do the fuel pump circuit troubleshooting. 11. Read the pressure gauge. The pressure should be 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 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 repeat the test. 12. Remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N.m (2.2 kgf.m, 16 lbf-ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed With no-load conditions: M/T ............................................................................................................... ..................................................................................................... 650 ± 50 rpm A/T ........................... .......................................................................................................................................................... 650 ± 50 rpm (in Park or neutral) With load conditions: M/T .................................................................................................................... ................................................................................................ 700 ± 50 rpm A/T ................................ ..................................................................................................................................................... 700 ± 50 rpm (in park or neutral) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1107 Idle Speed: Description and Operation Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the A/C valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the A/C valve is opened to obtain the proper fast idle speed. The amount of bypassed air is controlled in relation to engine coolant temperature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1108 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. - There are no vacuum leaks - Ignition timing - Throttle cable adjustment - 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 Park or 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: M/T ................................................................................................................... ...................................................................................... 650 ± 50 rpm A/T .......................................... ................................................................................................................................ 650 ± 50 rpm (in Park or neutral) 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: M/T ................................................................................................................... ...................................................................................... 700 ± 50 rpm A/T .......................................... .................................................................................................................................. 700 ± 50 rpm(in park or neutral) NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. 6. Reconnect the EVAP canister purge valve 2P connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 1113 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Remove the PCV hose (A). Open the air cleaner housing cover (B). 2. Remove the air cleaner (C) from the air cleaner housing (D). 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1128 Spark Plug: Application and ID Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure check at 250 rpm with wide open throttle Minimum Standard or new 930 kPa Maximum variation Standard or new 200 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1132 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 (see step 1). 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. Connect a tachometer. 10. 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) - 250 rpm 11. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 12. If the compression is not within specifications, check the following 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valves Clearance (cold) Intake Standard or new 0.21 - 0.25 mm Exhaust Standard or new 0.28 - 0.32 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1136 Valve Clearance: Adjustments Valve Clearance 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. 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 drab. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1137 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until tier? drag on the feeler clause 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. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 belt 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair Drive Belt: Service and Repair Drive Belt Replacement 1. Remove the splash shield. 2. Move the auto-tensioner (A) to relieve tension from the drive belt (B), and remove the drive belt. 3. Install the new belt in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations Intake Air System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 1149 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Remove the PCV hose (A). Open the air cleaner housing cover (B). 2. Remove the air cleaner (C) from the air cleaner housing (D). 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1153 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. 1. Open the glove box. Remove the glove box stop on each side, then hang the glove box down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation Technical Service Bulletin # 04-077 Date: 050301 Campaign - Oil Filter Campaign Cancellation 04-077 March 1, 2005 Applies To: See VEHICLES AFFECTED Customer Assurance Program: CR-V Engine Oil Filter (Supersedes 04-077, dated December 17, 2004) Updated information is shown by asterisks. *As of February 28, 2005, this program is no longer in effect.* BACKGROUND Although it is standard industry practice to make sure the old filter's gasket is removed from the engine block mounting surface before a new filter is installed, we are aware of several instances where this procedure was not properly followed during the first oil filter change. The result has been oil leakage and, in some cases, engine compartment fires. VEHICLES AFFECTED To see if an in-stock new vehicle has already been corrected, do an iN VIN status inquiry. CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification letter of this program. An example of the letter is at the end of this service bulletin. The letter offers customers an optional oil filter inspection. To receive the inspection, these criteria must be met: ^ The vehicle is within the affected VIN range (see VEHICLES AFFECTED). ^ The customer requests the inspection. ^ The first oil filter replacement was done within the last 30 days. Do an inspection only if all three criteria are met. Enclosed with the letter is an adhesive label to be used by the customer at the first oil filter change interval only. The label can be attached to the repair order as a technician reminder to return the old filter gasket to the customer to verify it was properly removed. An example of the label is at the end of this service bulletin. CORRECTIVE ACTION There are four possible corrective actions: ^ In-stock new vehicle: Replace the oil filter; top off but do not replace the engine oil. ^ Customer vehicle with a Honda oil filter: Inspect the oil filter installation. ^ Customer vehicle with a non-Honda oil filter: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1166 Inspect the oil filter installation; strongly suggest replacing the oil filter with a Honda oil filter; if the customer agrees, replace the oil filter, then top off but do not replace the engine oil. ^ Customer vehicle with a double-gasket condition: If a double-gasket condition is found during the inspection, submit a digital photo of the condition, install a new oil filter, then top off but do not replace the engine oil. PARTS INFORMATION Oil Filter: P/N 15400-PLM-A01, H/C 6446231 or P/N 15400-PLM-A02, H/C 6663991 REQUIRED MATERIALS Honda Genuine Motor Oil 5W-20: (Up to 1 quart per vehicle is allowed) P/N 08798-9023, H/C 6512610 WARRANTY CLAIM INFORMATION Failed Part: P/N 15400-PLM-A01 H/C 6446231 Defect Code: 5EBOO Symptom Code: P5700 Skill Level: Repair Technician INSPECTION PROCEDURE: CUSTOMER VEHICLES ONLY NOTE: For in-stock new vehicles, go to REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES. 1. Raise the vehicle on a lift, and look at the oil filter. ^ If a Honda filter is installed, go to step 2. ^ If a non-Honda filter is installed, strongly suggest to your customer that they let you replace it, free of charge, with a Honda oil filter. - If your customer agrees, go to step 2 of REPAIR PROCEDURE A: CUSTOMER VEHICLES. - If your customer does not want the oil filter replaced (unlikely, but possible), document this on the repair order, and let them know you cannot assure the continued reliability of the non-Honda filter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1167 2. Check for a protruding gasket between the oil filter base and the engine block by running your finger around the entire base of the oil filter: ^ If you can feel a protruding gasket, go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot feel a protruding gasket, go to step 3. 3. Try to insert a 0.25 mm (0.010-inch) feeler gauge between the base of the Honda oil filter and the engine block. ^ If you can insert the feeler gauge, the filter may have a double-gasket condition. Go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot insert the feeler gauge, the filter is properly installed. Return the vehicle to the customer. REPAIR PROCEDURE A: CUSTOMER VEHICLES 1. Take a clear, digital photo of the oil filter gasket area, and e-mail the photo to Tech Line: ^ Title your e-mail CR-V Oil Filter Gasket." ^ Attach the photo to your e-mail, then review the photo on your computer to make sure it is clear. ^ You must include the VIN and your dealer number with each e-mail. 2. Remove the oil filter. NOTE: If a non-Honda oil filter with a double-gasket condition is found, document it by taking a clear, digital photo (see step 1). 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1168 ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. NOTE: DO NOT replace the engine oil. 7. Retain any removed parts for DPSM verification and warranty purposes. REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES NOTE: DO NOT replace the engine oil. It contains additives needed for the engine's break-in period. 1. Raise the vehicle on a lift. 2. Remove the original oil filter. IMPORTANT: Remove the gasket from the original oil filter, attach the gasket to the repair order, then discard the filter using normal recycling practices. Retaining the oil filter gasket is required for DPSM verification and warranty purposes. 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1169 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1170 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation Technical Service Bulletin # 04-077 Date: 050301 Campaign - Oil Filter Campaign Cancellation 04-077 March 1, 2005 Applies To: See VEHICLES AFFECTED Customer Assurance Program: CR-V Engine Oil Filter (Supersedes 04-077, dated December 17, 2004) Updated information is shown by asterisks. *As of February 28, 2005, this program is no longer in effect.* BACKGROUND Although it is standard industry practice to make sure the old filter's gasket is removed from the engine block mounting surface before a new filter is installed, we are aware of several instances where this procedure was not properly followed during the first oil filter change. The result has been oil leakage and, in some cases, engine compartment fires. VEHICLES AFFECTED To see if an in-stock new vehicle has already been corrected, do an iN VIN status inquiry. CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification letter of this program. An example of the letter is at the end of this service bulletin. The letter offers customers an optional oil filter inspection. To receive the inspection, these criteria must be met: ^ The vehicle is within the affected VIN range (see VEHICLES AFFECTED). ^ The customer requests the inspection. ^ The first oil filter replacement was done within the last 30 days. Do an inspection only if all three criteria are met. Enclosed with the letter is an adhesive label to be used by the customer at the first oil filter change interval only. The label can be attached to the repair order as a technician reminder to return the old filter gasket to the customer to verify it was properly removed. An example of the label is at the end of this service bulletin. CORRECTIVE ACTION There are four possible corrective actions: ^ In-stock new vehicle: Replace the oil filter; top off but do not replace the engine oil. ^ Customer vehicle with a Honda oil filter: Inspect the oil filter installation. ^ Customer vehicle with a non-Honda oil filter: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1176 Inspect the oil filter installation; strongly suggest replacing the oil filter with a Honda oil filter; if the customer agrees, replace the oil filter, then top off but do not replace the engine oil. ^ Customer vehicle with a double-gasket condition: If a double-gasket condition is found during the inspection, submit a digital photo of the condition, install a new oil filter, then top off but do not replace the engine oil. PARTS INFORMATION Oil Filter: P/N 15400-PLM-A01, H/C 6446231 or P/N 15400-PLM-A02, H/C 6663991 REQUIRED MATERIALS Honda Genuine Motor Oil 5W-20: (Up to 1 quart per vehicle is allowed) P/N 08798-9023, H/C 6512610 WARRANTY CLAIM INFORMATION Failed Part: P/N 15400-PLM-A01 H/C 6446231 Defect Code: 5EBOO Symptom Code: P5700 Skill Level: Repair Technician INSPECTION PROCEDURE: CUSTOMER VEHICLES ONLY NOTE: For in-stock new vehicles, go to REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES. 1. Raise the vehicle on a lift, and look at the oil filter. ^ If a Honda filter is installed, go to step 2. ^ If a non-Honda filter is installed, strongly suggest to your customer that they let you replace it, free of charge, with a Honda oil filter. - If your customer agrees, go to step 2 of REPAIR PROCEDURE A: CUSTOMER VEHICLES. - If your customer does not want the oil filter replaced (unlikely, but possible), document this on the repair order, and let them know you cannot assure the continued reliability of the non-Honda filter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1177 2. Check for a protruding gasket between the oil filter base and the engine block by running your finger around the entire base of the oil filter: ^ If you can feel a protruding gasket, go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot feel a protruding gasket, go to step 3. 3. Try to insert a 0.25 mm (0.010-inch) feeler gauge between the base of the Honda oil filter and the engine block. ^ If you can insert the feeler gauge, the filter may have a double-gasket condition. Go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot insert the feeler gauge, the filter is properly installed. Return the vehicle to the customer. REPAIR PROCEDURE A: CUSTOMER VEHICLES 1. Take a clear, digital photo of the oil filter gasket area, and e-mail the photo to Tech Line: ^ Title your e-mail CR-V Oil Filter Gasket." ^ Attach the photo to your e-mail, then review the photo on your computer to make sure it is clear. ^ You must include the VIN and your dealer number with each e-mail. 2. Remove the oil filter. NOTE: If a non-Honda oil filter with a double-gasket condition is found, document it by taking a clear, digital photo (see step 1). 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1178 ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. NOTE: DO NOT replace the engine oil. 7. Retain any removed parts for DPSM verification and warranty purposes. REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES NOTE: DO NOT replace the engine oil. It contains additives needed for the engine's break-in period. 1. Raise the vehicle on a lift. 2. Remove the original oil filter. IMPORTANT: Remove the gasket from the original oil filter, attach the gasket to the repair order, then discard the filter using normal recycling practices. Retaining the oil filter gasket is required for DPSM verification and warranty purposes. 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1179 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1180 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1181 Oil Filter: Specifications After the rubber seal seats, tighten the oil filter clockwise with the special tool. Tighten: 7/8 turn clockwise Tightening torque: 22 Nm (2.2 kgf.m 16 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1182 Oil Filter: Service and Repair Engine Oil Filter Replacement Special Tools Required Oil filter wrench 07HAA-PJ70700 - 0il Filter wrench 07912-6110001 - Engine Oil Filter (3/4-turn type) 1. Remove the oil filter it with the special oil filter wrench. 2. Inspect the threads (A) and the 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1183 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 the 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. Engine Oil Filter (7/8-turn type) 1. Remove the oil filter with the special oil filter wrench. 2. Inspect the threads (A) and rubber seal (B) on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filters with a built-in bypass system. 3. Install the oil filter by hand. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1184 4. After the rubber seal seats, tighten the oil filter clockwise with the special tool. 5. If 8 numbers (1 to 8) are printed around the outside of the filter, use the following procedure to tighten the filter. - Spin the filter on until its seal lightly seats against the block, and note which number is at the bottom. - Tighten the filter by turning it clockwise 7 numbers from the one you noted. For example, if number 2 is at the bottom when the seal is seated, tighten the filter until the number 1 comes around the bottom. 6. After installation, fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oil leakage. Oil Filter Feed Pipe Replacement 1. Remove the oil filter. 2. Remove the oil filter feed pipe. 3. Tighten the new oil filter feed pipe to 49 Nm (5.0 kgf-m, 36 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Hose/Line HVAC: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1194 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1195 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1196 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1197 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1198 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1199 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1200 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1201 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1202 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1203 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1204 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1205 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1206 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1207 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Hose/Line HVAC: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1213 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1214 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1215 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1216 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1217 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1218 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1219 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1220 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1221 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1222 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1223 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1224 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1225 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 1226 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid .......................................................................................................................................... .......................... Genuine Honda DOT 3 Brake Fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1234 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1235 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid .................................................................................................................................................. Genuine Honda DOT 3 or DOT 4 Brake Fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Radiator Coolant capacity M/T at engine overhaul 7.2 L (7.6 US qt.) (includes engine, heater, hoses, and reservoir) M/T at coolant change 5.5 L (5.8 US qt.) A/T at engine overhaul 7.1 L (7.5 US qt.) A/T at coolant change 5.4 L (5.7 US qt.) Reservoir Coolant capacity 0.55 L (0.58 US qt.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1243 Coolant: Fluid Type Specifications Only use Honda All Season Antifreeze/Coolant Type 2 (P/N 0L999-9001) at 50 percent concentration with water. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1244 Coolant: Service Precautions 1. Genuine Honda Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1245 Coolant: Testing and Inspection Coolant 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1246 Coolant: Service and Repair Coolant 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 bulkhead cover (see step 7). 3. Remove the radiator cap. 4. Loosen the drain plug (A), and drain the coolant. 5. Remove the reserve tank mounting bolt (A), and remove the reserve tank. 6. Remove the coolant tube from the radiator. Put the end of the coolant tube lower than the reserve tank and drain the coolant from the tank. 7. After the coolant has drained, tighten the radiator drain plug. Reinstall the coolant tube and reserve tank. 8. Install the bulkhead cover (see step 4). 9. Fill the reserve tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1247 10. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. 11. Install the radiator cap loosely. 12. Start the engine, and let it run until it warms up (the radiator fan comes on at least twice). 13. Turn off the engine. Check the level in the radiator and add Honda All Season Antifreeze/Coolant Type 2 if needed. 14. Put the radiator cap on tightly, then run the engine again and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Fluid - A/T: Pressure, Vacuum and Temperature Specifications ATF pressure Line pressure at 2,000 rpm in P or N position Standard or new 900 - 960 kPa Service limit 950 kPa 1st clutch pressure at 2,000 rpm in 1st gear in 1 position Standard or new 890 - 970 kPa Service limit 840 kPa 2nd clutch pressure at 2,000 rpm in 2nd gear in 2 position Standard or new 890 - 970 kPa Service limit 840 kPa 3rd clutch pressure at 2,000 rpm in 3rd gear in D position Standard or new 890 - 970 kPa Service limit 840 kPa 4th clutch pressure at 2,000 rpm in 4th gear in D position Standard or new 890 - 970 kPa Service limit 840 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1254 Fluid - A/T: Capacity Specifications A/T Fluid Change ................................................................................................................................................ .............................................................. 3.1L (3.3 Qt) Total ................................................................ .................................................................................................................................................. 7.2L (7.6 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1255 Fluid - A/T: Fluid Type Specifications ATF (Automatic Transmission Fluid) ..................................................................................................................................................... Use Honda ATF-Z1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1256 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > ATF Level Check Fluid - A/T: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick back into the transmission. 5. Remove the dipstick (A), and check the fluid level. It should be at upper mark (B). 6. If the level is below the upper mark, check for fluid leaks at the transmission, hose and line joints, and cooler lines. 7. Pour the recommended fluid amount into the dipstick hole to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > ATF Level Check > Page 1259 8. Insert the dipstick (A) back into the transmission with the handle pointing toward the breather tube (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > ATF Level Check > Page 1260 Fluid - A/T: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. 1. Bring the transmission up to normal operating temperature (the radiator fan comes on) by driving the vehicle. 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 4. Reinstall the drain plug with a new sealing washer (B). 5. Refill transmission with the recommended fluid amount through the dipstick hole until the level reaches the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 4WD: 3.1 L (3.3 US qt. 2.7 Imp qt) at change 7.2 L (7.6 US qt. 6.3 Imp qt) at overhaul 2WD: 2.9 L (3.1 US qt. 2.6 Imp qt) at change 6.5 L (6.9 US qt. 5.7 Imp qt) at overhaul Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid Change ................................................................................................................................ ............................................................................... 2.0 Qt (1.9L) Overhaul ......................................... .............................................................................................................................................................. ...... 2.4 Qt (2.3L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1269 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ..................................................................................................................................................... ............... Honda Manual Transmission Fluid (MTF) If not available you may use 10W-30 or 10W-40 motor oil with an API certification seal that says "For Gasoline Engines" as a temporary replacement. However, motor oil does not contain the proper additives and continued use can cause stiffer shifting. Replace with Honda MTF as soon as it is convenient. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1270 Fluid - M/T: Testing and Inspection 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 1.9 L (2.0 US qt., 1.7 Imp qt.) at fluid change 2.3 L (2.4 US qt., 2.01 Imp qt.) at overhaul Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. 5. Reinstall the oil filler plug with a new washer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1271 Fluid - M/T: Service and Repair For further information, refer to Testing and Inspection; Procedures. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns Fluid - Differential: Customer Interest Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 1280 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 1281 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns Fluid - Differential: All Technical Service Bulletins Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 1287 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 1288 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Change ................................................................................................................................................ .............................................................. 1.0L (1.1 Qt) Total ................................................................ .................................................................................................................................................. 1.2L (1.3 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1291 Fluid - Differential: Fluid Type Specifications Differential Fluid Type ..................................................................................................................................................... ........................................... Honda Dual Pump Fluid Do NOT use Automatic Transmission Fluid (ATF). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1292 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1293 Fluid - Differential: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1294 Fluid - Differential: Service and Repair Inspection and Replacement 1. With the vehicle on level ground, inspect the differential fluid with engine OFF. 2. Remove the oil filler plug (A) and sealing washer (B), then check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. The fluid level must be up to the fill hole. If it is below the hole, add the recommended fluid until it runs out, then reinstall the oil filler plug with a new sealing washer. 4. If the differential fluid is dirty, remove the drain plug (A), and drain the fluid. 5. Clean the drain plug, then reinstall it with a new sealing washer, and refill the differential with the recommended fluid to the proper level. NOTE: If you disassembly the differential, check the fluid level again after the 4WD system check is finished. Add fluid if necessary. Fluid Capacity 1.0 L (1.1 US qt., 0.9 Imp qt.) at fluid change 1.2 L (1.3 US qt., 1.1 Imp qt.) at overhaul Recommended fluid: Honda Dual Pump Fluid 6. Reinstall the oil filler plug with a new sealing washer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Automatic Trans and Transfer Transfer Case Change ................................................................................................................................................ ......................................................................... 3.1 Qt Overhaul ......................................................... .............................................................................................................................................................. 7.2 Qt Manual Trans and Transfer Transfer Case Change................................................................................................................................................. .............................................................. 1.9L (2.0 Qt) Overhaul........................................................... .................................................................................................................................................. 2.3L (2.4 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1299 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............. Honda Manual Transmission Fluid (MTF). Do not use motor oil. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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) NOTE: Listed capacities are approximate. Check fluid level after filling. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1306 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification .................................................................................................................................... Make sure the label says "For Gasoline Engines". From -20°F (-30°C) to over 100°F (40°C) .......................................................................................................................................................... SAE 5W-20 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1307 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1308 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 quarts 3.5 Imp quarts) at oil change. 4.2 L (4.4 US quarts 3.7 Imp quarts) at oil change including filter. 5.3 L (5.6 US quarts 4.7 Imp quarts) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Capacity For fluid change ................................................................................................................................... ...................................... 0.26 L (0.27 US qt.) For system overhaul ..................................................... .............................................................................................................. 0.75 L (0.79 US qt.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1313 Power Steering Fluid: Fluid Type Specifications Power steering fluid ........................................................................................................................................................... Use Honda Power Steering Fluid Do not use ATF Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1314 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1315 Power Steering Fluid: Service and Repair Replacement Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. 1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once. 2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. 3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid. 4. Reinstall the return hose on the reservoir. 5. Fill the reservoir to the upper level line (C}. 6. Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system. 7. Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1320 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1321 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 1322 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Type HFC - 134a (R-134a) Capacity of Systems 480 - 530 g (17 - 18.7 oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1325 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Performance Test Refrigerant: Testing and Inspection Performance Test A/C System Tests Performance Test CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. WARNING: - Compressed air mixed R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134 a service equipment or vehicle air conditioning systems. The performance test will help determine if the air conditioner system is operating within specifications. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions. 2. Insert a thermometer in the center air vent. Determine the relative humidity and air temperature. 3. Test conditions: - Avoid direct sunlight. - Open the hood. - Open the front doors. - Set the temperature control dial on Max Cool, the mode control dial on Vent and the recirculation control switch on Recirculate. - Turn the A/C switch on and the fan switch on Max. - Run the engine at 1,500 rpm. - No driver or passengers in vehicle. 4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the A/C gauges. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 1328 5. To complete the charts: - Mark the delivery temperature along the vertical line. - Mark the intake temperature (ambient air temperature) along the bottom line. - Draw a line straight up from the air temperature to the humidity. - Mark a point 10 % above and 10 % below the humidity level. - From each point, draw a horizontal line across the delivery temperature. - The delivery temperature should fall between the two lines. - Complete the low-side pressure test and high-side pressure test in the same way. - Any measurements outside the line may indicate the need for further inspection. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 1329 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 1330 Refrigerant: Testing and Inspection Refrigerant Leak Test Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available WARNING: - Compressed air mixed with R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system. CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 480 to 530 g 1.48 to 0.53 kg 1.06 to 1.17 lbs 16.9 to 18.7 oz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. 5. After checking and repairing leaks, the system must be evacuated. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Refrigerant Recovery CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery > Page 1333 Refrigerant: Service and Repair System Evacuation System Evacuation CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C system has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) 2. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. Evacuate the system. 3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery > Page 1334 Refrigerant: Service and Repair System Charging System Charging CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (8) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Evacuate the system. 3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only KEIHIN SP-10 refrigerant oil. 4. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 480 to 530 g 0.48 to 0.53 kg 1.06 to 1.17 lbs 16.9 to 18.7 oz 5. Check for refrigerant leaks. 6. Check for system performance. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Oil Type KEIHIN: SP-10 Capacity Of Components Condenser 5/6 fl. oz (0.9 imp. oz) Evaporator 1 1/3 fl. oz (1.4 imp. oz) Each Line and Hose 1/3 fl. oz (0.5 imp. oz) Reciever 1/3 fl. oz (0.4 imp. oz) Compressor 4 1/3 fl. oz (4.6 imp. oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1339 Refrigerant Oil: Fluid Type Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Oil Type KEIHIN: SP-10 Capacity Of Components Condenser 5/6 fl. oz (0.9 imp. oz) Evaporator 1 1/3 fl. oz (1.4 imp. oz) Each Line and Hose 1/3 fl. oz (0.5 imp. oz) Reciever 1/3 fl. oz (0.4 imp. oz) Compressor 4 1/3 fl. oz (4.6 imp. oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1340 Refrigerant Oil: Service and Repair A/C Refrigerant Oil Replacement Recommended PAGoil: KEIHIN SP-10: - PIN 38897-P931A01AH: 120 ml (4 fl.oz) - PIN 38899-P13A01: 40 ml (1 1/3 fl.oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1341 Add the recommended refrigerant oil in the amount listed if you replace any of the following parts: - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Fluid type Honda DOT3 brake fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications > Page 1345 Brake Bleeding: Service and Repair Brake System Bleeding NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. - Do not reuse the drained fluid. - Always use Honda DOT3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Loosen the left-front brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications > Page 1346 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 1352 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 1353 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 1354 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 1355 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 1358 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 1359 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 1360 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 1361 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1364 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1365 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 1366 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1372 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 1373 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Connector Views Fuse: Connector Views (Honda Accessory) (Honda Accessory) (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1378 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1379 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1384 Fuse Block: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1385 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1388 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1389 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1390 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1391 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1392 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1393 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and the under-dash fuse/relay box (A). 6. Disconnect the 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 dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1398 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Component Locations > Page 1399 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1400 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1401 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1402 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1403 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1404 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1405 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 1408 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair 1. Turn off the engine. 2. Press and hold the Select/Reset button in the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button for at least 10 seconds, until the indicator resets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete the vehicle may fail the test, or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are complete. If it blinks five times, one or more readiness codes are not complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1416 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect a scan tool or the HDS to the data link connector (DLC). 2. Turn the ignition switch ON (II), and read the scan tool or the HDS. Does the scan tool or the HDS communicate with the ECM/PCM? YES - Go to step 3. NO - Go to "DLC Circuit Troubleshooting". 3. Check the scan tool or the HDS for DTCs. Are any DTCs indicated? YES - Go to the indicated DTCs Troubleshooting. 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 comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC) - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. - The readiness codes are not set. (This is indicated if the MIL blinks five times after you turn the ignition switch ON (II) and wait about 20 seconds.) 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 (50A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/WHT wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, intake manifold runner control (IMRC) valve position sensor, or countershaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, or mainshaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Check the low oil pressure light (with the ignition switch ON). Is the low oil pressure light on? YES - Go to step 9. NO - Go to step 7. 7. Inspect the No.10 METER (7.5A) fuse in the under dash fuse/relay box. Is the fuse OK? YES - Go to step 8. 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. 8. Inspect the No.20 IG (50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (50A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1417 NO - Repair short in the wire between No.20 IG (50A) fuse and the under-dash fuse/relay box. All replace the No.20 IG (50A) fuse. 9. Try to start the engine. Does the engine start? YES - Go to step 10. NO - Go to step 13. 10. Turn the ignition switch OFF. 11. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 12. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 13. Turn the ignition switch OFF. 14. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 15. 15. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box. 16. Remove the glove box. 17. Remove PGM-FI main relay 1(A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1418 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Did the continuity go away when one of the components or connectors was disconnected? YES - Replace the component that made the short to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 20. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1419 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31 P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 26. Make sure the SRS has no DTC. If there is any DTC, troubleshoot them first. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1420 27. Remove PGM-FI main relay 2 (A). 28. Disconnect the SRS unit connectors. 29. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or between the No.17 FUEL PUMP (15A) fuse and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 30. 30. Fold the rear seats forward, and pull back the carpet to expose the access panel. 31. Remove the access panel from the floor. 32. Disconnect the fuel pump 5P connector. 33. 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 34. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1421 34. Reinstall PGM-FI main relay 2 (A). 35. 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. 36. Disconnect ECM/PCM connector E (31P). 37. Turn the ignition switch ON (II). 38. Measure voltage between ECM/PCM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 39. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1422 39. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 44. NO - Go to step 40. 40. Turn the ignition switch OFF. 41. Remove PGM-FI main relay 1(A). 42. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 43. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1423 43. Check for continuity between PGM-FI main relay 14P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 44. Reconnect ECM/PCM connector E(31P). 45. Turn the ignition switch ON (II). 46. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 53. NO - Go to step 47. 47. Turn the ignition switch OFF. 48. Remove PGM-FI main relay 1(A). 49. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1424 50. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 51. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. 51. Turn the ignition switch OFF. 52. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminal 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/PCM (A2, A3). 53. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there more than 0.2 V? YES - Repair open in the wire(s) that had more than 0.2 V between G101 and the ECM/PCM (A4, A5, A23, A24). NO - Go to step 54. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1425 54. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 61. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect the 3P connector from these sensors. - Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) 59. Disconnect ECM/PCM connector A (31 P). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1426 60. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, the IMRC valve position sensor, or the output shaft (countershaft) speed sensor(A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 61. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connector from each of the following sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1427 NO - Go to step 64. 64. Turn the ignition switch OFF. 65. Disconnect the 3P connector from these sensors: - Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) 66. Disconnect ECM/PCM connector A (31 P). 67. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the TP sensor or input shaft (mainshaft) speed sensor (A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 68. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1428 72. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF. 74. Disconnect ECM/PCM connector E(31 P). 75. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). 78. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1429 NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM/PCM connector E(31 P). 81. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29), the SRS unit, or the ABS modulator-control unit. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 82. Turn the ignition switch OFF. 83. Disconnect ECM/PCM connector E(31P). 84. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse, or the automatic transmission in the P position. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Tubless Tire Repair Information Tires: Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Tubless Tire Repair Information > Page 1438 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Aluminum wheel runout Axial Standard or new 0 - 0.7 mm Service limit 2.0 mm Radial Standard or new 0 - 0.7 mm Service limit 1.5 mm Steering wheel runout Axial Standard or new 0 - 1.0 mm Service limit 2.0 mm Radial Standard or new 0 - 1.0 mm Service limit 1.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Wheel Bearings - Humming Or Growling Wheel Bearing: Technical Service Bulletins Wheel Bearings - Humming Or Growling SOURCE: Honda Service News November 2003 TITLE: Humming or Growling? Check the Wheel Bearings APPLIES TO: 1998-04 Accord, 2001-04 CR-V, 2003 Element, 1999-04 Odyssey SERVICE TIP: A bad front wheel bearing(s) can make a humming or growling that's easily mistaken for a noisy bearing or gear in the A/T. Before you order a reman A/T, test-drive the vehicle to make sure the A/T is really the problem. Listen carefully as you accelerate and decelerate during your test-drive. Shift into neutral. Varying throttle position and shifting into neutral changes the load on the A/T bearings and gears. If the A/T has a bad bearing or gear, the change in load will affect its noise level. If that's what you find, then go ahead and order a reman A/T. If the noise level isn't affected by changes in throttle position or shifting into neutral, then the culprit could be a bad front wheel bearing(s). Since the wheel bearings aren't mounted on shafts being spread apart by gears, they're not affected by changes in load. Also, since Honda uses angular contact wheel bearings, you won't normally hear a change in noise level when you swerve the vehicle from side to side. Hook up a STEELMAN® ChassisEAR (T/N JSP SM06600) to the front knuckles, and test-drive the vehicle again. Refer to S/B 00-063, STEELMAN ChassisEAR Diagnostic Tool, for more info. If you hear humming or growling from one or affected wheel bearing(s), and then test-drive the vehicle to make sure the noise is gone. If you don't hear any noise from the front wheel bearings, the problem could be from tire noise or vibration. Swap the front wheels and tires with a known-good vehicle. Testdrive the vehicle, and check if the noise or vibration goes away. STEELMAN(R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front > Page 1448 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Page 1449 Wheel Bearing: Testing and Inspection Inspection 1. Raise the vehicle, and make sure it is securely supported. 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. 3. Set up the dial gauge against the hub cap as shown, and measure the bearing end play by 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Special Tools Required Hub disassembly tool 07GAF-SD40100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle and Hub Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1452 2. Remove the wheel cap, wheel nuts, and front wheel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1453 8. With ABS: 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 clip (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the clip into the ball joint pin from the inside to the outside of the vehicle. The closed end of the clip must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1454 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. 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. - First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specific torques. Do not place the jack against the ball joint pin of the lower arm. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the clip hole. Do not align the castle nut by loosening it. - Install a new clip 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. - Replace the self-locking nuts, damper pinch bolts and nuts with new ones. 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. Wheel Bearing Replacement 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1455 3. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 5. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 6. 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. NOTE (with ABS): Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1456 7. Install the snap ring (A) securely in the knuckle (B). 8. Install the splash guard (C), and tighten the screws (D) to the specified torque. 9. Press a wheel bearing (A) onto the hub (B) using the special tools and a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1457 Wheel Bearing: Service and Repair Rear Knuckle/Hub/Wheel Bearing Special Tools Required Hub disassembly tool 07965-SA70100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1458 2. Release the parking brake lever. 3. Remove the brake hose mounting bolt (A). 4. 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. 5. Remove the brake disc retaining screw (A), and screw two 8 x 1.25 mm bolts into the brake disc/ drum (B) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the brake disc/drum excessively. Remove the brake disc/drum. 6. Raise the stake (A), and remove the spindle nut (B). Remove the rear axle shaft (C) from vehicles with 2WD. 7. Remove the parking brake shoes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1459 8. Remove the parking brake cable (A) from the backing plate. NOTE: The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. 9. Remove the wheel sensor (A) from the knuckle (if equipped with ABS). 10. Place a floor jack under the trailing arm (A) to support it. NOTE: Do not place the jack against the plate section of the lower arm. Be careful not to damage any suspension components. 11. Remove the flange bolt, and disconnect the upper arm (B) from the knuckle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1460 12. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), then remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 13. Remove the flange bolt (D). 14. Remove the knuckle (A) while pushing in the driveshaft and holding the driveshaft outboard joint (B) (4WD only). 15. 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 and adjusting cam with the marked positions when tightening. - Use a new self-locking nut on reassembly. - 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/drum, clean the mating surfaces of the rear hub and the inside of the brake disc/drum. - Before installing the wheel, clean the mating surfaces of the brake disc/drum and the inside of the wheel. - Check the rear wheel alignment, and adjust it if necessary. Wheel Bearing Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1461 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with a press attachment (C) or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. Remove the brake hose mounting bracket (A). 3. Remove the backing plate (B), and snap ring (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press. 5. Press the wheel bearing inner race (A) from the hub (B) using the special tool, a commercially available bearing separator (C), and a press. 6. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1462 7. 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. Be careful not to damage the sleeve of the pack seal. NOTE (with ABS) Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. 8. Install the snap ring (A), backing plate (B), and brake hose mounting bracket (C). Tighten the flange nuts and bolts to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1463 9. Install the hub (A) on the knuckle (B) using the special tools and a hydraulic press. Be careful not to deform the backing plate (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Diagrams > Front > Page 1468 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS Wheel Nuts .......................................................................................................................................... ............................................... 108 Nm (80 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair Jump Starting Jump Starting with an Auxiliary (Booster) Battery CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children. Jump Starting Procedure 1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the "PARK" position. If the vehicle is equipped with a manual transmission, place the shift lever in the "NEUTRAL" position. Turn "OFF" the ignition. Turn "OFF" all lights and any other accessory requiring electrical power. 2. Look at the built-in hydrometer. If the indication area of the built-in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned "OFF". 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 1475 Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 to transport 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 hooks 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. Never tow the vehicle with wheel lift equipment. 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. This method of towing the CR-V is unacceptable. The only recommended way of towing the CR-V is on a flat-bed truck. Towing the 4WD CR-V with only two wheels on the ground will damage parts of the 4WD system. The 2WD CR-V may also be towed with the front wheels off the ground, or with all four wheels on the ground. If the 2WD CR-V 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, or if the vehicle is towed with all four wheels on the ground, do the following: Manual Transmission - Release the parking brake. - Shift the transmission to Neutral. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Page 1479 Automatic Transmission - Release the parking brake. - Start the engine. - Shift to the D position, then the N position. - Turn off the engine. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse, or the automatic transmission in the P position. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1491 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1492 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1493 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1494 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1495 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1496 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1497 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1498 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1499 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1500 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1501 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1502 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1503 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1504 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1505 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1506 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1507 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1508 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1509 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1510 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1511 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1512 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1513 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1514 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1515 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1516 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1517 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1518 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1519 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1520 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1521 System Diagram Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1522 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 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. - Reduces the cam advance at idle, stabilizes 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1523 VTEC system - The VTEC system changes the cam profile to correspond to the 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 VTEC/VTC Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1524 Variable Valve Timing Actuator: Testing and Inspection VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1525 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1526 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1527 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations Variable Valve Timing Solenoid: Locations VTEC/VTC - Component Location Index 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1531 5. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1532 Variable Valve Timing Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1533 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Page 1534 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure check at 250 rpm with wide open throttle Minimum Standard or new 930 kPa Maximum variation Standard or new 200 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1538 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 (see step 1). 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. Connect a tachometer. 10. 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) - 250 rpm 11. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 12. If the compression is not within specifications, check the following 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft End play Standard or new 0.05 - 0.20 mm Service limit 0.4 mm Camshaft-to-holder oil clearance No.1 journal Standard or new 0.030 - 0.069 mm Service limit 0.15 mm No.2, 3, 4, 5 journals Stnadard or new 0.060 - 0.099 mm Service limit 0.15 mm Total runout Standard or new 0.03 mm Maximum Service limit 0.04 mm Cam lobe height Intake, primary Standard or new 33.925 mm Intake, secondary Standard or new 29.638 mm Exhaust Standard or new 34.092 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1546 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Service limit 0.08 mm Exhaust Standard or new 0.018 - 0.056 mm Service limit 0.08 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1550 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test Special Tools Required 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) (see step 1). 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), air socket adapter (E), and air pressure regulator with a 0 - 100 psi gauge (F). 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1551 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-m, 16 ft. lbs.). 14. Tighten the sealing bolt to 20 Nm (2.0 kgf-m, 14 ft. lbs.). 15. Install the cylinder head cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1552 Rocker Arm Assembly: 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1558 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1559 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1560 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1561 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1562 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1563 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1564 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1565 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1566 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1567 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1568 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1569 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1570 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1571 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1572 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1573 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1574 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1575 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1576 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1577 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1578 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1579 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1580 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1581 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1582 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1583 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1584 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1585 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1586 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1587 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1588 System Diagram Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1589 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 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. - Reduces the cam advance at idle, stabilizes 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1590 VTEC system - The VTEC system changes the cam profile to correspond to the 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 VTEC/VTC Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1591 Variable Valve Timing Actuator: Testing and Inspection VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1592 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1593 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1594 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Balancer Shaft Buzz Or Rattle Is Normal Balance Shaft: Technical Service Bulletins Balancer Shaft Buzz Or Rattle Is Normal SOURCE: Honda Service News June 2004 TITLE: Balancer Shaft Buzz or Rattle Is Normal APPLIES TO: A/T-equipped 2003-04 Accord L4s, 2002-04 CR-Vs, and 2003-04 Elements. SERVICE TIP: Have customers complained of a buzz or rattle when the vehicle is sitting in Park or Neutral and the engine is winding down from 3,000 to 2,000 rpm? What they're hearing is a harmonic resonation coming from the oil pump and balancer shaft assemblies, which is a normal characteristic of the vehicle. Don't bother replacing engine components; it won't change or reduce this condition. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Page 1600 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 1608 Connecting Rod: Specifications Connecting rod Pin-to-rod clearance Standard or new 0.005 - 0.015 mm Service limit 0.02 mm Small-end bore diameter Standard or new 21.970 - 21.976 mm Large-end bore diameter (Normal) Standard or new 51.0 mm End play installed on crankshaft Standard or new 0.15 - 0.30 mm Service limit 0.40 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Page 1609 Connecting Rod: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Information was not provided by manufacturer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft bearings Main bearing-to-journal oil clearance No.1 journal Standard or new 0.017 0.041 mm Service limit 0.050 mm No.2 journal Standard or new 0.017 - 0.041 mm Service limit 0.050 mm No.4 journal Standard or new 0.017 - 0.041 mm Service limit 0.050 mm No.5 journal Standard or new 0.017 - 0.041 mm Service limit 0.050 mm No.3 journal Standard or new 0.025 - 0.049 mm Service limit 0.055 mm Rod bearing clearance Standard or new 0.021 - 0.049 mm Service limit 0.060 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1616 Crankshaft Main Bearing: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 journal Standard or new 54.984 - 55.008 mm No.2 journal Standard or new 54.984 - 55.008 mm No.4 journal Standard or new 54.984 - 55.008 mm No.5 journal Standard or new 54.984 - 55.008 mm No.3 journal Standard or new 54.976 - 55.000 mm Rod journal diameter Standard or new 47.976 - 48.000 mm Rod/main journal taper Standard or new 0.005 mm Maximum Service limit 0.010 mm Rod/main journal out-of-round Standard or new 0.005 mm Maximum Service limit 0.010 mm End play Standard or new 0.10 - 0.35 mm Service limit 0.45 mm Runout Standard or new 0.03 mm Maximum Service limit 0.04 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1620 Crankshaft: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley 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 (see step 22). 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 below. 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-m, 181 ft. lbs.) with a torque wrench and 19 mm socket (c). Do not use an impact wrench. 4. Install the splash shield (see step 21). 5. Install front tires/wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Skirt O.D. at 13 mm (0.5 inch) from bottom of skirt No letter or A Standard or new 86.980 86.990 mm Service limit 86.930 mm Letter B Standard or new 86.970 - 86.980 mm Service limit 86.920 mm Clearance in cylinder Standard or new 0.020 - 0.040 mm Service limit 0.05 mm Ring groove width Top Standard or new 1.230 - 1.240 mm Service limit 1.26 mm Second Standard or new 1.240 - 1.250 mm Service limit 1.270 mm Oil Standard or new 2.005 - 2.025 mm Service limit 2.05 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1627 Piston: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 or new 21.961 - 21.965 mm Service limit 21.953 mm Pin-to-piston clearance Standard or new -0.005 - +0.002 mm Service limit 0.005 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1631 Piston Pin: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston ring Ring-to-groove clearance Top Standard or new 0.045 - 0.070 mm Service limit 0.13 mm Second Standard or new 0.050 - 0.075 mm Service limit 0.13 mm Ring end gap Top Standard or new 0.20 - 0.35 mm Service limit 0.60 mm Second Standard or new 0.40 - 0.55 mm Service limit 0.70 mm Oil Standard or new 0.20 - 0.70 mm Service limit 0.80 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1635 Piston Ring: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valves Clearance (cold) Intake Standard or new 0.21 - 0.25 mm Exhaust Standard or new 0.28 - 0.32 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1640 Valve Clearance: Adjustments Valve Clearance 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. 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 drab. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1641 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until tier? drag on the feeler clause 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. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Service limit 0.08 mm Exhaust Standard or new 0.018 - 0.056 mm Service limit 0.08 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1648 Rocker Arm Assembly: Testing and Inspection VTEC Rocker Arm Test Special Tools Required 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) (see step 1). 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), air socket adapter (E), and air pressure regulator with a 0 - 100 psi gauge (F). 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1649 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-m, 16 ft. lbs.). 14. Tighten the sealing bolt to 20 Nm (2.0 kgf-m, 14 ft. lbs.). 15. Install the cylinder head cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1650 Rocker Arm Assembly: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 or new 5.515 - 5.530 mm Service limit 5.55 mm Exhaust Standard or new 5.515 - 5.530 mm Service limit 5.55 mm Installed height Intake Standard or new 15.2 - 16.2 mm Exhaust Standard or new 15.5 - 16.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1657 Valve Guide: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 or new 1.25 - 1.55 mm Service limit 2.00 mm Exhaust Standard or new 1.25 - 1.55 mm Service limit 2.00 mm Stem installed height Intake Standard or new 40.8 - 41.0 mm Exhaust Standard or new 54.6 - 54.8 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1661 Valve Seat: 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Standard or new 47.61 mm Exhaust Standard or new 49.64 mm / 49.63 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1665 Valve Spring: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valves Clearance (cold) Intake Standard or new 0.21 - 0.25 mm Exhaust Standard or new 0.28 - 0.32 mm Stem O.D. Intake Standard or new 5.475 - 5.485 mm Service limit 5.445 mm Exhaust Standard or new 5.450 - 5.460 mm Service limit 5.42 mm Stem-to-guide clearance Intake Standard or new 0.030 - 0.055 mm Service limit 0.08 mm Exhaust Standard or new 0.055 - 0.080 mm Service limit 0.11 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1669 Valve: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair Drive Belt: Service and Repair Drive Belt Replacement 1. Remove the splash shield. 2. Move the auto-tensioner (A) to relieve tension from the drive belt (B), and remove the drive belt. 3. Install the new belt in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Drive Belt Auto-tensioner Replacement 1. Remove the drive belt. 2. Remove the power steering (P/S) pump without disconnecting the P/S hoses. 3. Remove the auto-tensioner pulley. 4. Remove the auto-tensioner. 5. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Growl When Accelerating? Check Left Motor Mount Engine Mount: Technical Service Bulletins Growl When Accelerating? Check Left Motor Mount SOURCE: Honda Service News June 2004 TITLE: Growl When Accelerating? Check the Left Motor Mount APPLIES TO: 2004 CR-V with A/T SERVICE TIP: If the left front motor mount in a isn't installed properly, you'll hear a growl when accelerating. The motor mount, which is attached to the A/T, has rubber ears that keep the motor mount from contacting the motor mount bracket. If the rubber ears aren't facing the right way, the motor mount can contact the body and transmit engine and A/T noise. To fix this problem, check the rubber ears on the left front motor mount, and make sure they're pointing down as shown. If the ears aren't pointing down, refer to step 11 on page 5-11 of the 2002-04 CR-V S/M, and install the ears correctly. (On ISIS, use the keyword ENGINE INSTALL, then select Engine Installation from the list.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F (80 deg C) at idle 70 kPa Minimum at 3,000 rpm 300 kPa Minimum Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1685 Engine Oil Pressure: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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) NOTE: Listed capacities are approximate. Check fluid level after filling. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1692 Engine Oil: Fluid Type Specifications New standard for engine oil, GF-4. See TSB SN050109 for Honda Service News 050109 for additional information. Engine Oil API Classification .................................................................................................................................... Make sure the label says "For Gasoline Engines". From -20°F (-30°C) to over 100°F (40°C) .......................................................................................................................................................... SAE 5W-20 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1693 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 quarts 3.5 Imp quarts) at oil change. 4.2 L (4.4 US quarts 3.7 Imp quarts) at oil change including filter. 5.3 L (5.6 US quarts 4.7 Imp quarts) after engine overhaul. 5. Run the engine for more than 3 minutes, then check for oil leakage. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation Technical Service Bulletin # 04-077 Date: 050301 Campaign - Oil Filter Campaign Cancellation 04-077 March 1, 2005 Applies To: See VEHICLES AFFECTED Customer Assurance Program: CR-V Engine Oil Filter (Supersedes 04-077, dated December 17, 2004) Updated information is shown by asterisks. *As of February 28, 2005, this program is no longer in effect.* BACKGROUND Although it is standard industry practice to make sure the old filter's gasket is removed from the engine block mounting surface before a new filter is installed, we are aware of several instances where this procedure was not properly followed during the first oil filter change. The result has been oil leakage and, in some cases, engine compartment fires. VEHICLES AFFECTED To see if an in-stock new vehicle has already been corrected, do an iN VIN status inquiry. CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification letter of this program. An example of the letter is at the end of this service bulletin. The letter offers customers an optional oil filter inspection. To receive the inspection, these criteria must be met: ^ The vehicle is within the affected VIN range (see VEHICLES AFFECTED). ^ The customer requests the inspection. ^ The first oil filter replacement was done within the last 30 days. Do an inspection only if all three criteria are met. Enclosed with the letter is an adhesive label to be used by the customer at the first oil filter change interval only. The label can be attached to the repair order as a technician reminder to return the old filter gasket to the customer to verify it was properly removed. An example of the label is at the end of this service bulletin. CORRECTIVE ACTION There are four possible corrective actions: ^ In-stock new vehicle: Replace the oil filter; top off but do not replace the engine oil. ^ Customer vehicle with a Honda oil filter: Inspect the oil filter installation. ^ Customer vehicle with a non-Honda oil filter: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1703 Inspect the oil filter installation; strongly suggest replacing the oil filter with a Honda oil filter; if the customer agrees, replace the oil filter, then top off but do not replace the engine oil. ^ Customer vehicle with a double-gasket condition: If a double-gasket condition is found during the inspection, submit a digital photo of the condition, install a new oil filter, then top off but do not replace the engine oil. PARTS INFORMATION Oil Filter: P/N 15400-PLM-A01, H/C 6446231 or P/N 15400-PLM-A02, H/C 6663991 REQUIRED MATERIALS Honda Genuine Motor Oil 5W-20: (Up to 1 quart per vehicle is allowed) P/N 08798-9023, H/C 6512610 WARRANTY CLAIM INFORMATION Failed Part: P/N 15400-PLM-A01 H/C 6446231 Defect Code: 5EBOO Symptom Code: P5700 Skill Level: Repair Technician INSPECTION PROCEDURE: CUSTOMER VEHICLES ONLY NOTE: For in-stock new vehicles, go to REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES. 1. Raise the vehicle on a lift, and look at the oil filter. ^ If a Honda filter is installed, go to step 2. ^ If a non-Honda filter is installed, strongly suggest to your customer that they let you replace it, free of charge, with a Honda oil filter. - If your customer agrees, go to step 2 of REPAIR PROCEDURE A: CUSTOMER VEHICLES. - If your customer does not want the oil filter replaced (unlikely, but possible), document this on the repair order, and let them know you cannot assure the continued reliability of the non-Honda filter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1704 2. Check for a protruding gasket between the oil filter base and the engine block by running your finger around the entire base of the oil filter: ^ If you can feel a protruding gasket, go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot feel a protruding gasket, go to step 3. 3. Try to insert a 0.25 mm (0.010-inch) feeler gauge between the base of the Honda oil filter and the engine block. ^ If you can insert the feeler gauge, the filter may have a double-gasket condition. Go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot insert the feeler gauge, the filter is properly installed. Return the vehicle to the customer. REPAIR PROCEDURE A: CUSTOMER VEHICLES 1. Take a clear, digital photo of the oil filter gasket area, and e-mail the photo to Tech Line: ^ Title your e-mail CR-V Oil Filter Gasket." ^ Attach the photo to your e-mail, then review the photo on your computer to make sure it is clear. ^ You must include the VIN and your dealer number with each e-mail. 2. Remove the oil filter. NOTE: If a non-Honda oil filter with a double-gasket condition is found, document it by taking a clear, digital photo (see step 1). 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1705 ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. NOTE: DO NOT replace the engine oil. 7. Retain any removed parts for DPSM verification and warranty purposes. REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES NOTE: DO NOT replace the engine oil. It contains additives needed for the engine's break-in period. 1. Raise the vehicle on a lift. 2. Remove the original oil filter. IMPORTANT: Remove the gasket from the original oil filter, attach the gasket to the repair order, then discard the filter using normal recycling practices. Retaining the oil filter gasket is required for DPSM verification and warranty purposes. 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1706 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Recalls: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1707 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation Technical Service Bulletin # 04-077 Date: 050301 Campaign - Oil Filter Campaign Cancellation 04-077 March 1, 2005 Applies To: See VEHICLES AFFECTED Customer Assurance Program: CR-V Engine Oil Filter (Supersedes 04-077, dated December 17, 2004) Updated information is shown by asterisks. *As of February 28, 2005, this program is no longer in effect.* BACKGROUND Although it is standard industry practice to make sure the old filter's gasket is removed from the engine block mounting surface before a new filter is installed, we are aware of several instances where this procedure was not properly followed during the first oil filter change. The result has been oil leakage and, in some cases, engine compartment fires. VEHICLES AFFECTED To see if an in-stock new vehicle has already been corrected, do an iN VIN status inquiry. CUSTOMER NOTIFICATION All owners of affected vehicles were mailed a notification letter of this program. An example of the letter is at the end of this service bulletin. The letter offers customers an optional oil filter inspection. To receive the inspection, these criteria must be met: ^ The vehicle is within the affected VIN range (see VEHICLES AFFECTED). ^ The customer requests the inspection. ^ The first oil filter replacement was done within the last 30 days. Do an inspection only if all three criteria are met. Enclosed with the letter is an adhesive label to be used by the customer at the first oil filter change interval only. The label can be attached to the repair order as a technician reminder to return the old filter gasket to the customer to verify it was properly removed. An example of the label is at the end of this service bulletin. CORRECTIVE ACTION There are four possible corrective actions: ^ In-stock new vehicle: Replace the oil filter; top off but do not replace the engine oil. ^ Customer vehicle with a Honda oil filter: Inspect the oil filter installation. ^ Customer vehicle with a non-Honda oil filter: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1717 Inspect the oil filter installation; strongly suggest replacing the oil filter with a Honda oil filter; if the customer agrees, replace the oil filter, then top off but do not replace the engine oil. ^ Customer vehicle with a double-gasket condition: If a double-gasket condition is found during the inspection, submit a digital photo of the condition, install a new oil filter, then top off but do not replace the engine oil. PARTS INFORMATION Oil Filter: P/N 15400-PLM-A01, H/C 6446231 or P/N 15400-PLM-A02, H/C 6663991 REQUIRED MATERIALS Honda Genuine Motor Oil 5W-20: (Up to 1 quart per vehicle is allowed) P/N 08798-9023, H/C 6512610 WARRANTY CLAIM INFORMATION Failed Part: P/N 15400-PLM-A01 H/C 6446231 Defect Code: 5EBOO Symptom Code: P5700 Skill Level: Repair Technician INSPECTION PROCEDURE: CUSTOMER VEHICLES ONLY NOTE: For in-stock new vehicles, go to REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES. 1. Raise the vehicle on a lift, and look at the oil filter. ^ If a Honda filter is installed, go to step 2. ^ If a non-Honda filter is installed, strongly suggest to your customer that they let you replace it, free of charge, with a Honda oil filter. - If your customer agrees, go to step 2 of REPAIR PROCEDURE A: CUSTOMER VEHICLES. - If your customer does not want the oil filter replaced (unlikely, but possible), document this on the repair order, and let them know you cannot assure the continued reliability of the non-Honda filter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1718 2. Check for a protruding gasket between the oil filter base and the engine block by running your finger around the entire base of the oil filter: ^ If you can feel a protruding gasket, go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot feel a protruding gasket, go to step 3. 3. Try to insert a 0.25 mm (0.010-inch) feeler gauge between the base of the Honda oil filter and the engine block. ^ If you can insert the feeler gauge, the filter may have a double-gasket condition. Go to REPAIR PROCEDURE A: CUSTOMER VEHICLES. ^ If you cannot insert the feeler gauge, the filter is properly installed. Return the vehicle to the customer. REPAIR PROCEDURE A: CUSTOMER VEHICLES 1. Take a clear, digital photo of the oil filter gasket area, and e-mail the photo to Tech Line: ^ Title your e-mail CR-V Oil Filter Gasket." ^ Attach the photo to your e-mail, then review the photo on your computer to make sure it is clear. ^ You must include the VIN and your dealer number with each e-mail. 2. Remove the oil filter. NOTE: If a non-Honda oil filter with a double-gasket condition is found, document it by taking a clear, digital photo (see step 1). 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1719 ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. NOTE: DO NOT replace the engine oil. 7. Retain any removed parts for DPSM verification and warranty purposes. REPAIR PROCEDURE B: IN-STOCK NEW VEHICLES NOTE: DO NOT replace the engine oil. It contains additives needed for the engine's break-in period. 1. Raise the vehicle on a lift. 2. Remove the original oil filter. IMPORTANT: Remove the gasket from the original oil filter, attach the gasket to the repair order, then discard the filter using normal recycling practices. Retaining the oil filter gasket is required for DPSM verification and warranty purposes. 3. Wipe off the oil filter seat on the engine block. 4. Apply a light coat of clean engine oil to the gasket on the new oil filter. Then install the new oil filter using the instructions printed on it. 5. Run the engine for 3 minutes, and check for leaks: ^ If there are no leaks, go to step 6. ^ If you find a leak, repair it, then go to step 6. 6. Add Honda Genuine Motor Oil 5W-20, as needed, to return the oil level on the dipstick to the full mark. Up to 1 quart per vehicle is allowed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1720 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > 04-002 > Feb > 04 > Recalls for Oil Filter: > 04-077 > Mar > 05 > Campaign - Oil Filter Campaign Cancellation > Page 1721 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Filter: > Page 1722 Steering Wheel: Specifications Steering Type Power-assisted rack and pinion Overall ratio 15.06 Turns, lock-to-lock 2.64 Steering wheel diameter 360 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1723 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1724 Steering Wheel: Service and Repair Removal SRS components are located in this area. Review the SRS component locations and precautions and procedures in Restraint Systems 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 horn switch connector (B). 3. Loosen the steering wheel bolt (C). 4. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller. Note these items when removing the steering wheel: ^ Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. ^ If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt. 5. Remove the steering wheel puller, then remove the steering wheel bolt and steering wheel from the steering column. Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1725 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 on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel. 3. Install the steering wheel bolt (A), and tighten it to the specified torque. Connect the horn and cruise control set/resume switch connectors. Make sure the wire harness is routed and fastened properly. 4. Install the driver's airbag, and confirm that the system is operating properly. 5. Check the horn and turn signal canceling for proper operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1729 Oil Pan: Service and Repair Oil Pan Removal 1. Drain the engine oil. 2. If the engine is still in the vehicle, remove the sub frame. - 1 Attach the chain hoist to the engine (see step 37). - 2 Disconnect the suspension lower arm ball joints (see step 10). - 3 Remove the rear mount mounting bolts (see step 41). - 4 Remove the front mount mounting bolt (see step 42). - 5 Remove the ATF filter mounting bolt (A/T) (see step 33). - 6 Make the appropriate reference lines at positions A and B that line up with the center of the sub-frame mounting bolts (see step 43). - 7 Attach the special tool to the sub-frame, then attach the jack to the special tool (see step 44) - 8 Remove the front sub-frame mounting bolts, then remove the sub-frame (see step 46) 3. Remove the stiffener (M/T). 4. Remove the bolts/nuts securing the oil pan. 5. Drive an oil pan seal cutter between the oil pan and cylinder block. 6. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan. 7. Remove the oil pan. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1733 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1738 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1739 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1743 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Oil Pressure Warning Lamp/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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F (80 deg C) at idle 70 kPa Minimum at 3,000 rpm 300 kPa Minimum Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1783 Engine Oil Pressure: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection; Procedures. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Standards and Service Limits Intake Manifold: Specifications Standards and Service Limits Information was not provided by manufacturer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Standards and Service Limits > Page 1788 Intake Manifold: Specifications Torque Specifications INTAKE MANIFOLD REMOVAL AND INSTALLATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1789 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1790 Intake Manifold: Service and Repair Removal: 1. Removal the intake manifold cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1791 2. Disconnect the intake air temperature (IAT) sensor connector (A), remove the breather hose (B), then remove the air cleaner housing (C). 3. Remove the throttle cover (A). Fully open the throttle link and cruise control link by hand, then remove the throttle cable (B) and cruise control cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket. 4. Remove the Evaporative Emission (EVAP) canister hose (A) and brake booster vacuum hose (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1792 5. Remove the water bypass hoses, then plug the water bypass hoses. 6. Disconnect the Intake Manifold Runner Control (IMRC) valve actuator control solenoid valve connector (A), then remove the Positive Crankcase Ventilation (PCV) hose (B) and IMRC valve control solenoid valve mounting bolt (C). 7. Removal the bolt (A) securing the battery clamp, then remove the bulkhead cover (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1793 8. Remove the harness clamps. 9. Remove the intake air duct mounting bolts (A) and upper bracket and cushion (B), then remove the bulkhead (c). 10. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. - Idle Air Control (IAC) valve connector - Throttle position sensor connector - Manifold Absolute Pressure (MAP) sensor connector - Evaporative Emission (EVAP) canister purge valve connector - IMRC valve position sensor connector 11. Remove the intake manifold. Installation: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1794 1. Install the intake manifold (A), and tighten the bolts/nuts in a crisscross pattern in two or three steps, beginning with the inner bolt. Use the new O-rings (B). 2. Install the bulkhead (A), then install the upper bracket and cushion (B) and intake air duct mounting bolts (C). Apply body paint to the bulkhead mounting bolts. 3. Connect the harness clamps. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1795 4. Install the bulkhead cover (A), then install the battery clamp bolt (B). 5. Connect Intake Manifold Runner Control (IMRC) valve actuator control solenoid valve connector (A), then install the Positive Crankcase Ventilation (PCV) hose (B) and IMRC valve actuator control solenoid valve mounting bolt (C). 6. Install the water bypass hoses. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1796 7. Install the Evaporative Emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 8. Install the throttle cable, then adjust the cable. 9. Install the cruise control cable, then adjust the cable. 10. Install the air cleaner housing (A), and connect the Intake Air Temperature (IAT) sensor connector (B). 11. Install the breather hose (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. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Oil Pressure Warning Lamp/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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1826 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1827 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1828 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1829 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1830 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1831 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1832 Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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-PNA0100 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1844 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1849 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 1850 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 1854 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Balancer Shaft Buzz Or Rattle Is Normal Balance Shaft: Technical Service Bulletins Balancer Shaft Buzz Or Rattle Is Normal SOURCE: Honda Service News June 2004 TITLE: Balancer Shaft Buzz or Rattle Is Normal APPLIES TO: A/T-equipped 2003-04 Accord L4s, 2002-04 CR-Vs, and 2003-04 Elements. SERVICE TIP: Have customers complained of a buzz or rattle when the vehicle is sitting in Park or Neutral and the engine is winding down from 3,000 to 2,000 rpm? What they're hearing is a harmonic resonation coming from the oil pump and balancer shaft assemblies, which is a normal characteristic of the vehicle. Don't bother replacing engine components; it won't change or reduce this condition. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Page 1860 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Information was not provided by manufacturer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation Timing Chain: Service and Repair Chain Case Oil Seal Installation 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1871 Timing Chain: Service and Repair Cam Chain Replacement Cam Chain 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 (see step 1). 9. Support the engine with a jack and wood block under the oil pan. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1872 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1873 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1874 17. Remove the cam chain guide B. 18. Remove the cam chain guide A (A) and tensioner arm (B). 19. Remove the cam chain. Cam Chain 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1875 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. 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1876 5. Install the cam chain guide A (A) and tensioner arm (B). 6. Install the auto-tensioner. 7. Install the cam chain guide B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1877 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. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1878 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. 16. Install the side engine mount bracket. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Chain Case Oil Seal Installation > Page 1879 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 (see step 1). 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. 24. Install the splash shield. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Idler Gear > Component Information > Service and Repair Timing Chain Idler Gear: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Timing Chain; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 1886 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 1887 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 belt 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1897 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1898 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1899 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1900 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1901 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1902 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1903 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1904 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1905 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1906 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1907 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1908 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1909 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1910 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1911 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1912 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1913 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1914 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1915 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1916 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1917 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1918 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1919 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1920 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1921 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1922 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1923 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1924 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1925 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1926 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1927 System Diagram Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1928 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 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. - Reduces the cam advance at idle, stabilizes 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1929 VTEC system - The VTEC system changes the cam profile to correspond to the 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 VTEC/VTC Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1930 Variable Valve Timing Actuator: Testing and Inspection VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1931 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1932 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1933 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 1937 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations Variable Valve Timing Solenoid: Locations VTEC/VTC - Component Location Index 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1941 5. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1942 Variable Valve Timing Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1943 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Page 1944 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 ...................................................................................................................................................... 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 psi) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1949 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1950 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment 07VAJ-0040100 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A) at the fuel rail. 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. 7. Remove the fuel pulsation damper from its fitting, and attach the fuel pressure gauge attachment. 8. Attach the fuel pressure gauge. 9. Start the engine and let it idle. - If the engine starts, go to step 11. - If the engine does not start, go to step 10. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1951 10. 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 (II). If the pump runs, go to step 11. - If the pump does not run, do the fuel pump circuit troubleshooting. 11. Read the pressure gauge. The pressure should be 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 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 repeat the test. 12. Remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N.m (2.2 kgf.m, 16 lbf-ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed With no-load conditions: M/T ............................................................................................................... ..................................................................................................... 650 ± 50 rpm A/T ........................... .......................................................................................................................................................... 650 ± 50 rpm (in Park or neutral) With load conditions: M/T .................................................................................................................... ................................................................................................ 700 ± 50 rpm A/T ................................ ..................................................................................................................................................... 700 ± 50 rpm (in park or neutral) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1955 Idle Speed: Description and Operation Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the A/C valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the A/C valve is opened to obtain the proper fast idle speed. The amount of bypassed air is controlled in relation to engine coolant temperature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1956 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. - There are no vacuum leaks - Ignition timing - Throttle cable adjustment - 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 Park or 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: M/T ................................................................................................................... ...................................................................................... 650 ± 50 rpm A/T .......................................... ................................................................................................................................ 650 ± 50 rpm (in Park or neutral) 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: M/T ................................................................................................................... ...................................................................................... 700 ± 50 rpm A/T .......................................... .................................................................................................................................. 700 ± 50 rpm(in park or neutral) NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. 6. Reconnect the EVAP canister purge valve 2P connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1961 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Remove the PCV hose (A). Open the air cleaner housing cover (B). 2. Remove the air cleaner (C) from the air cleaner housing (D). 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1976 Spark Plug: Application and ID Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure check at 250 rpm with wide open throttle Minimum Standard or new 930 kPa Maximum variation Standard or new 200 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1980 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 (see step 1). 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. Connect a tachometer. 10. 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) - 250 rpm 11. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 12. If the compression is not within specifications, check the following 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valves Clearance (cold) Intake Standard or new 0.21 - 0.25 mm Exhaust Standard or new 0.28 - 0.32 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1984 Valve Clearance: Adjustments Valve Clearance 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. 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 drab. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1985 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until tier? drag on the feeler clause 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. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise Water Pump: Customer Interest Cooling System - Engine Growling Noise 06-054 August 15, 2006 Applies To: 2002-06 CR-V - All UK-produced models (VIN begins with SHSRD) Engine Growls When Running SYMPTOM The engine growls when running. PROBABLE CAUSE The water pump bearing is faulty. CORRECTIVE ACTION Replace the water pump. PARTS INFORMATION Water Pump: P/N 19200-PNA-003, H/C 6732275 TOOL INFORMATION STEELMAN(R) ChassisEAR(TM): T/N JSP-SM-6600 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 113100 Flat Rate Time: 2.0 hours Failed Part: P/N 19200-PNA-003 H/C 6732275 Defect Code: 00504 Symptom Code: 04201 Template ID: 06-054A 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 NOTE: Make sure the ChassisEAR microphone leads are not touching any rotating parts. 1. Clip one of the microphones onto the water pump. 2. Start the engine. ^ If the microphone is picking up a growling noise from the water pump, go to the REPAIR PROCEDURE. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise > Page 1994 ^ If you do not hear a growling noise coming from the water pump, proceed with normal troubleshooting. This bulletin does not apply. REPAIR PROCEDURE Replace the water pump. ^ Refer to page 10-5 of the 2002-04 or 2005-06 CR-V Service Manual, or ^ Online, select the year and model, then enter keyword WATER PUMP, and select Water Pump Replacement from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise Water Pump: All Technical Service Bulletins Cooling System - Engine Growling Noise 06-054 August 15, 2006 Applies To: 2002-06 CR-V - All UK-produced models (VIN begins with SHSRD) Engine Growls When Running SYMPTOM The engine growls when running. PROBABLE CAUSE The water pump bearing is faulty. CORRECTIVE ACTION Replace the water pump. PARTS INFORMATION Water Pump: P/N 19200-PNA-003, H/C 6732275 TOOL INFORMATION STEELMAN(R) ChassisEAR(TM): T/N JSP-SM-6600 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 113100 Flat Rate Time: 2.0 hours Failed Part: P/N 19200-PNA-003 H/C 6732275 Defect Code: 00504 Symptom Code: 04201 Template ID: 06-054A 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 NOTE: Make sure the ChassisEAR microphone leads are not touching any rotating parts. 1. Clip one of the microphones onto the water pump. 2. Start the engine. ^ If the microphone is picking up a growling noise from the water pump, go to the REPAIR PROCEDURE. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise > Page 2000 ^ If you do not hear a growling noise coming from the water pump, proceed with normal troubleshooting. This bulletin does not apply. REPAIR PROCEDURE Replace the water pump. ^ Refer to page 10-5 of the 2002-04 or 2005-06 CR-V Service Manual, or ^ Online, select the year and model, then enter keyword WATER PUMP, and select Water Pump Replacement from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > SN040807 > Aug > 04 > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: All 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Water Pump: > SN040807 > Aug > 04 > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: All 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical Service Bulletins > Page 2010 Water Pump: Testing and Inspection Water Pump 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 hole (A) is normal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement Water Pump: Service and Repair Water Pump Replacement Water Pump 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 2013 Water Pump: Service and Repair Water Passage Replacement 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Radiator Coolant capacity M/T at engine overhaul 7.2 L (7.6 US qt.) (includes engine, heater, hoses, and reservoir) M/T at coolant change 5.5 L (5.8 US qt.) A/T at engine overhaul 7.1 L (7.5 US qt.) A/T at coolant change 5.4 L (5.7 US qt.) Reservoir Coolant capacity 0.55 L (0.58 US qt.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2019 Coolant: Fluid Type Specifications Only use Honda All Season Antifreeze/Coolant Type 2 (P/N 0L999-9001) at 50 percent concentration with water. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2020 Coolant: Service Precautions 1. Genuine Honda Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2021 Coolant: Testing and Inspection Coolant 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2022 Coolant: Service and Repair Coolant 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 bulkhead cover (see step 7). 3. Remove the radiator cap. 4. Loosen the drain plug (A), and drain the coolant. 5. Remove the reserve tank mounting bolt (A), and remove the reserve tank. 6. Remove the coolant tube from the radiator. Put the end of the coolant tube lower than the reserve tank and drain the coolant from the tank. 7. After the coolant has drained, tighten the radiator drain plug. Reinstall the coolant tube and reserve tank. 8. Install the bulkhead cover (see step 4). 9. Fill the reserve tank to the MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2023 10. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NOTE: Always use Honda All Season Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Premixing is not required. 11. Install the radiator cap loosely. 12. Start the engine, and let it run until it warms up (the radiator fan comes on at least twice). 13. Turn off the engine. Check the level in the radiator and add Honda All Season Antifreeze/Coolant Type 2 if needed. 14. Put the radiator cap on tightly, then run the engine again and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Reservoir Coolant capacity 0.55 L Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 2034 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations 16. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2054 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2055 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2056 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2057 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2058 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2059 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2060 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2061 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2067 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2068 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2069 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Testing Radiator Cooling Fan Motor: Testing and Inspection Fan Motor Testing 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Testing > Page 2072 Radiator Cooling Fan Motor: Testing and Inspection Radiator and Condenser Fans Circuit Radiator and Condenser Fans Common Circuit Troubleshooting 1. Check the No.1 (20A) and No.4 (20A) fuses in the under-hood fuse/relay box, and the No.14 (10A) 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. Remove the condenser fan relay from the under-hood fuse/relay box. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket 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 condenser fan relay socket. 5. Turn the ignition switch OFF. 6. Reinstall the condenser fan relay. 7. Make sure the A/C switch is OFF. 8. Turn the ignition switch ON (II). 9. Measure the voltage between the No.6 terminal of ECM/PCM connector B (24P) and body ground with the ECM/PCM connectors connected. Is there battery voltage? YES - Check for loose wires or poor connections at ECM/PCM connector B (24P). If the connections are good, substitute a known-good ECM/PCM, and recheck. If the symptom/indication goes away, replace the original ECM/PCM. NO - Repair open in the wire between the radiator fan relay socket, the condenser fan relay socket, and the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2076 Radiator Cooling Fan Motor Relay: Testing and Inspection 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. Radiator Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F Turns OFF Subtract 5 - 15 deg F from actual ON temperature Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2080 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2081 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2082 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 2083 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then 2. Install the radiator fan switch with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2088 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2089 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2090 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F Turns OFF Subtract 5 - 15 deg F from actual ON temperature Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2094 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2095 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2096 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2097 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then 2. Install the radiator fan switch with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2103 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 2104 Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 2108 Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 2109 8. Remove the mounting nut from the heater unit, Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the ECM/PCM. 11. Disconnect the connectors (A) from the heater unit, then disconnect the drain hose (B). Remove the mounting bolts and nuts, then remove the blower-heater unit (C). 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 self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Locations > Page 2110 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. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - For evaporator core and A/C-related information, refer to evaporator core replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation How the Circuit Works Coolant Temperature Gauge The coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit. The ECM/PCM receives coolant temperature information from the ECT sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2115 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge 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 and stay on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self- diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the GRY/RED wire (gauge connector terminal A1). NO - Go to step 4. 4. Do the gauge drive circuit check with the self- diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Mechanical Specifications Radiator: Mechanical Specifications RADIATOR AND FANS REPLACEMENT Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Mechanical Specifications > Page 2120 Radiator: Capacity Specifications Radiator Coolant capacity M/T at engine overhaul 7.2 L (includes engine, heater, hoses, and reservoir) M/T at coolant change 5.5 L A/T at engine overhaul 7.1 L A/T at coolant change 5.4 L Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2121 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2122 Radiator: Testing and Inspection Radiator Test 1. Wait until the engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant to the top of the filler neck. 2. 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. 6. Check for engine oil in the coolant and/or coolant in the engine oil. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2123 Radiator: Service and Repair Radiator and Fans Replacement 1. Drain the engine coolant. 2. Remove the bulkhead cover (see step 7). 3. Remove the upper bracket cushion, then remove the bulkhead (see step 9). 4. Remove the upper radiator hose and lower radiator hose. 5. Disconnect the fan motor connectors and radiator fan switch connector, then lift up the radiator. 6. Remove the fan shroud assemblies and other parts from the radiator. 7. Install the radiator in reverse order of removal. Make sure the upper and lower cushions are set securely. 8. Install the bulkhead in reverse order of removal. Apply body paint to the bulkhead mounting bolts. 9. Fill the radiator with engine coolant and bleed the air. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 2127 Radiator Cap: Testing and Inspection Radiator Cap 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2132 Radiator Cooling Fan Motor Relay: Testing and Inspection 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. Radiator Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 2137 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2142 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2143 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2144 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 deg F Turns OFF Subtract 5 - 15 deg F from actual ON temperature Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2148 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2149 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2150 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2151 Radiator Cooling Fan Temperature Sensor / Switch: Service and Repair Radiator Fan Switch Replacement 1. Disconnect the radiator fan switch connector, then 2. Install the radiator fan switch with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation How the Circuit Works Coolant Temperature Gauge The coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit. The ECM/PCM receives coolant temperature information from the ECT sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 2155 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge 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 and stay on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self- diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the GRY/RED wire (gauge connector terminal A1). NO - Go to step 4. 4. Do the gauge drive circuit check with the self- diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Minimum Torque Specifications THERMOSTAT REPLACEMENT Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 2160 Thermostat: Pressure, Vacuum and Temperature Specifications Thermostat Opening temperature Begins to open 169 - 176 deg F Fully open 194 deg F Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2161 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2162 Thermostat: Testing and Inspection Thermostat 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2163 Thermostat: Service and Repair Thermostat Replacement 1. Drain the engine coolant. 2. Remove the splash shield (see step 22). 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 (see step 23). 6. Refill the radiator with engine coolant, and bleed air from cooling system with the heater valve open. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise Water Pump: Customer Interest Cooling System - Engine Growling Noise 06-054 August 15, 2006 Applies To: 2002-06 CR-V - All UK-produced models (VIN begins with SHSRD) Engine Growls When Running SYMPTOM The engine growls when running. PROBABLE CAUSE The water pump bearing is faulty. CORRECTIVE ACTION Replace the water pump. PARTS INFORMATION Water Pump: P/N 19200-PNA-003, H/C 6732275 TOOL INFORMATION STEELMAN(R) ChassisEAR(TM): T/N JSP-SM-6600 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 113100 Flat Rate Time: 2.0 hours Failed Part: P/N 19200-PNA-003 H/C 6732275 Defect Code: 00504 Symptom Code: 04201 Template ID: 06-054A 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 NOTE: Make sure the ChassisEAR microphone leads are not touching any rotating parts. 1. Clip one of the microphones onto the water pump. 2. Start the engine. ^ If the microphone is picking up a growling noise from the water pump, go to the REPAIR PROCEDURE. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Customer Interest: > 06-054 > Aug > 06 > Cooling System - Engine Growling Noise > Page 2172 ^ If you do not hear a growling noise coming from the water pump, proceed with normal troubleshooting. This bulletin does not apply. REPAIR PROCEDURE Replace the water pump. ^ Refer to page 10-5 of the 2002-04 or 2005-06 CR-V Service Manual, or ^ Online, select the year and model, then enter keyword WATER PUMP, and select Water Pump Replacement from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 06-054 > Aug > 06 > Cooling System Engine Growling Noise Water Pump: All Technical Service Bulletins Cooling System - Engine Growling Noise 06-054 August 15, 2006 Applies To: 2002-06 CR-V - All UK-produced models (VIN begins with SHSRD) Engine Growls When Running SYMPTOM The engine growls when running. PROBABLE CAUSE The water pump bearing is faulty. CORRECTIVE ACTION Replace the water pump. PARTS INFORMATION Water Pump: P/N 19200-PNA-003, H/C 6732275 TOOL INFORMATION STEELMAN(R) ChassisEAR(TM): T/N JSP-SM-6600 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 113100 Flat Rate Time: 2.0 hours Failed Part: P/N 19200-PNA-003 H/C 6732275 Defect Code: 00504 Symptom Code: 04201 Template ID: 06-054A 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 NOTE: Make sure the ChassisEAR microphone leads are not touching any rotating parts. 1. Clip one of the microphones onto the water pump. 2. Start the engine. ^ If the microphone is picking up a growling noise from the water pump, go to the REPAIR PROCEDURE. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > 06-054 > Aug > 06 > Cooling System Engine Growling Noise > Page 2178 ^ If you do not hear a growling noise coming from the water pump, proceed with normal troubleshooting. This bulletin does not apply. REPAIR PROCEDURE Replace the water pump. ^ Refer to page 10-5 of the 2002-04 or 2005-06 CR-V Service Manual, or ^ Online, select the year and model, then enter keyword WATER PUMP, and select Water Pump Replacement from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Water Pump: > SN040807 > Aug > 04 > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: All 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Water Pump: > SN040807 > Aug > 04 > Drive Belt Noise? Could Be A Bad Water Pump Bearing Water Pump: All 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Technical Service Bulletins > Page 2188 Water Pump: Testing and Inspection Water Pump 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 hole (A) is normal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement Water Pump: Service and Repair Water Pump Replacement Water Pump 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Water Pump Replacement > Page 2191 Water Pump: Service and Repair Water Passage Replacement 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2197 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 (CO2), nitrogen (N2), and water vapor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD REMOVAL AND INSTALLATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2202 Exhaust Manifold: Service and Repair Exhaust Manifold Removal and Installation 1. Remove the VTEC solenoid valve. 2. Remove the driveshaft heat shield (see step 2). 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications EXHAUST PIPE AND MUFFLER REPLACEMENT Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2206 Exhaust Pipe: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Exhaust System; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications EXHAUST PIPE AND MUFFLER REPLACEMENT Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2210 Muffler: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Exhaust System; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2218 DTC P0A94 thru P0157 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2219 DTC P0158 thru P0400 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2220 DTC P0401 thru P0562 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2221 DTC P0563 thru P0748 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2222 DTC P0750 thru P0977 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2223 DTC P0979 thru P1193 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2224 DTC P1253 thru P1459 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2225 DTC P1486 thru P1585 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2226 DTC P1586 thru P1678 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2227 DTC P1679 thru P1860 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2228 DTC P1861 thru P2238 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2229 DTC P2240 thru U0073 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2230 DTC U0100 thru U1288 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2231 Engine Control Module: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2232 82. Behind Glove Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2235 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview Engine Control Module: Initial Inspection and Diagnostic Overview How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2238 Engine Control Module: Pinout Values and Diagnostic Parameters ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2239 ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2240 ECM/PCM Inputs And Outputs At Connector B (24P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2241 PCM Inputs And Outputs At Connector C (22P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2242 PCM Inputs And Outputs At Connector D (17P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2243 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2244 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove the ECM/PCM and test it: 1. Disconnect the negative cable from the battery. 2. Remove glove box. 3. Disconnect the gray 20P ECM/PCM wire harness connector, and remove it from the ECM/PCM mounting bracket. Disconnect the 7 P mode control motor connector. Remove PGM-FI main relay 2 (A). Remove the ECM/PCM mounting bolt (B) and the bracket. 4. Remove the nuts, then remove the ECM/PCM (C). 5. Install the ECM/PCM in the reverse order of removal. 6. Reconnect the negative cable to the battery. 7. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2247 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the HDS does not require you to do the idle learn procedure. - Replace the throttle body. - Replace the idle air control (IAC) valve. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 BATTERY (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fusel relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2248 Engine Control Module: Service and Repair ECM/PCM Updating and Substitution for Testing ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) E0S05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - You can not update an ECM/PCM with the program it already has. It will only accept a new program. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, 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/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the Honda interface module (HIM) to the data link connector (DLC) (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label. If the software in the ECM/PCM is the latest, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS again. 5. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2249 Engine Control Module: Service and Repair ECM Reset How to Reset the ECM/PCM You can reset the ECM/PCM in either of two ways: NOTE: After resetting the ECM/PCM, do the ECM/PCM idle learn procedure. Reset the ECM/PCM with the Scan Tool or the HDS 1. Turn the ignition switch ON (II). Do not start the engine. 2. Use the scan tool or the HDS to clear the DTC. NOTE: For the specific operations, refer to the user's manual that came with the scan tool or the HDS. Reset the ECM/PCM by removing the fuse 1. Turn the ignition switch OFF. 2. Remove the No.6 ECU (ECM/PCM) (15A) fuse (A) from the under-hood fuse/relay box (B) for 10 seconds. How to End a Troubleshooting Session (required after any troubleshooting) 1. Reset the ECM/PCM as described above. 2. Do the ECM/PCM idle learn procedure. 3. Turn the ignition switch OFF. 4. Disconnect the scan tool or the HDS from the DLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a different immobilizer code. To start the engine, you must rewrite the immobilizer code with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2253 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2254 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2255 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2256 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2257 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2258 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2262 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2263 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2268 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2269 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2273 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2274 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2275 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2276 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2277 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2278 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2291 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2292 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2293 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement > Page 2296 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2300 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2301 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2302 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2306 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2307 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2308 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2317 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2318 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2319 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2320 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2326 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2327 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2328 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2329 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2330 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2331 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2332 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2336 146. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2337 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2341 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2342 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2343 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the clip (A) and the IAT sensor (B). 3. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2347 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2348 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2349 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2353 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2354 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor convents manifold absolute pressure into electrical signals to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2359 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2360 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: Customer Interest Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 2369 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: All Technical Service Bulletins Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 2375 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2381 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2382 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2388 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 2389 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2392 144. Middle Underside of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2393 Oxygen Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM which varies the duration of fuel injection accordingly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2396 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/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The ECM/PCM compares the HO2S output with the A/F sensor output to determine catalyst efficiency. The secondary HO2S is installed in the TWC. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2399 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YAB875, 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2403 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2404 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2405 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2406 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2407 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 2416 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 2422 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2423 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2424 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2425 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2434 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2435 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2441 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2442 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2443 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2444 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2445 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2446 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2447 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2448 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2449 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2453 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2458 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2459 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2460 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) (M/T) 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2461 Vehicle Speed Sensor: Service and Repair VSS Replacement M/T only: 1. Remove the air cleaner. 2. Disconnect the 3P connector from the vehicle speed sensor (VSS). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 2466 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 2475 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 2481 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2482 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2483 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2484 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations Variable Induction Position Sensor: Locations Intake Air System - Component Location Index 6. Right Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 2488 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 2489 Variable Induction Position Sensor: Description and Operation Intake Manifold Runner Control (IMRC) Valve Position Sensor The IMRC position sensor is a potentiometer connected to the IMRC valve shaft. As the IMRC valve position changes, the sensor varies the signal voltage to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 2490 Variable Induction Position Sensor: Service and Repair IMRC Valve Position Sensor Replacement 1. Remove the two screws (A) and the IMRC position sensor (B). 2. Install the sensor with a new O-ring (C), and make sure the projection (D) inside the IMRC valve matches up with the groove (E) in the sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2495 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2496 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2497 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement > Page 2500 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2504 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2505 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2506 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2512 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2513 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2514 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2515 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2516 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2517 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2518 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2519 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2520 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2521 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2525 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2526 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2527 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................................... 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 psi) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2532 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2533 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment 07VAJ-0040100 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A) at the fuel rail. 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. 7. Remove the fuel pulsation damper from its fitting, and attach the fuel pressure gauge attachment. 8. Attach the fuel pressure gauge. 9. Start the engine and let it idle. - If the engine starts, go to step 11. - If the engine does not start, go to step 10. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2534 10. 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 (II). If the pump runs, go to step 11. - If the pump does not run, do the fuel pump circuit troubleshooting. 11. Read the pressure gauge. The pressure should be 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 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 repeat the test. 12. Remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N.m (2.2 kgf.m, 16 lbf-ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed With no-load conditions: M/T ............................................................................................................... ..................................................................................................... 650 ± 50 rpm A/T ........................... .......................................................................................................................................................... 650 ± 50 rpm (in Park or neutral) With load conditions: M/T .................................................................................................................... ................................................................................................ 700 ± 50 rpm A/T ................................ ..................................................................................................................................................... 700 ± 50 rpm (in park or neutral) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2538 Idle Speed: Description and Operation Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the A/C valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the A/C valve is opened to obtain the proper fast idle speed. The amount of bypassed air is controlled in relation to engine coolant temperature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2539 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. - There are no vacuum leaks - Ignition timing - Throttle cable adjustment - 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 Park or 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: M/T ................................................................................................................... ...................................................................................... 650 ± 50 rpm A/T .......................................... ................................................................................................................................ 650 ± 50 rpm (in Park or neutral) 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: M/T ................................................................................................................... ...................................................................................... 700 ± 50 rpm A/T .......................................... .................................................................................................................................. 700 ± 50 rpm(in park or neutral) NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. 6. Reconnect the EVAP canister purge valve 2P connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2544 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Remove the PCV hose (A). Open the air cleaner housing cover (B). 2. Remove the air cleaner (C) from the air cleaner housing (D). 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2559 Spark Plug: Application and ID Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure check at 250 rpm with wide open throttle Minimum Standard or new 930 kPa Maximum variation Standard or new 200 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2563 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 (see step 1). 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. Connect a tachometer. 10. 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) - 250 rpm 11. Measure the compression on the remaining cylinders. Maximum variation: Within 200 kPa (2.0 kgf/cm2, 28 psi) 12. If the compression is not within specifications, check the following 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valves Clearance (cold) Intake Standard or new 0.21 - 0.25 mm Exhaust Standard or new 0.28 - 0.32 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2567 Valve Clearance: Adjustments Valve Clearance 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. 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 drab. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2568 5. If you feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until tier? drag on the feeler clause 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. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM connector terminals A24 and E18 with a jumper wire several times. Is there a clicking noise from the A/C compressor clutch? YES - Go to step 3. NO - Go to step 6. 3. Start the engine. 4. Turn the blower switch ON. 5. Turn the A/C switch ON. Does the A/C operate? YES - The air conditioning signal is OK. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 6. Momentarily connect under-hood fuse/relay box 1 4P connector terminal No.10 to body ground with a jumper wire several times. Is there clicking noise from the A/C compressor clutch? YES - Repair open in the wire between the ECM/PCM (E18) and the A/C clutch relay. NO - Check the A/C system for other symptoms. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2580 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2581 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2582 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the clip (A) and the IAT sensor (B). 3. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 2586 Vacuum Hose Routing Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 2587 Auxiliary Air Valve (Idle Speed): Description and Operation Intake Air Bypass Control Thermal Valve When the engine is running and the engine coolant temperature is less than 113 °F (45 °C ), the intake air bypass control thermal valve sends air to the injector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 2588 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, and 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 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 damage intake air bypass control thermal valve. 4. Hold the engine at 3,000 rpm with no load (in Park or 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 Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2595 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2596 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2597 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement > Page 2600 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2604 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2605 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2606 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2610 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2611 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2612 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2616 51. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2617 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2618 Data Link Connector: Testing and Inspection DLC Circuit Troubleshooting If the ECM/PCM does not communicate with the scan tool, HDS, 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 (10A) 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 (G451). 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/PCM (E3). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2619 4. Turn the ignition switch ON (II). 5. Measure voltage between DLC terminals No.5 and No.7. Is there 8.5 V or more? YES - Go to step 10. NO - Go to step 6. 6. Turn the ignition switch OFF. 7. Disconnect ECM/PCM connector E(31P). Make sure the scan tool or the HDS is disconnected from the DLC. 8. Check for continuity between DLC terminal No.7 and body ground. Is there continuity? YES - Repair short to ground in the wire between DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the scan tool or the HDS, and go to the indicated DTC's Troubleshooting. NO - Go to step 9. 9. Check for continuity between DLC terminal No.7 and ECM/PCM terminal E23. Is there continuity? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2620 symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the scan tool or the HDS, and go to the indicated DTC's Troubleshooting. 10. Turn the ignition switch OFF. 11. Disconnect ECM/PCM connector E(31P). Make sure the scan tool or the HDS is disconnected from the DLC. 12. Turn the ignition switch ON (II). 13. Measure voltage between DLC terminals No.5 and No.7. Is there 0 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair short to power in the wire between the DLC terminal No.7 and the ECM/PCM (E23). After repairing the wire, check the DTC with the scan tool or the HDS, and go to the indication DTC's Troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2629 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2630 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2631 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2632 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2638 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2639 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2640 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2641 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2642 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2643 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric Load Sensor > Component Information > Technical Service Bulletins > Page 2644 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2649 DTC P0A94 thru P0157 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2650 DTC P0158 thru P0400 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2651 DTC P0401 thru P0562 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2652 DTC P0563 thru P0748 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2653 DTC P0750 thru P0977 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2654 DTC P0979 thru P1193 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2655 DTC P1253 thru P1459 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2656 DTC P1486 thru P1585 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2657 DTC P1586 thru P1678 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2658 DTC P1679 thru P1860 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2659 DTC P1861 thru P2238 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2660 DTC P2240 thru U0073 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2661 DTC U0100 thru U1288 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2662 Engine Control Module: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2663 82. Behind Glove Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2666 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Engine Control Module: Initial Inspection and Diagnostic Overview How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2669 Engine Control Module: Pinout Values and Diagnostic Parameters ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2670 ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2671 ECM/PCM Inputs And Outputs At Connector B (24P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2672 PCM Inputs And Outputs At Connector C (22P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2673 PCM Inputs And Outputs At Connector D (17P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2674 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2675 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove the ECM/PCM and test it: 1. Disconnect the negative cable from the battery. 2. Remove glove box. 3. Disconnect the gray 20P ECM/PCM wire harness connector, and remove it from the ECM/PCM mounting bracket. Disconnect the 7 P mode control motor connector. Remove PGM-FI main relay 2 (A). Remove the ECM/PCM mounting bolt (B) and the bracket. 4. Remove the nuts, then remove the ECM/PCM (C). 5. Install the ECM/PCM in the reverse order of removal. 6. Reconnect the negative cable to the battery. 7. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal and Installation > Page 2678 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the HDS does not require you to do the idle learn procedure. - Replace the throttle body. - Replace the idle air control (IAC) valve. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 BATTERY (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fusel relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal and Installation > Page 2679 Engine Control Module: Service and Repair ECM/PCM Updating and Substitution for Testing ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) E0S05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - You can not update an ECM/PCM with the program it already has. It will only accept a new program. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, 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/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the Honda interface module (HIM) to the data link connector (DLC) (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label. If the software in the ECM/PCM is the latest, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS again. 5. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal and Installation > Page 2680 Engine Control Module: Service and Repair ECM Reset How to Reset the ECM/PCM You can reset the ECM/PCM in either of two ways: NOTE: After resetting the ECM/PCM, do the ECM/PCM idle learn procedure. Reset the ECM/PCM with the Scan Tool or the HDS 1. Turn the ignition switch ON (II). Do not start the engine. 2. Use the scan tool or the HDS to clear the DTC. NOTE: For the specific operations, refer to the user's manual that came with the scan tool or the HDS. Reset the ECM/PCM by removing the fuse 1. Turn the ignition switch OFF. 2. Remove the No.6 ECU (ECM/PCM) (15A) fuse (A) from the under-hood fuse/relay box (B) for 10 seconds. How to End a Troubleshooting Session (required after any troubleshooting) 1. Reset the ECM/PCM as described above. 2. Do the ECM/PCM idle learn procedure. 3. Turn the ignition switch OFF. 4. Disconnect the scan tool or the HDS from the DLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a different immobilizer code. To start the engine, you must rewrite the immobilizer code with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2684 146. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2685 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Information Bus: Electrical Diagrams Wiring Diagrams Diagram 50 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2722 Information Bus: Description and Operation 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 one multiplex control unit to another as serial data over dedicated communication lines. When the appropriate control unit receives the digital signal, it converts it back to a switch signal and operates the related components. The multiplex control system schematic shows it's power, grounds, and communication lines. The ignition key light is also shown because it is used to blink DTCs in the system's self-diagnosis function. The rest of the multiplex control system wiring is shown in the following circuit schematics: - Low Oil Pressure Indicator - Seat Belt Reminder - Lights-on Reminder Key-in Reminder - Entry Light Control System - Dash and Console Lights (brightness control) - Wiper/Washers Keyless/Security Alarm System - Interlock System - HVAC Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Information Bus: Reading and Clearing Diagnostic Trouble Codes Reading Diagnostic Trouble Codes NOTE: THIS IS THE ONLY INFORMATION PROVIDED BY THE MANUFACTURER FOR READING DTCs. Special Tool Required: MPCS Service Connector 07WAZ-001010A 1. Check the No.9 (10 A) fuse in the under-hood fuse/relay box and the No.10 (7.5 A) fuse in the under- dash fuse/relay box. Are the fuses OK? YES - Go to step 2. NO - Find and repair the cause of the blown fuse. 2. Remove the driver's dashboard lower cover. 3. Switch the ceiling light to the middle position. Close all doors. Turn the ignition switch ON (II). If the driver's seatbelt is unbuckled, the beeper will beep five times. 4. Check self-diagnosis function Mode 1 for a diagnostic trouble code (DTC) by connecting the special tool (A) to the multiplex control inspection connector (B). After about 5 seconds, the ignition switch light and ceiling light should come on for 2 seconds, go out, then blink once for 0.2 second. This means that you are in Mode 1 of the selfdiagnosis function. Did the blinking lights confirm that you are in Mode 1? YES - Count the blinks, then go to step 5. NO - See if the SCS circuit is working properly. Go to step 6. 5. If there is a DTC, it will blink, pause, then repeat the DTC as long as the ignition switch is ON (II). Is there a repeating DTC? YES - Count the blinks, then go to Trouble Code Descriptions. NO - Go to step 9. 6. Check for continuity between the inspection connector T1 and body ground. Is there continuity? YES - Go to step 8. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2725 NO - Go to step 7. 7. Check for continuity between the connector J of under-dash fuse/relay box No.4 terminal and body ground. Is there continuity? YES - Faulty under-dash fuse/relay box. Replace and check for DTCs. NO - Repair the open in the wire, and recheck for DTCs. 8. From Mode 1, disconnect the special tool from the multiplex control inspection connector for about 5 to 10 seconds, then reconnect it. The ceiling light should come on for 2 seconds, then blink twice more at 0.2 second intervals. This means the system has gone from Mode 1 to Mode 2. NOTE: To cancel mode 2, disconnect the SCS service connector from the multiplex control inspection connector for more than 10 seconds or turn the ignition switch OFF. 9. Look in the table for the switches most closely related to the problem. While still in Mode 2, operate the switches. If the circuit is OK, the ceiling light should blink once. If the circuit is faulty, there will be no indication. Does the ceiling light blink? YES - Go to step 11. NO - Go to step 10. 10. Check two or three other circuits listed. Does the ceiling light blink for each circuit? YES - The additional circuits are OK. Repair the short or open in the circuit that failed the test in step 10. NO - Multiple failed circuits can mean that the control unit has failed without triggering a DTC. Test a few more circuits. If they also fail, test the multiplex control unit inputs. If all the input test are OK, substitute a known-good control unit, gauge assembly, or ECM/PCM, one at a time, then recheck. If the system works properly, the original control unit is faulty; replace it. If there is still a malfunction, substitute a known-good control unit for the next most likely faulty control unit, then recheck. If the system works properly, that control unit is faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2726 11. Shift to the sleep mode: Turn the ignition switch OFF, and remove the key. If the control unit receives no inputs from the inputs listed below, it will go into sleep mode after about 40 seconds. 12. Confirm the sleep mode: Check for voltage on the YEL and WHT/GRN wires. There should be battery voltage in the sleep mode. Check the parasitic draw at the battery while shifting into the sleep mode. Amperage should change from about 70 to 80 mA to less than 10 mA. 13. Shift to the wake up mode: When the ignition switch is turned ON (II), the multiplex control unit, gauge assembly, and ECM/PCM wake up at the same time without "talking" to each other through the communication lines. When any switch in the multiplex system is turned on, it wakes up its related control unit which, in turn, wakes up the other units. After confirming the sleep mode, look in the table for the switch most closely related to the problem. Operate that switch and see if its control unit wakes up. NOTE: If any control unit is faulty and will not wake up, several parts of the system will malfunction at the same time. In the table, the control unit is followed by a list of the switches and input signals that can wake it up. Is the wake-up function OK? YES - Intermittent failure; the system is OK at this time. NO - Test the multiplex control unit inputs. Clearing Diagnostic Trouble Codes NOTE: NO INFORMATION WAS PROVIDED BY THE MANUFACTURER FOR CLEARING DTCs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2727 Information Bus: Component Tests and General Diagnostics Multiplex Control Unit Input Test 1. Remove the dashboard lower cover. 2. Disconnect the under-dash fuse/relay box connectors C, E, F, K, O, P, Q, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2728 Part 1 Part 2 4. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the underdash 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2732 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2733 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2734 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2738 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2739 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2740 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2741 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2742 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2743 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete the vehicle may fail the test, or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are complete. If it blinks five times, one or more readiness codes are not complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2747 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect a scan tool or the HDS to the data link connector (DLC). 2. Turn the ignition switch ON (II), and read the scan tool or the HDS. Does the scan tool or the HDS communicate with the ECM/PCM? YES - Go to step 3. NO - Go to "DLC Circuit Troubleshooting". 3. Check the scan tool or the HDS for DTCs. Are any DTCs indicated? YES - Go to the indicated DTCs Troubleshooting. 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 comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC) - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. - The readiness codes are not set. (This is indicated if the MIL blinks five times after you turn the ignition switch ON (II) and wait about 20 seconds.) 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 (50A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/WHT wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, intake manifold runner control (IMRC) valve position sensor, or countershaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, or mainshaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Check the low oil pressure light (with the ignition switch ON). Is the low oil pressure light on? YES - Go to step 9. NO - Go to step 7. 7. Inspect the No.10 METER (7.5A) fuse in the under dash fuse/relay box. Is the fuse OK? YES - Go to step 8. 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. 8. Inspect the No.20 IG (50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (50A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2748 NO - Repair short in the wire between No.20 IG (50A) fuse and the under-dash fuse/relay box. All replace the No.20 IG (50A) fuse. 9. Try to start the engine. Does the engine start? YES - Go to step 10. NO - Go to step 13. 10. Turn the ignition switch OFF. 11. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 12. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 13. Turn the ignition switch OFF. 14. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 15. 15. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box. 16. Remove the glove box. 17. Remove PGM-FI main relay 1(A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2749 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Did the continuity go away when one of the components or connectors was disconnected? YES - Replace the component that made the short to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 20. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2750 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31 P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 26. Make sure the SRS has no DTC. If there is any DTC, troubleshoot them first. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2751 27. Remove PGM-FI main relay 2 (A). 28. Disconnect the SRS unit connectors. 29. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or between the No.17 FUEL PUMP (15A) fuse and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 30. 30. Fold the rear seats forward, and pull back the carpet to expose the access panel. 31. Remove the access panel from the floor. 32. Disconnect the fuel pump 5P connector. 33. 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 34. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2752 34. Reinstall PGM-FI main relay 2 (A). 35. 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. 36. Disconnect ECM/PCM connector E (31P). 37. Turn the ignition switch ON (II). 38. Measure voltage between ECM/PCM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 39. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2753 39. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 44. NO - Go to step 40. 40. Turn the ignition switch OFF. 41. Remove PGM-FI main relay 1(A). 42. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 43. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2754 43. Check for continuity between PGM-FI main relay 14P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 44. Reconnect ECM/PCM connector E(31P). 45. Turn the ignition switch ON (II). 46. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 53. NO - Go to step 47. 47. Turn the ignition switch OFF. 48. Remove PGM-FI main relay 1(A). 49. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2755 50. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 51. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. 51. Turn the ignition switch OFF. 52. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminal 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/PCM (A2, A3). 53. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there more than 0.2 V? YES - Repair open in the wire(s) that had more than 0.2 V between G101 and the ECM/PCM (A4, A5, A23, A24). NO - Go to step 54. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2756 54. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 61. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect the 3P connector from these sensors. - Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) 59. Disconnect ECM/PCM connector A (31 P). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2757 60. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, the IMRC valve position sensor, or the output shaft (countershaft) speed sensor(A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 61. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connector from each of the following sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2758 NO - Go to step 64. 64. Turn the ignition switch OFF. 65. Disconnect the 3P connector from these sensors: - Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) 66. Disconnect ECM/PCM connector A (31 P). 67. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the TP sensor or input shaft (mainshaft) speed sensor (A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 68. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2759 72. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF. 74. Disconnect ECM/PCM connector E(31 P). 75. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). 78. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2760 NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM/PCM connector E(31 P). 81. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29), the SRS unit, or the ABS modulator-control unit. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 82. Turn the ignition switch OFF. 83. Disconnect ECM/PCM connector E(31P). 84. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2764 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2765 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor convents manifold absolute pressure into electrical signals to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2770 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2771 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control MIL ON, DTC P1163 Oxygen Sensor: Customer Interest Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control MIL ON, DTC P1163 > Page 2780 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: All Technical Service Bulletins Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 2786 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2789 144. Middle Underside of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2790 Oxygen Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM which varies the duration of fuel injection accordingly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Air Fuel (A/F) Ratio Sensor > Page 2793 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/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The ECM/PCM compares the HO2S output with the A/F sensor output to determine catalyst efficiency. The secondary HO2S is installed in the TWC. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > A/F Sensor Replacement > Page 2796 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YAB875, 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Oxygen Sensor Relay: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2800 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2801 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2805 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2806 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2807 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2808 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2809 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2815 DTC P0A94 thru P0157 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2816 DTC P0158 thru P0400 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2817 DTC P0401 thru P0562 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2818 DTC P0563 thru P0748 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2819 DTC P0750 thru P0977 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2820 DTC P0979 thru P1193 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2821 DTC P1253 thru P1459 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2822 DTC P1486 thru P1585 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2823 DTC P1586 thru P1678 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2824 DTC P1679 thru P1860 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2825 DTC P1861 thru P2238 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2826 DTC P2240 thru U0073 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2827 DTC U0100 thru U1288 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2828 Engine Control Module: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 2829 82. Behind Glove Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2832 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview Engine Control Module: Initial Inspection and Diagnostic Overview How to Troubleshoot Circuits at the ECM/PCM Special Tools Required - Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter - Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digital multimeter (C). 2. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it touches the end of the wire terminal. 3. If you cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and probe the terminals (B) from the terminal side. Do not force the probe into the connector. NOTE: Do not puncture the insulation on a wire. Punctures can cause poor or intermittent electrical connections. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2835 Engine Control Module: Pinout Values and Diagnostic Parameters ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2836 ECM/PCM Inputs And Outputs At Connector A (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2837 ECM/PCM Inputs And Outputs At Connector B (24P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2838 PCM Inputs And Outputs At Connector C (22P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2839 PCM Inputs And Outputs At Connector D (17P)*1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2840 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Initial Inspection and Diagnostic Overview > Page 2841 ECM/PCM Inputs And Outputs At Connector E (31P) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation Engine Control Module: Service and Repair Removal and Installation How to Remove the ECM/PCM for Testing If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove the ECM/PCM and test it: 1. Disconnect the negative cable from the battery. 2. Remove glove box. 3. Disconnect the gray 20P ECM/PCM wire harness connector, and remove it from the ECM/PCM mounting bracket. Disconnect the 7 P mode control motor connector. Remove PGM-FI main relay 2 (A). Remove the ECM/PCM mounting bolt (B) and the bracket. 4. Remove the nuts, then remove the ECM/PCM (C). 5. Install the ECM/PCM in the reverse order of removal. 6. Reconnect the negative cable to the battery. 7. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2844 Engine Control Module: Service and Repair ECM/PCM Idle Learn Procedure ECM/PCM Idle Learn Procedure The idle learn procedure must be done so the ECM/PCM can learn the engine idle characteristics. Do the idle learn procedure whenever you do any of these actions: - Disconnect the battery. - Replace the ECM/PCM or disconnect its connector. - Reset the ECM/PCM. NOTE: Erasing DTCs with the HDS does not require you to do the idle learn procedure. - Replace the throttle body. - Replace the idle air control (IAC) valve. - Remove the No.6 ECU (ECM/PCM) (15A) fuse from the under-hood fuse/relay box. - Remove the No.19 BATTERY (80A) fuse from the under-hood fuse/relay box. - Remove PGM-FI main relay 1. - Remove any of the wires from the under-hood fusel relay box. - Disconnect any of the connectors from the under-hood fuse/relay box. - Disconnect the connector between the engine compartment wire harness and ECM/PCM wire harness. - Disconnect the G2 terminal from the transmission housing. - Disconnect the G1 terminal from the body. - Disconnect the G101 terminal from the cylinder head cover. Procedure 1. Make sure all electrical items (A/C, audio, rear window defogger, lights, etc.) are off. 2. Start the engine, and hold it at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, or until the engine coolant temperature reaches 194 °F (90 °C). 3. Let the engine idle for about 5 minutes with the throttle fully closed. NOTE: If the radiator fan comes on, do not include its running time in the 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2845 Engine Control Module: Service and Repair ECM/PCM Updating and Substitution for Testing ECM/PCM Updating and Substitution for Testing Special Tools Required Honda Interface Module (HIM) E0S05A35570 Use this procedure when you have to substitute a known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only if the ECM/PCM does not already have the latest software loaded. NOTE: Do not turn the ignition switch OFF while updating; the ECM/PCM can be damaged. How to Update the ECM/PCM NOTE: - To ensure the latest program is installed, do an ECM/PCM update whenever the ECM/PCM is substituted or replaced. - You can not update an ECM/PCM with the program it already has. It will only accept a new program. - Before you update the ECM/PCM, make sure the vehicle's battery is fully charged. - To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, 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/PCM damage. 1. Turn the ignition switch ON (II). Do not start the engine. 2. Connect the Honda interface module (HIM) to the data link connector (DLC) (A) located under the driver's side of dashboard. 3. Do the ECM/PCM update procedure as described on the HIM label. If the software in the ECM/PCM is the latest, replace the ECM/PCM. How to Substitute the ECM/PCM 1. Remove the ECM/PCM from the vehicle. 2. Install a known-good ECM/PCM in the vehicle. 3. Rewrite the immobilizer code with the ECM/PCM replacement procedure in the HDS: It allows you to start the engine. 4. After completing your tests, reinstall the original ECM/PCM and rewrite the immobilizer code with the PCM replacement procedure in the HDS again. 5. Do the ECM/PCM idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 and Installation > Page 2846 Engine Control Module: Service and Repair ECM Reset How to Reset the ECM/PCM You can reset the ECM/PCM in either of two ways: NOTE: After resetting the ECM/PCM, do the ECM/PCM idle learn procedure. Reset the ECM/PCM with the Scan Tool or the HDS 1. Turn the ignition switch ON (II). Do not start the engine. 2. Use the scan tool or the HDS to clear the DTC. NOTE: For the specific operations, refer to the user's manual that came with the scan tool or the HDS. Reset the ECM/PCM by removing the fuse 1. Turn the ignition switch OFF. 2. Remove the No.6 ECU (ECM/PCM) (15A) fuse (A) from the under-hood fuse/relay box (B) for 10 seconds. How to End a Troubleshooting Session (required after any troubleshooting) 1. Reset the ECM/PCM as described above. 2. Do the ECM/PCM idle learn procedure. 3. Turn the ignition switch OFF. 4. Disconnect the scan tool or the HDS from the DLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a different immobilizer code. To start the engine, you must rewrite the immobilizer code with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2850 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2851 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2852 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2853 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2854 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2855 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2859 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 2860 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM. It converts atmospheric pressure into a voltage signal that the ECM/PCM uses to modify the basic duration of the fuel injection discharge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2872 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2873 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2874 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Sensor A Replacement > Page 2877 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Coolant Temperature Sensor/Switch (For Computer): Locations PGM-FI System - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2881 45. ECT Sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2882 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2883 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2887 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2888 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2889 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2898 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2899 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2900 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2901 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2907 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2908 5. Remove the lower cover from the fuse/relay box. 6. Disconnect the 3P ELD connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2909 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-006 > May > 05 > Electrical - DTC P1298 Stored in ECM/PCM > Page 2910 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Electric Load Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Electric Load Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 2916 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Electric Load Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 2922 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2923 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2924 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2925 Electric Load Sensor: Description and Operation Electrical Load Detector (ELD) Since the early ’90s, Honda vehicles have come with an electrical load detector (ELD) unit in the under-hood fuse/relay box. This unit allows the ECM/PCM to regulate the alternator (switch it between high output and low output) to provide the best combination of fuel economy and electrical system operation. The ELD sends a signal to the ECM/PCM that is proportional to the electrical demand. The ECM/PCM switches the alternator between high output and low output depending on several factors, which include electrical demand, battery charge level, and the driving cycle. When the alternator is in low output, the engine load is reduced and fuel economy improves. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2929 146. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2930 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2934 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2935 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature (IAT) Sensor The IAT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2936 Intake Air Temperature Sensor: Service and Repair IAT Sensor Replacement 1. Disconnect the IAT sensor 2P connector. 2. Remove the clip (A) and the IAT sensor (B). 3. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2940 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2941 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2942 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2946 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2947 Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure (MAP) Sensor The MAP sensor convents manifold absolute pressure into electrical signals to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls - DTC P2646, P2647 Oil Pressure Sensor: Technical Service Bulletins Engine Controls - DTC P2646, P2647 SOURCE: Honda Service News TITLE: Replace VTEC Oil Pressure Switch for DTC P2646, P2647 APPLIES TO: 03-05 Accord 4-cylinder 03-05 Element 02-05 CR-V SERVICE TIP: Got a vehicle in your shop with either of these DTCs? - DTC P2646 (VTEC oil pressure switch circuit low voltage) - DTC P2647 (VTEC oil pressure switch circuit high voltage) Replacing the VTEC oil pressure switch usually fixes the problem. If it doesn't, then press on with normal troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2952 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 2953 Oil Pressure Sensor: 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: Customer Interest Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 2962 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 Oxygen Sensor: All Technical Service Bulletins Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 2968 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2971 144. Middle Underside of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2972 Oxygen Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM which varies the duration of fuel injection accordingly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2975 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/PCM which checks the efficiency of the TWC. To stabilize its output, the sensor has an internal heater. The ECM/PCM compares the HO2S output with the A/F sensor output to determine catalyst efficiency. The secondary HO2S is installed in the TWC. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 2978 Oxygen Sensor: Service and Repair Secondary HO2S Replacement Secondary HO2S Replacement Special Tools Required O2 sensor wrench, Snap-on YAB875, 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2982 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2983 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2984 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2985 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2986 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 2995 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3001 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3002 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3003 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3004 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3013 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3014 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3020 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3021 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3022 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3023 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3024 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3025 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3026 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3027 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3028 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3032 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3037 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3038 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3039 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) (M/T) 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3040 Vehicle Speed Sensor: Service and Repair VSS Replacement M/T only: 1. Remove the air cleaner. 2. Disconnect the 3P connector from the vehicle speed sensor (VSS). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3049 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3055 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 3061 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 3067 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3068 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3069 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3070 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3079 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3080 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3086 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3087 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3088 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3089 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3090 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3091 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3092 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3093 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3094 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Locations VTEC/VTC - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 System Diagram Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3131 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 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. - Reduces the cam advance at idle, stabilizes 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3132 VTEC system - The VTEC system changes the cam profile to correspond to the 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 VTEC/VTC Camshaft Position (CMP) Sensor A The CMP sensor A detects camshaft angle position for the VTC system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3133 Variable Valve Timing Actuator: Testing and Inspection VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3134 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3135 Variable Valve Timing Actuator: Service and Repair VTC Oil Control Solenoid Valve Removal/Test/Installation 1. Disconnect the VTC oil control solenoid valve 2P connector. 2. Remove the bolt (A) and VTC oil control solenoid valve (B). 3. Check the VTC oil control solenoid valve oil 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. The valve should be closed. If you see the shoulder of the piston, the valve is open and must be replaced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3136 5. 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 (0.05 in.). If the inner valve does not open, replace it; then go to step 6. 6. Replace the VTC oil control solenoid valve O-ring (A). 7. Coat a new O-ring with engine oil, then install it. 8. Clean and dry the mating surface of the valve. 9. Install the valve. NOTE: Do not install the valve while wearing cloth fibrous gloves. Be careful not to contaminate the cylinder head opening. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Pressure Switch > Component Information > Locations > Page 3140 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations Variable Valve Timing Solenoid: Locations VTEC/VTC - Component Location Index 2. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 3144 5. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 3145 Variable Valve Timing Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 3146 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Page 3147 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 2P 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3152 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3153 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3154 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) (M/T) 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3155 Vehicle Speed Sensor: Service and Repair VSS Replacement M/T only: 1. Remove the air cleaner. 2. Disconnect the 3P connector from the vehicle speed sensor (VSS). 3. Remove the mounting bolt, then remove the VSS. 4. Install the VSS in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM/PCM connector terminals A24 and B13 Is there about 5 V? YES - Go to step 4. NO - Go to step 13. 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 7. Measure voltage between ECM/PCM connector terminals A24 and B13. Does the voltage decrease when the headlights and rear window defogger are turned on? YES - The alternator FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect ECM/PCM connector B (24P). 10. Disconnect the alternator 4P connector. 11. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Testing and Inspection > Page 3159 12. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Test the alternator. NO - Repair open in the wire between the ECM/PCM (B13) and the alternator. 13. Turn the ignition switch OFF. 14. Disconnect ECM/PCM connector B (24P). 15. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM/PCM (B13) and the alternator. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3165 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 (CO2), nitrogen (N2), and water vapor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Locations Canister Purge Control Valve: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Locations > Page 3170 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Connector Views > Page 3173 Vacuum Hose Routing Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3174 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve When the engine coolant temperature is below 149 °F (65 °C), the ECM/PCM turns off the EVAP canister purge valve which cuts vacuum to the EVAP canister. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Locations > Page 3178 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Volume Control Valve > Component Information > Locations > Page 3179 Canister Purge Volume Control Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank and prevents excessive vacuum in the fuel tank by drawing in fresh air through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve during the EVAP leak check. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3188 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3189 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3190 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3191 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3192 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3198 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3199 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3200 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3201 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 08-016 > Mar > 08 > Emissions - MIL ON/DTC P1457 Set > Page 3202 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 3203 EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 3204 Evaporative Check Valve: Description and Operation EVAP Two Way Valve and EVAP Bypass Solenoid Valve The EVAP two way valve is installed between the fuel tank and the EVAP canister line. The EVAP two way valve sends fuel vapor to the EVAP canister corresponding to the pressure inside the fuel tank and prevents excessive vacuum in the fuel tank by drawing in fresh air through the EVAP canister. The EVAP bypass solenoid valve opens to bypass the two way valve during the EVAP leak check. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Page 3205 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 the line 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Emissions - DTC P1457 Possible Clogged Line Evaporative Emissions Hose: Technical Service Bulletins Emissions - DTC P1457 Possible Clogged Line SOURCE: Honda Service News July 2004 TITLE: Got DTC P1457? Check for a Clogged EVAP Canister Purge Line. APPLIES TO: 2002-03 CR-V SERVICE TIP: Got a DTC P1457 [EVAP control system leakage (EVAP canister system)]? The problem could be a clogged EVAP canister purge line. If your customer was out four-wheeling it, there's a good possibility that mud, sand, or debris could have been sucked into the line, especially if the EVAP canister got damaged or ripped from the vehicle or if the vehicle was plowing through some deep, standing water. A clogged EVAP canister purge line can delay the supply of vacuum to the fuel tank pressure (FTP) sensor. If the FTP sensor reacts sluggishly, the voltage won't drop down fast enough, and the ECM/PCM will set a DTC P1457 and maybe a test ID (TID) 2D. To check for a clogged EVAP canister purge line, connect the HDS with version 1.012.023 or later software to the 16P DLC, and run the EVAP System Function Test. If the EVAP system fails the test, you'll need to troubleshoot and repair the problem. If the EVAP system passes the test, then follow these steps to check for a clog in the purge line from the EVAP canister to the engine: 1. Disconnect the purge hose at the EVAP canister, and attach a vacuum gauge to the hose. 2. Start the engine, and activate the purge control valve by back-probing and grounding the YEL/BLU wire. Watch the vacuum gauge. - If the gauge needle instantly reads the manifold vacuum, then the purge valve is clear. Reconnect the purge hose to the EVAP canister, and look for other possible causes. - If the gauge needle doesn't instantly read the manifold vacuum, then the purge control valve could be clogged. Go to step 3. 3. Disconnect the hose between the EVAP test port and the purge control valve. Attach a vacuum gauge to the test port end of the hose. 4. Activate the purge control valve by backprobing and grounding the YEL/BLU wire. Watch the vacuum gauge. - If the gauge needle instantly reads the manifold vacuum, then clean or replace the EVAP test port, the purge line to the rear of the vehicle, or both. - If the gauge needle doesn't instantly read the manifold vacuum, then look for a clogged purge control valve port in the intake manifold. If the port is clear, then replace the purge control valve, and retest. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Shut Valve > Component Information > Locations Evaporative Shut Valve: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Shut Valve > Component Information > Locations > Page 3217 147. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Shut Valve > Component Information > Locations > Page 3218 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Locations 146. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Locations > Page 3222 46. EVAP Bypass Solenoid Valve Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3227 Refueling Control Valve: Testing and Inspection Fuel Tank Vapor Control Valve Test Special Tools Required Vacuum pump/gauge, 0-30 in.Hg A973X-041-XXXXX Float Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap to relieve fuel tank pressure, then reinstall the cap. 3. Disconnect the fuel tank vapor recirculation tube (A), and connect a vacuum pump to the vapor recirculation tube. 4. Plug the line (B). 5. Apply vacuum to the fuel tank vapor recirculation tube. - If the vacuum holds, replace the fuel tank vapor control valve. - If the vacuum does not hold, the float is OK. Do the valve test Valve Test 1. Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap 3. Disconnect the fuel tank vapor signal tube (A). 4. Disconnect the vacuum hoses (A) from the EVAP canister (B), then plug the ports with plugs (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3228 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, then check the vacuum on the pump in step6. - 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 the 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 is OK. 10. Disconnect the fuel tank vapor vent tube 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3229 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 hose for cracks or damage. If the hose is OK, replace the PCV valve and recheck. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection > Page 3234 Positive Crankcase Ventilation Valve: Service and Repair PCV Valve Replacement 1. Unscrew the PCV valve (A), and remove it. 2. Install the valve in the reverse order of removal with a new washer (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................................... 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 psi) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3239 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3240 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment 07VAJ-0040100 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A) at the fuel rail. 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. 7. Remove the fuel pulsation damper from its fitting, and attach the fuel pressure gauge attachment. 8. Attach the fuel pressure gauge. 9. Start the engine and let it idle. - If the engine starts, go to step 11. - If the engine does not start, go to step 10. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3241 10. 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 (II). If the pump runs, go to step 11. - If the pump does not run, do the fuel pump circuit troubleshooting. 11. Read the pressure gauge. The pressure should be 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 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 repeat the test. 12. Remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N.m (2.2 kgf.m, 16 lbf-ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed With no-load conditions: M/T ............................................................................................................... ..................................................................................................... 650 ± 50 rpm A/T ........................... .......................................................................................................................................................... 650 ± 50 rpm (in Park or neutral) With load conditions: M/T .................................................................................................................... ................................................................................................ 700 ± 50 rpm A/T ................................ ..................................................................................................................................................... 700 ± 50 rpm (in park or neutral) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3248 Idle Speed: Description and Operation Idle Control System Diagram The idle speed of the engine is controlled by the idle air control (IAC) valve: - After the engine starts, the A/C valve opens for a certain amount of time. The amount of air is increased to raise the idle speed. - When the engine coolant temperature is low, the A/C valve is opened to obtain the proper fast idle speed. The amount of bypassed air is controlled in relation to engine coolant temperature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3249 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. - There are no vacuum leaks - Ignition timing - Throttle cable adjustment - 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 Park or 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: M/T ................................................................................................................... ...................................................................................... 650 ± 50 rpm A/T .......................................... ................................................................................................................................ 650 ± 50 rpm (in Park or neutral) 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: M/T ................................................................................................................... ...................................................................................... 700 ± 50 rpm A/T .......................................... .................................................................................................................................. 700 ± 50 rpm(in park or neutral) NOTE: If the idle speed is not within specification, go to the Symptom Troubleshooting. 6. Reconnect the EVAP canister purge valve 2P connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3254 Air Filter Element: Service and Repair Air Cleaner Element Replacement 1. Remove the PCV hose (A). Open the air cleaner housing cover (B). 2. Remove the air cleaner (C) from the air cleaner housing (D). 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 3258 Vacuum Hose Routing Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 3259 Auxiliary Air Valve (Idle Speed): Description and Operation Intake Air Bypass Control Thermal Valve When the engine is running and the engine coolant temperature is less than 113 °F (45 °C ), the intake air bypass control thermal valve sends air to the injector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Locations > Page 3260 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, and 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 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 damage intake air bypass control thermal valve. 4. Hold the engine at 3,000 rpm with no load (in Park or 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Before disconnecting fuel lines or hoses, relieve pressure from the system by loosening the fuel pulsation damper on top of the fuel rail. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A). 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. NOTE: Replace all washers whenever the fuel pulsation damper is loosened or removed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3275 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3276 Fuel Injector: Locations PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3277 10. Middle of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3278 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3279 Fuel Injector: Service and Repair Injector Replacement 1. Relieve the fuel pressure. 2. Disconnect the connectors from the injectors (A), then remove the ground cable (B) and the harness holder (C). 3. Disconnect the quick-connect fitting (D). 4. Remove the fuel rail mounting nuts (E) from the fuel rail (F). 5. Remove the injector clip (G) from the injector. 6. Remove the injector from the fuel rail. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3280 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 in the injector base (F). 11. Install the fuel rail mounting nuts. 12. Connect the connectors on the injectors, then install the ground cable and the harness holder. 13. Connect the quick-connect fitting. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3284 Fuel Line Coupler: Service Precautions Fuel Line/Quick-Connect Fitting Precaution The fuel line/quick-connect fittings connect the fuel rail (A) to fuel feed hose (B), the fuel feed hose (B) to the fuel line (C), and the fuel tube (D) to the fuel tank unit (E). When removing or installing the fuel feed hose, fuel tank unit, or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose (B), fuel tube (D), and quick-connect fittings (F) are not heat-resistant; be careful not to damage them during welding or other heat- generating procedures. - The fuel feed hose (B), fuel tube (D), and quick-connect fittings (F) are not acid-proof; do not touch them with a shop towel that 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 (B), fuel tube (D), and quick-connect fittings (F), be careful not to bend or twist them excessively. Replace them if they are damaged. A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3285 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3286 Fuel Line Coupler: Service and Repair Fuel Line/Quick-Connect Fitting Precaution The fuel line/quick-connect fittings connect the fuel rail (A) to fuel feed hose (B), the fuel feed hose (B) to the fuel line (C), and the fuel tube (D) to the fuel tank unit (E). When removing or installing the fuel feed hose, fuel tank unit, or fuel tank, it is necessary to disconnect or connect the quick-connect fittings. Pay attention to the following: - The fuel feed hose (B), fuel tube (D), and quick-connect fittings (F) are not heat-resistant; be careful not to damage them during welding or other heat- generating procedures. - The fuel feed hose (B), fuel tube (D), and quick-connect fittings (F) are not acid-proof; do not touch them with a shop towel that 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 (B), fuel tube (D), and quick-connect fittings (F), be careful not to bend or twist them excessively. Replace them if they are damaged. A disconnected quick-connect fitting can be reconnected, but the retainer on the mating line cannot be reused once it has been removed from the line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3287 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 the fuel pressure. 2. Check the fuel quick-connect fitting for dirt, and clean it if necessary. 3. Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking pawls (C). Pull the connector off. NOTE: Be careful not to damage the line (D) or other parts. Do not use tools. - If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily. - Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one. 4. Check the contact area (A) of the line (B) for dirt or damage. - If the surface is dirty, clean it. - If the surface is rusty or damaged, replace the fuel pump, fuel filter, or fuel feed line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3288 5. To prevent damage and keep foreign matter out, cover the disconnected connector and line end with plastic bags (A). NOTE: The retainer cannot be reused once it has been removed from the line. - Replace 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. - it is damaged. Fuel Line/Quick-Connect Fitting Installation 1. Check the contact area (A) of the line (B) for dirt or damage, and clean it if necessary 2. Insert a new retainer (A) into the connector (B) if the retainer is damaged, or after: - replacing the fuel rail. - replacing the fuel feed line. - replacing the fuel pump. - replacing the fuel filter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3289 - replacing the fuel gauge sending unit - removing the retainer from the line. 3. Before connecting a new fuel line/quick-connect fitting assembly (A), remove the old retainer from the mating line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Locations > Page 3290 4. Align the quick-connect fittings with the line (A), and align the retainer (B) locking pawls with the connector (C) grooves. Then press the quickconnect fittings onto the line until both retainer pawls lock with a clicking sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the line end. 5. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector. 6. Reconnect the negative cable to the battery, and turn the ignition switch ON (II). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat two or three times, and check that there are no fuel leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3294 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement 1. Remove the fuel pump. 2. Remove the clip (A). 3. Remove the fuel pressure regulator (B). 4. Install the regulator in the reverse order of removal with new O-rings (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................................... 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 psi) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3302 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3303 Fuel Pressure: Testing and Inspection Fuel Pressure Test Special Tools Required - Fuel pressure gauge 07406-004000A - Fuel pressure gauge attachment 07VAJ-0040100 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Remove the fuel fill cap and the engine cover. 4. Use a wrench on the fuel pulsation damper (A) at the fuel rail. 5. Place a rag or shop towel (B) over the fuel pulsation damper. 6. Slowly loosen the fuel pulsation damper one complete turn. 7. Remove the fuel pulsation damper from its fitting, and attach the fuel pressure gauge attachment. 8. Attach the fuel pressure gauge. 9. Start the engine and let it idle. - If the engine starts, go to step 11. - If the engine does not start, go to step 10. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3304 10. 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 (II). If the pump runs, go to step 11. - If the pump does not run, do the fuel pump circuit troubleshooting. 11. Read the pressure gauge. The pressure should be 330-380 kPa (3.4-3.9 kgf/sq.cm, 48-55 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 repeat the test. 12. Remove the pressure gauge, and reinstall the fuel pulsation damper with a new washer. Tighten the fuel pulsation damper to 22 N.m (2.2 kgf.m, 16 lbf-ft). NOTE: Disassemble and clean the fuel pressure gauge attachment thoroughly after use. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3308 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3309 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations > Page 3316 Fuel Return Line: Testing and Inspection Fuel Line Inspection Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations > Page 3317 Fuel Line Inspection Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 3321 Fuel Supply Line: Testing and Inspection Fuel Line Inspection Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 3322 Fuel Line Inspection Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Evaporative Shut Valve > Component Information > Locations Evaporative Shut Valve: Locations EVAP System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Evaporative Shut Valve > Component Information > Locations > Page 3327 147. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Evaporative Shut Valve > Component Information > Locations > Page 3328 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) Fuel Filler Neck: Customer Interest Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) 04-002 February 13, 2004 Applies To: See VEHICLES AFFECTED Fuel Fill Cap Binds and Possible MIL Comes On With DTC P1456 (Supersedes 04-002, dated January 30, 2004) Updated information is shown with black bars. SYMPTOM The fuel fill cap is binding and, if not tightened fully, may cause the MIL to come on and DTC P1456 (EVAP control system leakage, fuel tank system) to set. PROBABLE CAUSE The threads in the fuel fill pipe bind on the fuel fill cap. VEHICLES AFFECTED CORRECTIVE ACTION Replace the fuel fill pipe, and do an EVAP system function test with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3337 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 17660-S9A-A01 H/C 6887210 Defect Code: 03214 Symptom Code: 03203 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 Remove the fuel fill cap, reinsert it, then tighten it. The cap should turn, without resistance, until its 0-ring touches the fuel fill pipe. ^ If the cap turns freely, this service bulletin does not apply; continue with normal troubleshooting. ^ If the cap binds or drags, go to REPAIR PROCEDURE. REPAIR PROCEDURE A - CR-V NOTE: Make sure the fuel tank is less than half full before starting this procedure. 1. Raise the vehicle on a lift, and remove the left rear wheel. 2. Remove the three EVAP canister mounting bolts. Let the canister hang in place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3338 3. Support the rear suspension cross beam with a powertrain lift or commercially available jack as shown. 4. Disconnect the fuel fill pipe hoses from the fuel fill pipe. 5. Remove the two lower rear cross beam bolts, the two fuel fill pipe bracket bolts, and the fuel fill pipe gasket. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3339 6. Using a pry bar, move the rear cross beam down to make room to remove the fuel fill pipe. 7. Install the new fuel fill pipe, the fuel fill pipe gasket, and the hoses. Torque the two cross beam bolts to 69 Nm (51 lb-ft). Reinstall the EVAP canister and the wheel. 8. Connect the HDS to the vehicle's DLC (data link connector), and do the EVAP function test: ^ From the HDS main menu, select Honda System. ^ From the Honda System menu, select PGM-FI. ^ From the PGM-FI menu, select Inspection. ^ From the Inspection menu, select EVAP Test. ^ From the EVAP Test menu, select Function Test. ^ Follow the instructions on the screen. 9. Check the results of the EVAP function test. ^ If the vehicle passed the test, return it to the customer. ^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the appropriate CR-V service manual. REPAIR PROCEDURE B - S2000 NOTE: Make sure the fuel tank is less than half full before starting this procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3340 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) Fuel Filler Neck: All Technical Service Bulletins Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) 04-002 February 13, 2004 Applies To: See VEHICLES AFFECTED Fuel Fill Cap Binds and Possible MIL Comes On With DTC P1456 (Supersedes 04-002, dated January 30, 2004) Updated information is shown with black bars. SYMPTOM The fuel fill cap is binding and, if not tightened fully, may cause the MIL to come on and DTC P1456 (EVAP control system leakage, fuel tank system) to set. PROBABLE CAUSE The threads in the fuel fill pipe bind on the fuel fill cap. VEHICLES AFFECTED CORRECTIVE ACTION Replace the fuel fill pipe, and do an EVAP system function test with the HDS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3346 PARTS INFORMATION WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 17660-S9A-A01 H/C 6887210 Defect Code: 03214 Symptom Code: 03203 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 Remove the fuel fill cap, reinsert it, then tighten it. The cap should turn, without resistance, until its 0-ring touches the fuel fill pipe. ^ If the cap turns freely, this service bulletin does not apply; continue with normal troubleshooting. ^ If the cap binds or drags, go to REPAIR PROCEDURE. REPAIR PROCEDURE A - CR-V NOTE: Make sure the fuel tank is less than half full before starting this procedure. 1. Raise the vehicle on a lift, and remove the left rear wheel. 2. Remove the three EVAP canister mounting bolts. Let the canister hang in place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3347 3. Support the rear suspension cross beam with a powertrain lift or commercially available jack as shown. 4. Disconnect the fuel fill pipe hoses from the fuel fill pipe. 5. Remove the two lower rear cross beam bolts, the two fuel fill pipe bracket bolts, and the fuel fill pipe gasket. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3348 6. Using a pry bar, move the rear cross beam down to make room to remove the fuel fill pipe. 7. Install the new fuel fill pipe, the fuel fill pipe gasket, and the hoses. Torque the two cross beam bolts to 69 Nm (51 lb-ft). Reinstall the EVAP canister and the wheel. 8. Connect the HDS to the vehicle's DLC (data link connector), and do the EVAP function test: ^ From the HDS main menu, select Honda System. ^ From the Honda System menu, select PGM-FI. ^ From the PGM-FI menu, select Inspection. ^ From the Inspection menu, select EVAP Test. ^ From the EVAP Test menu, select Function Test. ^ Follow the instructions on the screen. 9. Check the results of the EVAP function test. ^ If the vehicle passed the test, return it to the customer. ^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the appropriate CR-V service manual. REPAIR PROCEDURE B - S2000 NOTE: Make sure the fuel tank is less than half full before starting this procedure. 1. Remove the left side trunk lining. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3349 2. Slide up the fuel fill pipe cover, and disconnect the fuel fill pipe hoses. 3. Remove the fuel fill pipe attachment nuts. 4. Install the new fuel fill pipe with the original nuts. 5. Install the fuel fill pipe hoses with the original clamps. Make sure the fuel fill pipe cover is seated properly. Install the trunk lining. 6. Connect the HDS to the vehicle's DLC (data link connector), and do an EVAP function test: ^ From the HDS main menu, select Honda System. ^ From the Honda System menu, select PGM-FI. ^ From the PGM-FI menu, select Inspection. ^ From the Inspection menu, select EVAP Test. ^ From the EVAP Test menu, select Function Test. 7. Check the results of the EVAP function test. ^ If the vehicle passed the test, return it to the customer. ^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the 2002-04 S2000 Service Manual. REPAIR PROCEDURE C - INSIGHT 1. Remove the trunk lining and the cargo box. (See page 20-44 of the 2000-04 Insight Service Manual.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3350 2. Remove the right trunk side bulkhead and the right side trunk shelf support. 3. Remove the middle floor pan. (See page 20-92 of the 2000-04 Insight Service Manual.) 4. Remove the battery inner duct and the fuel fill pipe grommet. 5. Slide the fuel fill pipe grommet upward. Then disconnect the fuel fill pipe hoses. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 04-002 > Feb > 04 > Fuel/Emissions - MIL ON/DTC P01456 (EVAP System) > Page 3351 6. Remove the fuel fill pipe bracket bolt and the three fuel fill pipe flange nuts. 7. Install the new fuel fill pipe with the original nuts and bolt. 8. Install the fuel fill pipe hoses with the original clamps. Install the fuel fill pipe grommet. 9. Reinstall all removed parts. 10. Connect the HDS to the vehicle's DLC (data link connector), and do the EVAP function test: ^ From the HDS main menu, select Honda System. ^ From the Honda System menu, select PGM-FI. ^ From the PGM-FI menu, select Inspection. ^ From the Inspection menu, select EVAP Test. ^ From the EVAP Test menu, select Function Test. ^ Follow the instructions on the screen. 11. Check the results of the EVAP function test. ^ If the vehicle passed the test, return it to the customer. ^ If the vehicle failed the test, do the DTC P1456 troubleshooting in section 11 of the 2000-04 Insight Service Manual. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3355 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from the 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 correctly, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 OK, go to step 8. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fusel relay box for at least 30 seconds, then reinstall it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3356 9. Install a 2 Ohm resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicate "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom 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 locknut (A), and remove the fuel tank unit from the fuel tank. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3357 15. Measure resistance between the No.1 and No.2 terminals with the float at E(EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting. Otherwise, it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3358 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3359 8. Remove the locknut (A) and the fuel tank unit. 9. 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). Be sure to check these items: - When connecting the wire harness, make sure the connection is secure and the connectors (K) are firmly locked into 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 it excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations 100. Middle of Floor (Carpet Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3363 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3367 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3368 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3369 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3370 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3371 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3372 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3376 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3381 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3382 Fuel Pump Relay: Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 PGM-FI System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3386 Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3387 150. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3388 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3389 Main Relay (Computer/Fuel System): Description and Operation PGM-FI Main Relay 1 and 2 The PGM-FI relay consists of two separate relays. PGM-FI main relay 1 is energized whenever the ignition switch is ON (II) to supply battery voltage to the ECM/PCM, power to the injectors, and power for PGM-FI main relay 2. PGM-FI main relay 2 is energized to supply power to the fuel pump for 2 seconds when the ignition switch is turned ON (II), and when the engine is cranking running. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3390 Main Relay (Computer/Fuel System): Testing and Inspection 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. PGM-FI Main Relay 1, 2 PGM-FI Main Relay 1 PGM-FI Main Relay 2 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 3391 PGM-FI Main Relay 2 PGM-FI Main Relay 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Locations > Page 3396 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3405 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3411 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 05-073 > Dec > 05 > Restraints - Rear Seat Belt Retractor Rattles/Squeaks Seat Belt Retractor: All Technical Service Bulletins Restraints - Rear Seat Belt Retractor Rattles/Squeaks 05-073 December 16, 2005 Applies To: 2002-04 CR-V - ALL Japan-Produced Vehicles 2005 CR-V - From VIN JHLRD7...5C000001 thru JHLRD7...5C059336 - From VIN JHLRD6...5C000001 thru JHLRD6...5C019332 Rear Seat Belt Retractor Noise SYMPTOM A squeak or rattle is heard from the rear seat belt retractors while driving over bumps or rough roads. PROBABLE CAUSE The seat belt retractor tab is rubbing against the body. CORRECTIVE ACTION Remove any felt from the seat belt retractor tab, then install a floor boot to insulate the retractors from the body. PARTS INFORMATION Floor Boot (two required): P/N 91608-S5A-003, H/C 6634497 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 854078 Flat Rate Time: 0.4 hour Failed Part: Right Rear P/N 04824-SCA-A11ZA H/C 7743685 Left Rear P/N 04828-SCA-A12ZA H/C 7822885 Defect Code: 07404 Symptom Code: 04205 Template ID: 05-073A 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 side trim panel: 2002-04 CR-V: ^ Refer to page 20-66 of the 2002-04 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 05-073 > Dec > 05 > Restraints - Rear Seat Belt Retractor Rattles/Squeaks > Page 3417 2005 CR-V: ^ Refer to page 20-72 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. 2. Remove the retractor self-tapping screw and the retractor bolt. 3. Using an X-acto knife, carefully remove any felt from the retractor tab. 4. Install the floor boot. 5. Repeat steps 1 thru 4 for the other side. 6. Reinstall the seat belt retractors. Torque the retractor mounting screws to 4 Nm (3 lb-ft) and torque the retractor mounting bolts to 32 Nm (24 lb-ft). 7. Install the rear side trim in the reverse order of removal. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 05-073 > Dec > 05 > Restraints - Rear Seat Belt Retractor Rattles/Squeaks > Page 3423 2005 CR-V: ^ Refer to page 20-72 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. 2. Remove the retractor self-tapping screw and the retractor bolt. 3. Using an X-acto knife, carefully remove any felt from the retractor tab. 4. Install the floor boot. 5. Repeat steps 1 thru 4 for the other side. 6. Reinstall the seat belt retractors. Torque the retractor mounting screws to 4 Nm (3 lb-ft) and torque the retractor mounting bolts to 32 Nm (24 lb-ft). 7. Install the rear side trim in the reverse order of removal. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3424 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3425 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3426 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations Variable Induction Position Sensor: Locations Intake Air System - Component Location Index 6. Right Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 3430 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 3431 Variable Induction Position Sensor: Description and Operation Intake Manifold Runner Control (IMRC) Valve Position Sensor The IMRC position sensor is a potentiometer connected to the IMRC valve shaft. As the IMRC valve position changes, the sensor varies the signal voltage to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Variable Induction Position Sensor > Component Information > Locations > Page 3432 Variable Induction Position Sensor: Service and Repair IMRC Valve Position Sensor Replacement 1. Remove the two screws (A) and the IMRC position sensor (B). 2. Install the sensor with a new O-ring (C), and make sure the projection (D) inside the IMRC valve matches up with the groove (E) in the sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Body: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3441 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Body: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3447 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > SN040705 > Jul > 04 > A/T Stuck In Park After Throttle Body Replacement Throttle Body: All Technical Service Bulletins A/T - Stuck In Park After Throttle Body Replacement SOURCE: Honda Service News July 2004 TITLE: A/T Stuck in Park After Throttle Body Replacement APPLIES TO: A/T-equipped 2003-04 Accords, 2002-04 CR-Vs, and 2003-04 Elements. SERVICE TIP: Has this happened to you? You've replaced the throttle body, now you start the engine, but the A/T won't shift out of Park. If this situation strikes an all-too-familiar chord, it could be that the PCM needs to learn the relative throttle position. This is a learned value, just like idle learn. To make this happen, here's what you do: 1. Connect the HDS with version 1.012.023 or later software to the 16P DLC. 2. With the engine turned off, check the TPS sensor voltage and the relative throttle position. The TPS sensor voltage should read 0.49 volt; the relative throttle position should read 0 %. If both the TPS sensor voltage and the throttle position are OK, then continue with normal troubleshooting. If the TPS sensor voltage doesn't read 0.49 volt, go to step 3. If the relative throttle position doesn¡C■t read 0%, go to step 4. 3. TPS sensor voltage greater than 0.49 volt: Check the adjustment of the cruise control and throttle cables. If the cables are properly adjusted, then replace the throttle body, and retest. TPS sensor voltage less than 0.49 volt: Replace the throttle body, and retest. 4. Reset the PCM with the HDS, then do the idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > SN040705 > Jul > 04 > A/T Stuck In Park After Throttle Body Replacement Throttle Body: All Technical Service Bulletins A/T - Stuck In Park After Throttle Body Replacement SOURCE: Honda Service News July 2004 TITLE: A/T Stuck in Park After Throttle Body Replacement APPLIES TO: A/T-equipped 2003-04 Accords, 2002-04 CR-Vs, and 2003-04 Elements. SERVICE TIP: Has this happened to you? You've replaced the throttle body, now you start the engine, but the A/T won't shift out of Park. If this situation strikes an all-too-familiar chord, it could be that the PCM needs to learn the relative throttle position. This is a learned value, just like idle learn. To make this happen, here's what you do: 1. Connect the HDS with version 1.012.023 or later software to the 16P DLC. 2. With the engine turned off, check the TPS sensor voltage and the relative throttle position. The TPS sensor voltage should read 0.49 volt; the relative throttle position should read 0 %. If both the TPS sensor voltage and the throttle position are OK, then continue with normal troubleshooting. If the TPS sensor voltage doesn't read 0.49 volt, go to step 3. If the relative throttle position doesn¡C■t read 0%, go to step 4. 3. TPS sensor voltage greater than 0.49 volt: Check the adjustment of the cruise control and throttle cables. If the cables are properly adjusted, then replace the throttle body, and retest. TPS sensor voltage less than 0.49 volt: Replace the throttle body, and retest. 4. Reset the PCM with the HDS, then do the idle learn procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3457 Intake Air System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3458 Throttle Body: Description and Operation Throttle Body The throttle body is a single-barrel side draft type. The lower portion of the idle air control (IAC) valve is heated by engine coolant from the cylinder head. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3459 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 operates OK, go to step 2. - If the cable binds or sticks, check it and its routing. - If the cable is faulty, reroute it or replace it, and adjust it, then go to step 2. 2. Operate the throttle lever by hand to see if the throttle valve and/or shaft are too loose or too tight. - If there is excessive play in the throttle valve shaft, or any binding in the throttle valve at the fully closed or fully opened position, replace the throttle body. - If the throttle valve and shaft are OK, go to step 3. 3. Connect the scan tool or the HDS to the data link connector (DLC). 4. Turn the ignition switch ON (II). 5. Check the throttle position with the scan tool or the HDS. The reading should be about 10 % or 0.5 V when the throttle is fully closed and about 90 % or 4.5 V when the throttle is fully opened. If the throttle position is correct, the throttle body is OK. - If the throttle position is not correct, check for poor connections or loose terminals at the TP sensor and the ECM/PCM. If the connections and terminals are OK, replace the throttle body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal/Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Removal/Installation > Page 3462 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations Intake Air System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 3466 Throttle Cable/Linkage: Adjustments Throttle Cable Adjustment 1. Remove the throttle linkage cover plug (A). 2. Check cable free play at the throttle linkage. Cable free play (B) should be 10-12 mm (3/8-1/2 in.). 3. If the free play is not within spec (10-12 mm, 3/8-1/2 in.), remove the throttle linkage cover (A). 4. Loosen the locknut (A), turn the adjusting nut (B) until the free play (C) is as specified, then retighten the locknut. 5. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 3467 Throttle Cable/Linkage: Service and Repair Throttle Cable Removal/Installation 1. Remove the throttle linkage cover (A). 2. Fully open the throttle valve, then remove the throttle cable (A) from the throttle link (B). 3. Remove the cable housing (C) from the cable bracket (D). 4. Remove the throttle cable (A) from the accelerator pedal (B). 5. Install in the reverse order of removal. 6. After installing, start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 7. Hold the cable, removing all slack from it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Locations > Page 3468 8. Turn the adjusting nut (A) so that its free play is 0 mm. 9. Remove the cable from the cable bracket (B). Set the adjusting nut on the other side of cable bracket, then tighten the locknut (C). 10. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: Customer Interest Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3477 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls/Fuel System - MIL ON/DTC P0122 Set 04-008 May 6, 2005 *Applies To: 2002-2004 CR-V - ALL* Updated information is noted by asterisks. MIL Comes on With DTC P0122 (Supersedes 04-008, dated March 30, 2004) Updated information is noted by asterisks. SYMPTOM *The MIL is on, and DTC P0122 (throttle position sensor circuit low voltage) is set.* PROBABLE CAUSE The throttle position sensor in certain throttle bodies becomes contaminated due to a manufacturing defect. CORRECTIVE ACTION Replace the throttle body. PARTS INFORMATION *Throttle Body Kit: P/N 06160-PPA-A11, H/C 8003774 Throttle Body Gasket: P/N 17107-PNA-J01, H/C 6731210* WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 16400-PPA-A11 H/C 6886584 Defect Code: 06601 Symptom Code: 03203 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. Replace the throttle body. ^ Refer to page 11-189 of the 2002-2004 CR-V Service Manual, or Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 04-008 > May > 05 > Engine Controls/Fuel System - MIL ON/DTC P0122 Set > Page 3483 * ^ Online, enter keyword THROTTLE BODY, and select Throttle Body Removal/Installation from the list. NOTE: The new throttle body does not require a throttle drum cap.* 2. Adjust the throttle cable. * ^ Refer to page 11-187 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword THROTTLE CABLE, and select Throttle Cable Adjustment from the list.* 3. Adjust the cruise control actuator cable. ^ Refer to page 4-44 of the 2001-2004 CR-V Service Manual, or * ^ Online, enter keyword CRUISE ACTUATOR, and select Cruise Control Actuator Cable Adjustment from the list.* 4. Connect the HDS to the DLC (data link connector), and clear the DTC. 5. Do the idle learn procedure. * ^ Refer to page 11-168 of the 2001-2004 CR-V Service Manual, or ^ Online, enter keyword ECM IDLE, and select ECM/PCM Idle Learn Procedure from the list.* Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3484 Throttle Position Sensor: Locations PGM-FI System - Component Location Index 9. Left Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3485 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3486 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Check Valve > Component Information > Diagrams Vacuum Hose Routing Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Variable Induction Control Solenoid: > 05-052 > Nov > 05 > Engine Controls - MIL ON/DTC P1077 Variable Induction Control Solenoid: Customer Interest Engine Controls - MIL ON/DTC P1077 05-052 November 2, 2005 *Applies To: See VEHICLES AFFECTED* MIL Comes On With DTC P1077 (Supersedes 05-052, dated October 8, 2005, to update the information indicated by asterisks) SYMPTOM The MIL is on with DTC P1077 [intake manifold runner control (IMRC) / intake manifold tuning (IMI) system malfunction (low rpm)]. PROBABLE CAUSE Internal sticking of the IMI (IMRC) solenoid valve. VEHICLES AFFECTED 2004 CR-V - ALL 2005 CR-V Japan-produced From VIN JHLRD....5C000001 thru JHLRD....5C062481 England-produced VINs begin with SHS - ALL 2006 CR-V Japan-produced - None England-produced From VIN SHSRD6...6U400001 thru SHSRD6...6U401420 From VIN SHSRD7...6U400001 thru SHSRD7...6U405865 CORRECTIVE ACTION Replace the IMI (IMRC) solenoid valve. PARTS INFORMATION Valve Assembly: P/N 361 63-PND-A01, H/C 6890305 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 1201A7 Flat Rate Time: 0.7 hour Failed Part: P/N 36163-PND-A01 H/C 6890305 Defect Code: 03001 Symptom Code: 03203 Template ID: 05-052A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Variable Induction Control Solenoid: > 05-052 > Nov > 05 > Engine Controls - MIL ON/DTC P1077 > 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. REPAIR PROCEDURE 1. Replace the IMI (IMRC) solenoid valve. 2. Clear the DTC with the HDS. 3. Start the engine, press the accelerator pedal, and hold the engine at 3,000 rpm with no load (in Park or Neutral) until the radiator fan comes on. Is DTC P1077 stored? YES - Do the troubleshooting in the appropriate service manual or in ISIS. NO - Repair is complete, return the vehicle to your customer. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Induction Control Solenoid: > 05-052 > Nov > 05 > Engine Controls - MIL ON/DTC P1077 Variable Induction Control Solenoid: All Technical Service Bulletins Engine Controls - MIL ON/DTC P1077 05-052 November 2, 2005 *Applies To: See VEHICLES AFFECTED* MIL Comes On With DTC P1077 (Supersedes 05-052, dated October 8, 2005, to update the information indicated by asterisks) SYMPTOM The MIL is on with DTC P1077 [intake manifold runner control (IMRC) / intake manifold tuning (IMI) system malfunction (low rpm)]. PROBABLE CAUSE Internal sticking of the IMI (IMRC) solenoid valve. VEHICLES AFFECTED 2004 CR-V - ALL 2005 CR-V Japan-produced From VIN JHLRD....5C000001 thru JHLRD....5C062481 England-produced VINs begin with SHS - ALL 2006 CR-V Japan-produced - None England-produced From VIN SHSRD6...6U400001 thru SHSRD6...6U401420 From VIN SHSRD7...6U400001 thru SHSRD7...6U405865 CORRECTIVE ACTION Replace the IMI (IMRC) solenoid valve. PARTS INFORMATION Valve Assembly: P/N 361 63-PND-A01, H/C 6890305 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 1201A7 Flat Rate Time: 0.7 hour Failed Part: P/N 36163-PND-A01 H/C 6890305 Defect Code: 03001 Symptom Code: 03203 Template ID: 05-052A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Variable Induction Control Solenoid: > 05-052 > Nov > 05 > Engine Controls - MIL ON/DTC P1077 > Page 3505 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. Replace the IMI (IMRC) solenoid valve. 2. Clear the DTC with the HDS. 3. Start the engine, press the accelerator pedal, and hold the engine at 3,000 rpm with no load (in Park or Neutral) until the radiator fan comes on. Is DTC P1077 stored? YES - Do the troubleshooting in the appropriate service manual or in ISIS. NO - Repair is complete, return the vehicle to your customer. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > Page 3506 Variable Induction Control Solenoid: Locations Intake Air System - Component Location Index 6. Right Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Technical Service Bulletins > Page 3507 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations Intake Air System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3511 Vacuum Hose Routing Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3512 Variable Induction Control Valve: Service and Repair IMRC Valve Replacement 1. Remove the intake manifold. 2. Disconnect the vacuum hose (A). 3. Remove the bolts (B). 4. Remove the IMRC actuator assembly (C). NOTE: When installing the IMRC actuator, make sure the bearing (D) is in place. - Make sure the IMRC assembly does not interfere with the intake manifold (E). - When installing the IMRC actuator, replace the new O-rings (F). 5. Install the IMRC actuator assembly (A) so that the hole (B) is visible. 6. Turn the IMRC actuator assembly (A), and align the bolt holes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3513 NOTE: When turning the IMRC actuator assembly, make sure the stop (B) fits into the groove (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Position Sensor > Component Information > Locations Variable Induction Position Sensor: Locations Intake Air System - Component Location Index 6. Right Side of Intake Manifold Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Position Sensor > Component Information > Locations > Page 3517 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Position Sensor > Component Information > Locations > Page 3518 Variable Induction Position Sensor: Description and Operation Intake Manifold Runner Control (IMRC) Valve Position Sensor The IMRC position sensor is a potentiometer connected to the IMRC valve shaft. As the IMRC valve position changes, the sensor varies the signal voltage to the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Position Sensor > Component Information > Locations > Page 3519 Variable Induction Position Sensor: Service and Repair IMRC Valve Position Sensor Replacement 1. Remove the two screws (A) and the IMRC position sensor (B). 2. Install the sensor with a new O-ring (C), and make sure the projection (D) inside the IMRC valve matches up with the groove (E) in the sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3531 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3532 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3533 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement > Page 3536 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations PGM-FI System - Component Location Index 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3540 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3541 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3542 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations 11. Middle of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 3546 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations PGM-FI System - Component Location Index 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3550 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3551 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3552 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3557 VTEC/VTC - Component Location Index 18. Left Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3558 Camshaft Position Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3559 Camshaft Position Sensor: Description and Operation Camshaft Position (CMP) Sensor B (Top Dead Center (TDC) Sensor) The CMP sensor B (TDC sensor) detects the position of the No.1 cylinder as a reference for sequential fuel injection to each cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement Camshaft Position Sensor: Service and Repair CMP Sensor A Replacement CMP Sensor A Replacement NOTE: CMP sensor A is on the intake side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor A 3P connector. 3. Remove CMP sensor A (A) from the intake camshaft side of the cylinder head. 4. Install the sensor in the reverse order of removal with a new O-ring (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > CMP Sensor A Replacement > Page 3562 Camshaft Position Sensor: Service and Repair CMP Sensor B (TDC Sensor) Replacement CMP Sensor B (TDC Sensor) Replacement NOTE: CMP sensor B (TDC sensor) is on the exhaust side of the cylinder head. 1. Remove the air cleaner. 2. Disconnect the CMP sensor B (TDC sensor) (A) 3P connector. 3. Remove CMP sensor B (TDC sensor) (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 143. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3566 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3567 Crankshaft Position Sensor: Description and Operation Crankshaft Position (CKP) Sensor The CKP sensor detects crankshaft speed. It is used by the ECM/PCM to determine ignition timing and timing for fuel injection of each cylinder, as well as to detect engine misfire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3568 Crankshaft Position Sensor: Service and Repair CKP Sensor Replacement 1. Disconnect the CKP 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3574 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3575 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3576 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3577 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3578 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3579 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3580 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3581 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3582 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3583 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3587 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3588 Knock Sensor: Description and Operation Knock Sensor The knock control system adjusts the ignition timing to minimize knock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3589 Knock Sensor: Service and Repair Knock Sensor Replacement 1. Remove the splash shield. 2. Disconnect the knock sensor 1P connector. 3. Remove the knock sensor (A). 4. install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3593 Spark Plug: Application and ID Spark plug ........................................................................................................................................................ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Tachometer Connector > Component Information > Locations 27. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Ignition System > Tachometer Connector > Component Information > Locations > Page 3597 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 19. Transmission Housing 140. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3604 Pressure Regulating Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection Shift Interlock Solenoid: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3608 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Test/Replacement 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Connect the battery positive terminal to the No. 4 terminal of the O/D switch/shift lock solenoid/park pin switch connector, and connect the battery negative terminal to the No. 3 terminal. NOTE: Do not connect the battery positive terminal to the No. 3 terminal or you will damage the diode inside the solenoid. 4. Check that the shift lever can be moved from the P position. Release the battery terminals, move the shift lever back to P, and make sure it locks. If the shift lock solenoid works properly, connect the connector and install the removed parts. If the shift lock solenoid is faulty, go to step 5 for replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable end holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3609 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry up the tabs on the O/D switch/shift lock solenoid/park pin switch connector (A) to release the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever cover. 15. Remove the shift lock solenoid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3610 16. Install the shift lock solenoid plunger (A) and plunger spring (B) in the new shift lock solenoid (C). 17. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (D). 18. Route the harnesses, and clamp them as shown. 19. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 20. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 21. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity and the RED harness terminal (D) in the No. 4 cavity. Make sure that all six terminals lock securely, then install the lock (E) securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3611 22. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. 23. Install the shift lever cover. 24. Install the shift lever assembly. 25. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 26. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 27. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3612 28. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 29. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 30. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3613 31. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 32. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 33. Connect the O/D switch/shift lock solenoid/park pin switch connector. 34. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 35. Check that the shift lock solenoid operates. 36. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3617 Shift Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3618 Shift Solenoid: Testing and Inspection Shift Solenoid Valves Test 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure shift solenoid valves resistance between the shift solenoid harness connector terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3619 No. 1, No. 2, No. 3, No. 5 and body ground. Shift solenoid valve A: No. 5 terminal (BLU) Shift solenoid valve B: No. 2 terminal (ORN) Shift solenoid valve C: No. 1 terminal (GRN) Shift solenoid valve E: No. 3 terminal (RED) STANDARD: 12 - 25 Ohms 9. If the resistance is out of standard, disconnect the shift solenoid valve connector, and measure its resistance at the solenoid valve connector. Replace the shift solenoid valve if the resistance is out of standard. 10. Connect the battery positive terminal to the shift solenoid harness connector terminals, and connect the battery negative terminal to body ground individually. A clicking sound should be heard. 11. If no sound is heard, connect the battery positive terminal to the shift solenoid valve connector terminal, and check the clicking sound is heard. Replace the shift solenoid valve if no sound is heard. 12. Replace the solenoid harness if the tests results are OK. 13. Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3620 Shift Solenoid: Service and Repair Shift Solenoid Valves Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 5. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 6. Disconnect the shift solenoid valve connectors. 7. Remove the bolts, and hold the shift solenoid valve body, then remove them. Do not hold the connector to remove. 8. Install the new O-rings (two O-rings per solenoid valve) (F) on the good solenoid valve. The replacement solenoid valve comes with new O-rings. 9. Install shift solenoid valve A, C, and E by holding the shift solenoid valve body; be sure to install the solenoid valves until their mounting bolt brackets contact the servo body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3621 10. Install shift solenoid valve B by holding the shift solenoid valve body; be sure to install the solenoid valve until its mounting bolt bracket contacts to the bracket of installed solenoid. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. 11. Connect shift solenoid valve A connector (G) with the ATF temperature sensor. 12. Connect solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the shift solenoid valve cover with the new gasket and dowel pins. 14. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 15. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 16. Remove the transmission jack. 17. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valve A Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Measure A/T clutch pressure control solenoid valve A resistance at the solenoid valve A connector. STANDARD: About 5 Ohms 4. If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valve A. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valve moves. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valve A body. 10. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valve A. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test > Page 3626 Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves B and C Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Measure A/T clutch pressure control solenoid valve B resistance at the solenoid valve B connector, and measure A/T clutch pressure control solenoid valve C resistance at the solenoid valve C connector. STANDARD: About 5 Ohms 4. If the resistance of either of the A/T clutch pressure control solenoid valves is out of standard, replace A/T clutch pressure control solenoid valves B and C. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valves B and C. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure A/T clutch pressure control solenoid valves B and C move. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves B and C body. 10. If either valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valves B and C. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valve A Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Remove the mounting bolts and A/T clutch pressure control solenoid valve A. 4. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valve A and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF pipe and ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valve A. 9. Check the A/T clutch pressure control solenoid valve A connector for rust, dirt, and oil, then connect it securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement > Page 3629 Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves B and C Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Remove the mounting bolts, harness clamp brackets (A), and A/T clutch pressure control solenoid valves B and C. 4. Remove the ATF joint pipes (D), O-rings (E), and gasket (F). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valves B and C and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valves B and C, and harness clamp brackets. 9. Check the A/T clutch pressure control solenoid valves B and C connectors for rust, dirt, and oil, then connect them securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 3635 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 3641 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 3642 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3646 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 3649 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 3653 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 3654 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3658 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3659 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3660 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3661 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3662 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3663 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3672 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3673 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3679 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3680 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3681 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3682 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3683 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3684 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3685 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3686 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3687 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 3692 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3696 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3697 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3698 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 3699 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3709 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3710 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3716 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 3717 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 PROM - Programmable Read Only Memory: Customer Interest Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 3730 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3736 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3737 *MVCI: (Available through the Honda Tool and Equipment Program)* Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3738 GNA600: (No longer available for purchase) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3739 HDS Tablet: HDS Pocket Tester: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3740 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3741 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3742 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3743 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3744 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3745 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3746 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3747 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3748 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3749 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3750 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3751 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3752 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3753 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3754 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3755 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3756 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3757 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-023 > Apr > 10 > Computers/Controls Updating Control Units And Modules > Page 3758 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Control - MIL ON, DTC P1163 04-013 April 2, 2004 Applies To: 2002-03 CR-V - ALL CR-V: MIL Comes On With DTC P1163 (Supersedes 04-013, dated March 2, 2004) Updated information is shown with asterisks. SYMPTOM The MIL is on and DTC P1163 (air fuel ratio sensor slow response) is set. PROBABLE CAUSE *Some driving conditions may cause the ECM/PCM software to set DTC P1163. This is a software issue, and it is not an A/F (air/fuel ratio) sensor problem.* CORRECTIVE ACTION Update the ECM/PCM with the software from the Interactive Network (iN) CD, March 2004 version or later. TOOL INFORMATION You will need these tools and equipment items: ^ iN CD (March 2004 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 HIM to the iN workstation. The cable is blue with an attached adapter. ^ AC Adapter (110 VAC/12 VDC Power Supply): T/N: VET-02002426 This is the adapter needed for the HIM. These tools are already at your dealership. To order additional HIMs, interface cables, or AC adapters, call the Honda Tool and Equipment Program at 1-888-424-6857. Phone lines are open Monday through Friday from 7:30 a.m. to 7:00 p.m. CT. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 37820-PPA-A52 H/C 6917710 Defect Code: 07201 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-013 > Apr > 04 > Engine Control - MIL ON, DTC P1163 > Page 3763 Symptom Code: 03203 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. Use the HDS to read and clear the DTCs. 2. If not already done, load the March 2004 or later iN CD onto the iN master terminal. Loading instructions are included with the CD. 3. Update the ECM/PCM software with the Honda Interface Module (HIM). For updating instructions, refer to Programming the HIM and Updating a Control Unit (Module With the Programmed HIM in Service Bulletin 01-023, Using the Honda Interface Module to Update Control Units/Modules. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3769 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3770 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3771 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3777 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3778 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 02-002 > Jan > 05 > M/T - Clutch Pedal Squeak/Twang or Notchy Feel > Page 3779 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 19. Transmission Housing 140. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3786 Pressure Regulating Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection Shift Interlock Solenoid: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3790 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Test/Replacement 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Connect the battery positive terminal to the No. 4 terminal of the O/D switch/shift lock solenoid/park pin switch connector, and connect the battery negative terminal to the No. 3 terminal. NOTE: Do not connect the battery positive terminal to the No. 3 terminal or you will damage the diode inside the solenoid. 4. Check that the shift lever can be moved from the P position. Release the battery terminals, move the shift lever back to P, and make sure it locks. If the shift lock solenoid works properly, connect the connector and install the removed parts. If the shift lock solenoid is faulty, go to step 5 for replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable end holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3791 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry up the tabs on the O/D switch/shift lock solenoid/park pin switch connector (A) to release the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever cover. 15. Remove the shift lock solenoid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3792 16. Install the shift lock solenoid plunger (A) and plunger spring (B) in the new shift lock solenoid (C). 17. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (D). 18. Route the harnesses, and clamp them as shown. 19. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 20. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 21. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity and the RED harness terminal (D) in the No. 4 cavity. Make sure that all six terminals lock securely, then install the lock (E) securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3793 22. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. 23. Install the shift lever cover. 24. Install the shift lever assembly. 25. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 26. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 27. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3794 28. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 29. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 30. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3795 31. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 32. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 33. Connect the O/D switch/shift lock solenoid/park pin switch connector. 34. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 35. Check that the shift lock solenoid operates. 36. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3799 Shift Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3800 Shift Solenoid: Testing and Inspection Shift Solenoid Valves Test 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure shift solenoid valves resistance between the shift solenoid harness connector terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3801 No. 1, No. 2, No. 3, No. 5 and body ground. Shift solenoid valve A: No. 5 terminal (BLU) Shift solenoid valve B: No. 2 terminal (ORN) Shift solenoid valve C: No. 1 terminal (GRN) Shift solenoid valve E: No. 3 terminal (RED) STANDARD: 12 - 25 Ohms 9. If the resistance is out of standard, disconnect the shift solenoid valve connector, and measure its resistance at the solenoid valve connector. Replace the shift solenoid valve if the resistance is out of standard. 10. Connect the battery positive terminal to the shift solenoid harness connector terminals, and connect the battery negative terminal to body ground individually. A clicking sound should be heard. 11. If no sound is heard, connect the battery positive terminal to the shift solenoid valve connector terminal, and check the clicking sound is heard. Replace the shift solenoid valve if no sound is heard. 12. Replace the solenoid harness if the tests results are OK. 13. Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3802 Shift Solenoid: Service and Repair Shift Solenoid Valves Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 5. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 6. Disconnect the shift solenoid valve connectors. 7. Remove the bolts, and hold the shift solenoid valve body, then remove them. Do not hold the connector to remove. 8. Install the new O-rings (two O-rings per solenoid valve) (F) on the good solenoid valve. The replacement solenoid valve comes with new O-rings. 9. Install shift solenoid valve A, C, and E by holding the shift solenoid valve body; be sure to install the solenoid valves until their mounting bolt brackets contact the servo body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3803 10. Install shift solenoid valve B by holding the shift solenoid valve body; be sure to install the solenoid valve until its mounting bolt bracket contacts to the bracket of installed solenoid. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. 11. Connect shift solenoid valve A connector (G) with the ATF temperature sensor. 12. Connect solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the shift solenoid valve cover with the new gasket and dowel pins. 14. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 15. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 16. Remove the transmission jack. 17. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valve A Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Measure A/T clutch pressure control solenoid valve A resistance at the solenoid valve A connector. STANDARD: About 5 Ohms 4. If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valve A. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valve moves. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valve A body. 10. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valve A. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test > Page 3808 Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves B and C Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Measure A/T clutch pressure control solenoid valve B resistance at the solenoid valve B connector, and measure A/T clutch pressure control solenoid valve C resistance at the solenoid valve C connector. STANDARD: About 5 Ohms 4. If the resistance of either of the A/T clutch pressure control solenoid valves is out of standard, replace A/T clutch pressure control solenoid valves B and C. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valves B and C. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure A/T clutch pressure control solenoid valves B and C move. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves B and C body. 10. If either valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valves B and C. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valve A Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Remove the mounting bolts and A/T clutch pressure control solenoid valve A. 4. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valve A and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF pipe and ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valve A. 9. Check the A/T clutch pressure control solenoid valve A connector for rust, dirt, and oil, then connect it securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement > Page 3811 Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves B and C Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Remove the mounting bolts, harness clamp brackets (A), and A/T clutch pressure control solenoid valves B and C. 4. Remove the ATF joint pipes (D), O-rings (E), and gasket (F). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valves B and C and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valves B and C, and harness clamp brackets. 9. Check the A/T clutch pressure control solenoid valves B and C connectors for rust, dirt, and oil, then connect them securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 19. Transmission Housing 140. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3817 Pressure Regulating Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection Shift Interlock Solenoid: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3821 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Test/Replacement 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Connect the battery positive terminal to the No. 4 terminal of the O/D switch/shift lock solenoid/park pin switch connector, and connect the battery negative terminal to the No. 3 terminal. NOTE: Do not connect the battery positive terminal to the No. 3 terminal or you will damage the diode inside the solenoid. 4. Check that the shift lever can be moved from the P position. Release the battery terminals, move the shift lever back to P, and make sure it locks. If the shift lock solenoid works properly, connect the connector and install the removed parts. If the shift lock solenoid is faulty, go to step 5 for replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable end holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3822 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry up the tabs on the O/D switch/shift lock solenoid/park pin switch connector (A) to release the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever cover. 15. Remove the shift lock solenoid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3823 16. Install the shift lock solenoid plunger (A) and plunger spring (B) in the new shift lock solenoid (C). 17. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (D). 18. Route the harnesses, and clamp them as shown. 19. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 20. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 21. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity and the RED harness terminal (D) in the No. 4 cavity. Make sure that all six terminals lock securely, then install the lock (E) securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3824 22. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. 23. Install the shift lever cover. 24. Install the shift lever assembly. 25. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 26. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 27. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3825 28. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 29. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 30. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 3826 31. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 32. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 33. Connect the O/D switch/shift lock solenoid/park pin switch connector. 34. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 35. Check that the shift lock solenoid operates. 36. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3830 Shift Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3831 Shift Solenoid: Testing and Inspection Shift Solenoid Valves Test 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure shift solenoid valves resistance between the shift solenoid harness connector terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3832 No. 1, No. 2, No. 3, No. 5 and body ground. Shift solenoid valve A: No. 5 terminal (BLU) Shift solenoid valve B: No. 2 terminal (ORN) Shift solenoid valve C: No. 1 terminal (GRN) Shift solenoid valve E: No. 3 terminal (RED) STANDARD: 12 - 25 Ohms 9. If the resistance is out of standard, disconnect the shift solenoid valve connector, and measure its resistance at the solenoid valve connector. Replace the shift solenoid valve if the resistance is out of standard. 10. Connect the battery positive terminal to the shift solenoid harness connector terminals, and connect the battery negative terminal to body ground individually. A clicking sound should be heard. 11. If no sound is heard, connect the battery positive terminal to the shift solenoid valve connector terminal, and check the clicking sound is heard. Replace the shift solenoid valve if no sound is heard. 12. Replace the solenoid harness if the tests results are OK. 13. Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3833 Shift Solenoid: Service and Repair Shift Solenoid Valves Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 5. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 6. Disconnect the shift solenoid valve connectors. 7. Remove the bolts, and hold the shift solenoid valve body, then remove them. Do not hold the connector to remove. 8. Install the new O-rings (two O-rings per solenoid valve) (F) on the good solenoid valve. The replacement solenoid valve comes with new O-rings. 9. Install shift solenoid valve A, C, and E by holding the shift solenoid valve body; be sure to install the solenoid valves until their mounting bolt brackets contact the servo body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3834 10. Install shift solenoid valve B by holding the shift solenoid valve body; be sure to install the solenoid valve until its mounting bolt bracket contacts to the bracket of installed solenoid. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. 11. Connect shift solenoid valve A connector (G) with the ATF temperature sensor. 12. Connect solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the shift solenoid valve cover with the new gasket and dowel pins. 14. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 15. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 16. Remove the transmission jack. 17. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valve A Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Measure A/T clutch pressure control solenoid valve A resistance at the solenoid valve A connector. STANDARD: About 5 Ohms 4. If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valve A. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valve moves. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valve A body. 10. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valve A. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test > Page 3839 Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves B and C Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Measure A/T clutch pressure control solenoid valve B resistance at the solenoid valve B connector, and measure A/T clutch pressure control solenoid valve C resistance at the solenoid valve C connector. STANDARD: About 5 Ohms 4. If the resistance of either of the A/T clutch pressure control solenoid valves is out of standard, replace A/T clutch pressure control solenoid valves B and C. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valves B and C. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure A/T clutch pressure control solenoid valves B and C move. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves B and C body. 10. If either valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valves B and C. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valve A Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Remove the mounting bolts and A/T clutch pressure control solenoid valve A. 4. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valve A and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF pipe and ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valve A. 9. Check the A/T clutch pressure control solenoid valve A connector for rust, dirt, and oil, then connect it securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement > Page 3842 Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves B and C Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Remove the mounting bolts, harness clamp brackets (A), and A/T clutch pressure control solenoid valves B and C. 4. Remove the ATF joint pipes (D), O-rings (E), and gasket (F). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valves B and C and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valves B and C, and harness clamp brackets. 9. Check the A/T clutch pressure control solenoid valves B and C connectors for rust, dirt, and oil, then connect them securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications Band Apply Servo: Specifications Servo body Shift fork shaft bore I.D. Standard or new 14.000 - 14.010 mm Shift fork shaft valve bore I.D. Standard or new 37.000 - 37.039 mm Service limit 37.045 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Clutch Clutch end-plate-to-top-disc clearance 1st Service limit 1.23 - 1.43 mm 2nd Service limit 0.75 - 0.95 mm 3rd and 4th Service limit 0.73 - 0.93 mm Clutch return spring free length 1st and 2nd Standard or new 50.8 mm Service limit 48.8 mm 3rd and 4th Standard or new 33.5 mm Service limit 31.5 mm Clutch disc thickness Standard or new 1.94 mm Clutch plate thickness Standard or new 2.00 mm Service limit When discolored Clutch waved-plate phase difference Standard or new 0.07 - 0.20 mm Service limit 0.05 mm 1st clutch end plate thickness Mark 1 Standard or new 2.3 mm Service limit When discolored Mark 2 Standard or new 2.4 mm Service limit When discolored Mark 3 Standard or new 2.5 mm Service limit When discolored Mark 4 Standard or new 2.6 mm Service limit When discolored Mark 5 Standard or new 2.7 mm Service limit When discolored Mark 6 Standard or new 2.8 mm Service limit When discolored Mark 7 Standard or new 2.9 mm Service limit When discolored Mark 8 Standard or new 3.0 mm Service limit When discolored Mark 9 Standard or new 3.1 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3849 Service limit When discolored Mark 10 Standard or new 3.2 mm Service limit When discolored Mark 11 Standard or new 3.3 mm Service limit When discolored Mark 12 Standard or new 3.4 mm Service limit When discolored 2nd clutch end plate thickness Mark 1 Standard or new 2.6 mm Service limit When discolored Mark 2 Standard or new 2.7 mm Service limit When discolored Mark 3 Standard or new 2.8 mm Service limit When discolored Mark 4 Standard or new 2.9 mm Service limit When discolored Mark 5 Standard or new 3.0 mm Service limit When discolored Mark 6 Standard or new 3.1 mm Service limit When discolored Mark 7 Standard or new 3.2 mm Service limit When discolored Mark 8 Standard or new 3.3 mm Service limit When discolored Mark 9 Standard or new 3.4 mm Service limit When discolored 3rd and 4th clutch end plate thickness Mark 11 Standard or new 3.1 mm Service limit When discolored Mark 12 Standard or new 3.2 mm Service limit When discolored Mark 13 Standard or new 3.3 mm Service limit When discolored Mark 14 Standard or new 3.4 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3850 Service limit When discolored Mark 15 Standard or new 3.5 mm Service limit When discolored Mark 16 Standard or new 3.6 mm Service limit When discolored Mark 17 Standard or new 3.7 mm Service limit When discolored Mark 18 Standard or new 3.8 mm Service limit When discolored Mark 19 Standard or new 3.9 mm Service limit When discolored Secondary shaft Diameter of needle bearing contact area at 1st gear Standard or new 39.986 39.999 mm Service limit When wore or damaged at 2nd gear Standard or new 39.986 - 39.999 mm Service limit When wore or damaged I.D. of gears 1st gear Standard or new 47.000 - 47.016 mm Service limit When wore or damaged 2nd gear Standard or new 46.000 - 46.016 mm Service limit When wore or damaged End play of gears 1st gear Standard or new 0.07 - 0.15 mm 2nd gear Standard or new 0.04 - 0.12 mm 37 x 58 mm thrust washer thickness No.1 Standard or new 3.900 mm Service limit When wore or damaged No.2 Standard or new 3.925 mm Service limit When wore or damaged No.3 Standard or new 3.950 mm Service limit When wore or damaged No.4 Standard or new 3.975 mm Service limit When wore or damaged No.5 Standard or new 4.000 mm Service limit When wore or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3851 No.6 Standard or new 4.025 mm Service limit When wore or damaged No.7 Standard or new 4.050 mm Service limit When wore or damaged No.8 Standard or new 4.075 mm Service limit When wore or damaged No.9 Standard or new 4.100 mm Service limit When wore or damaged No.10 Standard or new 4.125 mm Service limit When wore or damaged No.11 Standard or new 4.150 mm Service limit When wore or damaged No.12 Standard or new 4.175 mm Service limit When wore or damaged No.13 Standard or new 4.200 mm Service limit When wore or damaged No.14 Standard or new 4.225 mm Service limit When wore or damaged No.15 Standard or new 4.250 mm Service limit When wore or damaged No.16 Standard or new 4.275 mm Service limit When wore or damaged No.17 Standard or new 4.300 mm Service limit When wore or damaged No.18 Standard or new 4.325 mm Service limit When wore or damaged No.19 Standard or new 4.350 mm Service limit When wore or damaged No.20 Standard or new 4.375 mm Service limit When wore or damaged 40 x 51.5 mm thrust washer thickness No.1 Standard or new 4.80 mm Service limit When wore or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3852 No.2 Standard or new 4.85 mm Service limit When wore or damaged No.3 Standard or new 4.90 mm Service limit When wore or damaged No.4 Standard or new 4.95 mm Service limit When wore or damaged No.5 Standard or new 5.00 mm Service limit When wore or damaged No.6 Standard or new 5.05 mm Service limit When wore or damaged 27 x 45 x 44 mm gear collar length Standard or new 43.9 - 44.0 mm Sealing ring thickness Standard or new 1.91 - 1.97 mm Service limit 1.86 mm Width of sealing ring groove Standard or new 2.025 - 2.060 mm Service limit 2.080 mm Clutch feed pipe O.D. Standard or new 7.97 - 7.98 mm Service limit 7.95 mm Clutch feed pipe bushing O.D. Standard or new 8.000 - 8.015 mm Service limit 8.030 mm ATF guide of sealing ring contact I.D. Standard or new 29.000 - 29.021 mm Service limit 29.05 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Countershaft, A/T > Component Information > Specifications Countershaft: Specifications Countershaft Diameter of needle bering contact area at torque converter housing Standard or new 36.005 - 36.015 mm Service limit When worn or damaged at 4th gear collar Standard or new 37.982 - 37.996 mm Service limit When worn or damaged at reverse gear collar Standard or new 39.979 - 40.000 mm Service limit When worn or damaged I.D. of gears 4th gear Standard or new 43.000 - 43.016 mm Service limit When worn or damaged Reverse gear Standard or new 46.000 - 46.016 mm Service limit When worn or damaged End pay of gears 1st gear Standard or new 0.10 - 0.42 mm 2nd gear Standard or new 0.10 - 0.42 mm 3rd gear Standard or new 0.10 - 0.42 mm 4th gear Standard or new 0.1 - 0.2 mm Reverse gear Standard or new 0.10 - 0.25 mm 4th gear collar length Standard or new 24.00 - 24.05 mm Distance collar length Standard or new 74.25 - 74.30 mm Reverse selector hub width Standard or new 25.45 - 25.65 mm Reverse selector hub O.D. Standard or new 55.87 - 55.90 mm Service limit When worn or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Countershaft Sensor, A/T > Component Information > Locations > Page 3859 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Countershaft Sensor, A/T > Component Information > Locations > Page 3860 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Carrier Assembly, A/T > Component Information > Specifications Differential Carrier Assembly: Specifications A/T differential carrier Pinion shaft contact area I.D. Standard or new 18.00 - 18.025 mm Carrier-to-pinion shaft clearance Standard or new 0.013 - 0.054 mm Service limit 0.1 mm Drive shaft contact area I.D. Standard or new 28.015 - 28.045 mm Carrier-to-driveshaft clearance Standard or new 0.035 - 0.086 mm Service limit 0.12 mm Intermediate shaft contact I.D. Standard or new 28.015 - 28.045 mm Carrier-to-intermediate shaft clearance Standard or new 0.065 - 0.111 mm Service limit 0.12 mm Carrier bearing starting torque (preload) For new bearing Standard or new 2.7 - 3.9 Nm Service limit Adjust For bearing reused Standard or new 2.5 - 3.6 Nm Service limit Adjust Final driven gear backlash (references) Standard or new 0.087 - 0.146 mm Service limit 0.2 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Pinion Gear, A/T > Component Information > Specifications Pinion Gear: Specifications A/T differential pinion gear Backlash Standard or new 0.05 - 0.15 mm I.D. Standard or new 18.042 - 18.066 mm Pinion gear-to-pinion shaft clearance Standard or new 0.055 - 0.095 mm Service limit 0.12 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Fluid - A/T: Pressure, Vacuum and Temperature Specifications ATF pressure Line pressure at 2,000 rpm in P or N position Standard or new 900 - 960 kPa Service limit 950 kPa 1st clutch pressure at 2,000 rpm in 1st gear in 1 position Standard or new 890 - 970 kPa Service limit 840 kPa 2nd clutch pressure at 2,000 rpm in 2nd gear in 2 position Standard or new 890 - 970 kPa Service limit 840 kPa 3rd clutch pressure at 2,000 rpm in 3rd gear in D position Standard or new 890 - 970 kPa Service limit 840 kPa 4th clutch pressure at 2,000 rpm in 4th gear in D position Standard or new 890 - 970 kPa Service limit 840 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3874 Fluid - A/T: Capacity Specifications A/T Fluid Change ................................................................................................................................................ .............................................................. 3.1L (3.3 Qt) Total ................................................................ .................................................................................................................................................. 7.2L (7.6 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3875 Fluid - A/T: Fluid Type Specifications ATF (Automatic Transmission Fluid) ..................................................................................................................................................... Use Honda ATF-Z1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3876 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > ATF Level Check Fluid - A/T: Service and Repair ATF Level Check ATF Level Check NOTE: Keep all foreign particles out of the transmission. 1. Warm up the engine to normal operating temperature (the radiator fan comes on). 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the dipstick (yellow loop) (A) from the transmission, and wipe it with a clean cloth. 4. Insert the dipstick back into the transmission. 5. Remove the dipstick (A), and check the fluid level. It should be at upper mark (B). 6. If the level is below the upper mark, check for fluid leaks at the transmission, hose and line joints, and cooler lines. 7. Pour the recommended fluid amount into the dipstick hole to bring it to the upper mark. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > ATF Level Check > Page 3879 8. Insert the dipstick (A) back into the transmission with the handle pointing toward the breather tube (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > ATF Level Check > Page 3880 Fluid - A/T: Service and Repair ATF Replacement ATF Replacement NOTE: Keep all foreign particles out of the transmission. 1. Bring the transmission up to normal operating temperature (the radiator fan comes on) by driving the vehicle. 2. Park the vehicle on level ground, and turn the engine off. 3. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 4. Reinstall the drain plug with a new sealing washer (B). 5. Refill transmission with the recommended fluid amount through the dipstick hole until the level reaches the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 4WD: 3.1 L (3.3 US qt. 2.7 Imp qt) at change 7.2 L (7.6 US qt. 6.3 Imp qt) at overhaul 2WD: 2.9 L (3.1 US qt. 2.6 Imp qt) at change 6.5 L (6.9 US qt. 5.7 Imp qt) at overhaul Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 3885 Fluid Line/Hose: Service and Repair ATF Cooler Hoses Replacement 1. Slide the ATF cooler hoses (A) on the ATF filter (B) until they are 5 - 6 mm (0.20 - 0.24 inch) (C) away from the filter housing. 2. Secure the hoses with the clips (D) at 10 - 12 mm (0.4 - 0.5 inch) (E) from the filter housing. 3. Slide the ATF cooler hoses (F) over the ATF cooler lines (G), then secure the hoses with the clips (H) at 2 - 4 mm (0.1 - 0.2 inch) (I) from the hose ends. 4. Install the hose clamp (J) at the marks (K) on the ATF cooler hoses. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3889 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 3892 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications ATF pump ATF pump thrust clearance Standard or new 0.03 - 0.05 mm Service limit 0.07 mm ATF pump gear-to-body clearance Drive gear Standard or new 0.210 - 0.265 mm Driven gear Standard or new 0.070 - 0.125 mm ATF pump driven gear I.D. Standard or new 14.016 - 14.036 mm Service limit When wore or damaged ATF pump driven gear shaft O.D. Standard or new 13.980 - 13.990 mm Service limit When wore or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Idler Gear, A/T > Component Information > Specifications Idler Gear: Specifications Reverse idler gear Reverse idler gear shaft diameter at needle bearing contact area Standard or new 14.99 - 15.00 mm Service limit When wore or damaged I.D. Standard or new 20.007 - 20.020 mm Service limit When wore or damaged I.D. of reverse idler gear shaft contact area on transmission Standard or new 14.800 - 14.818 mm housing I.D. of reverse idler gear shaft holder Standard or new 14.800 - 14.824 mm Service limit When wore or damaged Idler gear shaft Diameter of needle bearing contact area End cover side Standard or new 32.003 32.013 mm Service limit When wore or damaged Thickness of cotters Standard or new 1.39 - 1.42 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Mainshaft, A/T > Component Information > Specifications Mainshaft: Specifications Mainshaft Diameter of needle bearing contact area at stator shaft Standard or new 22.984 - 23.000 mm Service limit When wore or damaged at 3rd gear Standard or new 51.975 - 51.991 mm Service limit When wore or damaged at 4th gear collar Standard or new 33.975 - 33.991 mm Service limit When wore or damaged I.D. of gears 3rd gear Standard or new 57.000 - 59.019 mm Service limit When wore or damaged 4th gear Standard or new 40.000 - 40.016 mm Service limit When wore or damaged End play of gears 3rd gear Standard or new 0.03 - 0.31 mm 4th gear Standard or new 0.1 - 0.212 mm 41 x 68 mm thrust washer thickness No.1 Standard or new 6.35 mm Service limit When wore or damaged No.2 Standard or new 6.40 mm Service limit When wore or damaged No.3 Standard or new 6.45 mm Service limit When wore or damaged No.4 Standard or new 6.50 mm Service limit When wore or damaged No.5 Standard or new 6.55 mm Service limit When wore or damaged No.6 Standard or new 6.60 mm Service limit When wore or damaged 4th gear collar length Standard or new 66.3 - 66.4 mm Length of 4th gear collar flange from end Standard or new 19.15 - 19.30 mm Service limit When wore or damaged Sealing ring thickness Standard or new 1.91 - 1.97 mm Service limit 1.86 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Mainshaft, A/T > Component Information > Specifications > Page 3902 Width of sealing ring groove Standard or new 2.025 - 2.060 mm Service limit 2.080 mm Clutch feed pipe O.D. Standard or new 7.97 - 7.98 mm Service limit 7.95 mm Clutch feed pipe bushing I.D. Standard or new 8.000 - 8.015 mm Service limit 8.030 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Mainshaft Sensor, A/T > Component Information > Locations > Page 3906 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Mainshaft Sensor, A/T > Component Information > Locations > Page 3907 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3911 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3912 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3913 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3914 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3915 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3916 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Park Gear, A/T > Component Information > Specifications Park Gear: Specifications Park gear and pawl Service limit When wore or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications Parking Pawl: Specifications Park gear and pawl Service limit When wore or damaged Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 19. Transmission Housing 140. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3926 Pressure Regulating Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 3931 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 3936 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 3937 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3941 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 3944 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 3948 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 3949 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3953 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3954 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3955 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3956 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3957 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 3958 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3967 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3968 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3974 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 3975 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns Transmission Mount: All Technical Service Bulletins Engine, M/T, A/T - Grind/Rattle on L/H Turns 04-005 July 30, 2005 *Applies To: 2002-05 CR-V - See VEHICLES AFFECTED* Noise When Turning Left (Supersedes 04-005, dated January 30, 2004) Updated information is shown with black bars and asterisks. SYMPTOM A rattle, grind, or growl can be heard from the A-pillar or right front side of the vehicle when turning left. VEHICLES AFFECTED PROBABLE CAUSE There is not enough clearance between the right transmission mount bracket and the engine, causing them to rub together. CORRECTIVE ACTION Move the engine away from the right transmission mount bracket. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112321 Flat Rate Time: 0.3 hour Failed Part: P/N 50821-S9A-023 H/C 7095599 Defect Code: 07404 Symptom Code: 04201 Template ID: 04-005A Skill Level: Repair Technician Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 3981 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop Transmission Mount: All Technical Service Bulletins A/T, M/T - Vibration Accelerating From a Stop 04-070 November 19, 2004 Applies To Noise or Vibration When Accelerating From a Stop SYMPTOM There is a noise or vibration when accelerating from a stop. PROBABLE CAUSE The transmission mount limiter tabs are out of position. CORRECTIVE ACTION Reposition the limiter tabs, and glue them to the transmission mount. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112002 Flat Rate Time: 0.2 hour Failed Part: P/N 50805-S9A-983 H/C 7114614 Defect Code: 02502 Symptom Code: 04216 Template ID: 04-070A 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. INSPECTION PROCEDURE Inspect the transmission mount. The limiter tabs should be positioned as shown in step 2 of the REPAIR PROCEDURE. If the limiter tabs are out of position, proceed with REPAIR PROCEDURE. If the tabs are in the correct position, troubleshoot for other causes. REPAIR PROCEDURE 1. Open the hood. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 3986 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 3987 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 3993 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 3998 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Other Service Bulletins for Transmission Position Switch/Sensor: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 3999 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4000 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4001 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4002 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4003 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4004 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4005 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4006 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4011 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4015 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4016 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4017 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4018 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Relay > Component Information > Locations > Page 4023 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection Shift Interlock Solenoid: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4027 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Test/Replacement 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Connect the battery positive terminal to the No. 4 terminal of the O/D switch/shift lock solenoid/park pin switch connector, and connect the battery negative terminal to the No. 3 terminal. NOTE: Do not connect the battery positive terminal to the No. 3 terminal or you will damage the diode inside the solenoid. 4. Check that the shift lever can be moved from the P position. Release the battery terminals, move the shift lever back to P, and make sure it locks. If the shift lock solenoid works properly, connect the connector and install the removed parts. If the shift lock solenoid is faulty, go to step 5 for replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable end holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4028 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry up the tabs on the O/D switch/shift lock solenoid/park pin switch connector (A) to release the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever cover. 15. Remove the shift lock solenoid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4029 16. Install the shift lock solenoid plunger (A) and plunger spring (B) in the new shift lock solenoid (C). 17. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (D). 18. Route the harnesses, and clamp them as shown. 19. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 20. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 21. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity and the RED harness terminal (D) in the No. 4 cavity. Make sure that all six terminals lock securely, then install the lock (E) securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4030 22. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. 23. Install the shift lever cover. 24. Install the shift lever assembly. 25. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 26. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 27. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4031 28. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 29. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 30. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4032 31. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 32. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 33. Connect the O/D switch/shift lock solenoid/park pin switch connector. 34. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 35. Check that the shift lock solenoid operates. 36. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4036 Shift Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4037 Shift Solenoid: Testing and Inspection Shift Solenoid Valves Test 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure shift solenoid valves resistance between the shift solenoid harness connector terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4038 No. 1, No. 2, No. 3, No. 5 and body ground. Shift solenoid valve A: No. 5 terminal (BLU) Shift solenoid valve B: No. 2 terminal (ORN) Shift solenoid valve C: No. 1 terminal (GRN) Shift solenoid valve E: No. 3 terminal (RED) STANDARD: 12 - 25 Ohms 9. If the resistance is out of standard, disconnect the shift solenoid valve connector, and measure its resistance at the solenoid valve connector. Replace the shift solenoid valve if the resistance is out of standard. 10. Connect the battery positive terminal to the shift solenoid harness connector terminals, and connect the battery negative terminal to body ground individually. A clicking sound should be heard. 11. If no sound is heard, connect the battery positive terminal to the shift solenoid valve connector terminal, and check the clicking sound is heard. Replace the shift solenoid valve if no sound is heard. 12. Replace the solenoid harness if the tests results are OK. 13. Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4039 Shift Solenoid: Service and Repair Shift Solenoid Valves Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 5. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 6. Disconnect the shift solenoid valve connectors. 7. Remove the bolts, and hold the shift solenoid valve body, then remove them. Do not hold the connector to remove. 8. Install the new O-rings (two O-rings per solenoid valve) (F) on the good solenoid valve. The replacement solenoid valve comes with new O-rings. 9. Install shift solenoid valve A, C, and E by holding the shift solenoid valve body; be sure to install the solenoid valves until their mounting bolt brackets contact the servo body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4040 10. Install shift solenoid valve B by holding the shift solenoid valve body; be sure to install the solenoid valve until its mounting bolt bracket contacts to the bracket of installed solenoid. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. 11. Connect shift solenoid valve A connector (G) with the ATF temperature sensor. 12. Connect solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the shift solenoid valve cover with the new gasket and dowel pins. 14. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 15. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 16. Remove the transmission jack. 17. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal and Installation Shifter A/T: Service and Repair Removal and Installation Removal 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Shift the shift lever to the R position. 4. Slide the lock tab (A) down on the shift cable end holder (B). 5. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 6. Separate the shift cable end from the shift cable end holder. 7. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal and Installation > Page 4046 8. Remove the shift lever assembly. Installation 1. Install the shift lever assembly. 2. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 3. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 4. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal and Installation > Page 4047 5. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning hole (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the HI position. 6. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 7. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal and Installation > Page 4048 8. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 9. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 10. Connect the O/D switch/shift lock solenoid/park pin switch connector. 11. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 12. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal and Installation > Page 4049 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Adjustment 1. Remove the driver's dashboard lower cover, and instrument panel. 2. Shift the shift lever to the R position. 3. Slide the lock tab (A) down on the shift cable end holder (B). 4. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 5. Separate the shift cable end (A) from the shift cable end holder (B). 6. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4054 7. Push the shift cable down until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 8. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 9. Turn the ignition switch OFF. 10. Insert a m6.0 mm (0.24 inch) pin (A) into the positioning hole (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 11. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4055 12. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 13. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 14. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 15. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 16. Allow the wheels to rotate freely. 17. Start the engine, and check the shift lever operation in all gears. 18. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4056 Shift Cable: Service and Repair Replacement 1. Raise the front of the vehicle, or lift the vehicle up, and make sure it is securely supported. 2. Remove the driver's dashboard lower cover, and the instrument panel. 3. Shift the shift lever to the R position. 4. Slide the lock tab (A) down on the shift cable end holder (B). 5. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 6. Separate the shift cable end (A) from the shift cable holder (B). 7. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4057 8. Remove the grommet under the body, and pull out the shift cable. 9. 4WD model: Replace the shift cable. 1. Remove the bolts (A) securing the shift cable bracket (B), then remove the shift cable cover (C). 2. Remove the spring clip (D) and control pin (E), then separate the shift cable (F) from the control lever (G). 3. Remove the bolts (H) securing the shift cable bracket (I), then remove the shift cable bracket (I) from the shift cable. 4. Replace the shift cable, and insert it through the grommet hole. Do not bend the shift cable excessively. Face the dot (J) on the shift cable (F) down, then install the shift cable bracket (I) on the shift cable. 5. Attach the shift cable end (K) to the control lever (G), then insert the control pin (E) into the control lever hole through the shift cable end. Secure the control pin with the spring clip (D). 6. Secure the shift cable bracket (B) with the bolts (A), and install the shift cable cover (C), but do not tighten the bolts. 7. Tighten the front bolt (L) on the cover first, then the lower bolt (M), and lastly the middle bolt (N). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4058 10. 2WD model: Replace the shift cable. 1. Remove the shift cable cover (A). 2. Remove the spring clip (B) and control pin (C), then separate the shift cable (D) from the control lever (E). 3. Remove the bolts securing the shift cable bracket (F). 4. Replace the shift cable, and insert it through the grommet hole. Do not bend the shift cable excessively. 5. Attach the shift cable end (D) to the control lever (E), then insert the control pin (C) into the control lever hole through the shift cable end, and secure the control pin with the spring clip (B). 6. Secure the shift cable bracket (F) with the bolt, and install the shift cable cover (A), but do not tighten the bolts. 7. Tighten the front bolt (G) on the cover first, then the lower bolt (H), and lastly the middle bolt (I). 11. Install the shift cable bracket (A) on the body, then install the grommet (B) in its hole (C). 12. Turn the ignition switch ON (II), and verify that the R position indicator comes on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4059 13. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in by. Do not hold the shift cable guide (A) to adjust the shift cable (B). 14. Turn the ignition switch OFF. 15. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in [R] position. 16. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4060 17. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 18. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 19. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 20. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 21. Allow the wheels to rotate freely. 22. Start the engine, and check the shift lever operation in all gears. 23. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Stator Shaft, A/T > Component Information > Specifications Stator Shaft: Specifications Stator shaft Needle bearing contact I.D. Torque converter side Standard or new 27.000 - 27.021 mm Service limit When wore or damaged ATF pump side Standard or new 29.000 - 29.021 mm Sealing ring contact area I.D. Standard or new 29.000 - 29.021 mm Service limit 29.05 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4068 Torque Converter: Specifications Torque converter Stall speed Check with vehicle in level ground Standard or new 2,100 rpm Service limit 1,950 - 2,250 rpm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valve A Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Measure A/T clutch pressure control solenoid valve A resistance at the solenoid valve A connector. STANDARD: About 5 Ohms 4. If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valve A. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valve moves. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valve A body. 10. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valve A. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test > Page 4073 Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves B and C Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Measure A/T clutch pressure control solenoid valve B resistance at the solenoid valve B connector, and measure A/T clutch pressure control solenoid valve C resistance at the solenoid valve C connector. STANDARD: About 5 Ohms 4. If the resistance of either of the A/T clutch pressure control solenoid valves is out of standard, replace A/T clutch pressure control solenoid valves B and C. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valves B and C. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure A/T clutch pressure control solenoid valves B and C move. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves B and C body. 10. If either valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valves B and C. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valve A Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Remove the mounting bolts and A/T clutch pressure control solenoid valve A. 4. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valve A and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF pipe and ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valve A. 9. Check the A/T clutch pressure control solenoid valve A connector for rust, dirt, and oil, then connect it securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement > Page 4076 Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves B and C Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Remove the mounting bolts, harness clamp brackets (A), and A/T clutch pressure control solenoid valves B and C. 4. Remove the ATF joint pipes (D), O-rings (E), and gasket (F). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valves B and C and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valves B and C, and harness clamp brackets. 9. Check the A/T clutch pressure control solenoid valves B and C connectors for rust, dirt, and oil, then connect them securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4081 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4082 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4083 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4084 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 4085 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4086 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4087 Transmission Cooler: Service and Repair ATF Cooler Flushing Special Tools Required Commercially Available Transmission Cooler Flusher Kent-Moore J38405-A or equivalent This procedure should be performed before reinstalling the transmission. 1. Check equipment for wear and cracks before using. Replace any worn or cracked components. 2. Using the measuring cup, fill the flusher (A) with 21 ounces (approximately 2/3 full) of biodegradable flushing fluid (J35944-20). Do not substitute with any other fluid. Follow the handling procedure on the fluid container. 3. Secure the flusher filler cap, and pressurize the flusher with compressed air to 550 - 829 kPa (5.6 - 8.45 kgf/cm2, 80 - 120 psi). The air line should be equipped with a water trap to ensure a dry air system. 4. Hang the flusher under the vehicle. 5. Attach the flusher discharge hose (B) to the return line of the ATF cooler using a clamp. 6. Connect the drain hose (C) to the inlet line on the ATF cooler using a clamp. Securely clamp the opposite end of the drain hose to a bucket (D) or floor drain. 7. With the water and air valves (A) off, attach the water and air supplies to the flusher. (Hot water if available.) 8. Turn on the water valve for 10 seconds. If water does not flow through the cooler, it is completely plugged, it cannot be flushed, and must be replaced. 9. Depress the trigger to mix the flushing fluid into the water flow. Use the wire clip to hold the trigger down. 10. While flushing with the water and flushing fluid for 2 minutes, turn the air valve on for 5 seconds every 15 - 20 seconds to create a surging action. AIR PRESSURE: MAX 845 kPa (8.45 kgf/cm2, 120 psi) 11. Turn the water valve off. Release the trigger, then reverse the hoses to the cooler so you can flush in the opposite direction. Repeat steps 8 through 10. 12. Release the trigger, and rinse the cooler with water for 1 minute. 13. Turn the water valve off and the water supply off. 14. Turn the air valve on for 2 minutes, or until no moisture is visible leaving the drain hose. Residual moisture in the cooler or lines can damage the transmission. 15. Remove the flusher from the cooler line. Attach the drain hose to an ATF container. 16. Install the transmission, and leave the drain hose attached to the cooler line. 17. Make sure the transmission is in the P position. Fill the transmission with ATF, and run the engine for 30 seconds or until approximately 0.95 L (1.0 US qt., 0.8 Imp qt.) is discharged. 18. Remove the drain hose, and reconnect the cooler return hose to the transmission. 19. Refill the transmission with ATF to the proper level. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns Transmission Mount: Customer Interest Engine, M/T, A/T - Grind/Rattle on L/H Turns 04-005 July 30, 2005 *Applies To: 2002-05 CR-V - See VEHICLES AFFECTED* Noise When Turning Left (Supersedes 04-005, dated January 30, 2004) Updated information is shown with black bars and asterisks. SYMPTOM A rattle, grind, or growl can be heard from the A-pillar or right front side of the vehicle when turning left. VEHICLES AFFECTED PROBABLE CAUSE There is not enough clearance between the right transmission mount bracket and the engine, causing them to rub together. CORRECTIVE ACTION Move the engine away from the right transmission mount bracket. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112321 Flat Rate Time: 0.3 hour Failed Part: P/N 50821-S9A-023 H/C 7095599 Defect Code: 07404 Symptom Code: 04201 Template ID: 04-005A Skill Level: Repair Technician Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 4096 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop Transmission Mount: Customer Interest A/T, M/T - Vibration Accelerating From a Stop 04-070 November 19, 2004 Applies To Noise or Vibration When Accelerating From a Stop SYMPTOM There is a noise or vibration when accelerating from a stop. PROBABLE CAUSE The transmission mount limiter tabs are out of position. CORRECTIVE ACTION Reposition the limiter tabs, and glue them to the transmission mount. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112002 Flat Rate Time: 0.2 hour Failed Part: P/N 50805-S9A-983 H/C 7114614 Defect Code: 02502 Symptom Code: 04216 Template ID: 04-070A 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. INSPECTION PROCEDURE Inspect the transmission mount. The limiter tabs should be positioned as shown in step 2 of the REPAIR PROCEDURE. If the limiter tabs are out of position, proceed with REPAIR PROCEDURE. If the tabs are in the correct position, troubleshoot for other causes. REPAIR PROCEDURE 1. Open the hood. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4101 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4102 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns Transmission Mount: All Technical Service Bulletins Engine, M/T, A/T - Grind/Rattle on L/H Turns 04-005 July 30, 2005 *Applies To: 2002-05 CR-V - See VEHICLES AFFECTED* Noise When Turning Left (Supersedes 04-005, dated January 30, 2004) Updated information is shown with black bars and asterisks. SYMPTOM A rattle, grind, or growl can be heard from the A-pillar or right front side of the vehicle when turning left. VEHICLES AFFECTED PROBABLE CAUSE There is not enough clearance between the right transmission mount bracket and the engine, causing them to rub together. CORRECTIVE ACTION Move the engine away from the right transmission mount bracket. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112321 Flat Rate Time: 0.3 hour Failed Part: P/N 50821-S9A-023 H/C 7095599 Defect Code: 07404 Symptom Code: 04201 Template ID: 04-005A Skill Level: Repair Technician Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 4108 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop Transmission Mount: All Technical Service Bulletins A/T, M/T - Vibration Accelerating From a Stop 04-070 November 19, 2004 Applies To Noise or Vibration When Accelerating From a Stop SYMPTOM There is a noise or vibration when accelerating from a stop. PROBABLE CAUSE The transmission mount limiter tabs are out of position. CORRECTIVE ACTION Reposition the limiter tabs, and glue them to the transmission mount. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112002 Flat Rate Time: 0.2 hour Failed Part: P/N 50805-S9A-983 H/C 7114614 Defect Code: 02502 Symptom Code: 04216 Template ID: 04-070A 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. INSPECTION PROCEDURE Inspect the transmission mount. The limiter tabs should be positioned as shown in step 2 of the REPAIR PROCEDURE. If the limiter tabs are out of position, proceed with REPAIR PROCEDURE. If the tabs are in the correct position, troubleshoot for other causes. REPAIR PROCEDURE 1. Open the hood. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4113 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4114 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4123 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4124 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4130 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4131 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4132 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4133 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4134 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4135 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4136 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4137 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4138 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4143 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4147 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4148 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4149 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4150 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Regulator valve body Sealing ring contact I.D. Standard or new 29.000 - 29.021 mm Service limit 29.05 mm Main valve body springs Shift valve A spring Wire diameter Standard or new 0.8 mm O.D. Standard or new 5.6 mm Free length Standard or new 28.1 mm No. of coils Standard or new 15.9 Shift valve B spring Wire diameter Standard or new 0.8 mm O.D. Standard or new 5.6 mm Free length Standard or new 28.1 mm No. of coils Standard or new 15.9 Shift valve C spring Wire diameter Standard or new 0.8 mm O.D. Standard or new 5.6 mm Free length Standard or new 28.1 mm No. of coils Standard or new 15.9 Relief valve spring Wire diameter Standard or new 1.0 mm O.D. Standard or new 9.6 mm Free length Standard or new 34.1 mm No. of coils Standard or new 10.2 Lock-up control valve spring Wire diameter Standard or new 0.65 mm O.D. Standard or new 7.1 mm Free length Standard or new 25.0 mm No. of coils Standard or new 12.7 Cooler check valve spring Wire diameter Standard or new 0.9 mm O.D. Standard or new 6.6 mm Free length Standard or new 26.5 mm Regulator valve body springs Stator reaction spring Wire diameter Standard or new 4.5 mm O.D. Standard or new 35.4 mm Free length Standard or new 30.3 mm No. of coils Standard or new 1.92 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4154 Regulator valve spring A Wire diameter Standard or new 1.9 mm O.D. Standard or new 14.7 mm Free length Standard or new 80.6 mm No. of coils Standard or new 16.1 Regulator valve spring B Wire diameter Standard or new 1.6 mm O.D. Standard or new 9.2 mm Free length Standard or new 44.0 mm No. of coils Standard or new 12.5 Torque converter check valve spring Wire diameter Standard or new 1.2 mm O.D. Standard or new 8.6 mm Free length Standard or new 33.8 mm No. of coils Standard or new 12.2 Lock-up shift valve spring Wire diameter Standard or new 1.0 mm O.D. Standard or new 6.6 mm Free length Standard or new 35.5 mm No. of coils Standard or new 18.3 1st accumulator spring A Wire diameter Standard or new 2.4 mm O.D. Standard or new 18.6 mm Free length Standard or new 49.0 mm No. of coils Standard or new 7.1 1st accumulator spring B Wire diameter Standard or new 2.3 mm O.D. Standard or new 12.2 mm Free length Standard or new 31.5 mm No. of coils Standard or new 6.6 Servo body springs CPB valve spring Wire diameter Standard or new 0.7 mm O.D. Standard or new 9.1 mm Free length Standard or new 32.3 mm No. of coils Standard or new 8.6 4th accumulator spring B Wire diameter Standard or new 2.3 mm O.D. Standard or new 12.2 mm Free length Standard or new 31.5 mm No. of coils Standard or new 6.6 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4155 4th accumulator spring A Wire diameter Standard or new 2.4 mm O.D. Standard or new 18.6 mm Free length Standard or new 49.0 mm No. of coils Standard or new 7.1 2nd accumulator spring B Wire diameter Standard or new 2.0 mm O.D. Standard or new 10.6 mm Free length Standard or new 34.0 mm No. of coils Standard or new 8.0 2nd accumulator spring A Wire diameter Standard or new 2.2 mm O.D. Standard or new 16.6 mm Free length Standard or new 48.2 mm No. of coils Standard or new 8.5 3rd accumulator spring Wire diameter Standard or new 2.5 mm O.D. Standard or new 14.6 mm Free length Standard or new 29.9 mm No. of coils Standard or new 4.9 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Service limit 0.7 mm Thickness Standard or new 8.7 - 9.3 mm Service limit 6.0 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid .................................................................................................................................................. Genuine Honda DOT 3 or DOT 4 Brake Fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4172 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4173 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4174 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4180 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4181 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4182 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4183 Clutch Master Cylinder: Service and Repair Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Remove the brake fluid from the clutch master cylinder reservoir with a syringe. 2. Remove the retaining clip holder (A) and 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. 3. 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. 4. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C). 5. Remove the clutch master cylinder (A). 6. Remove the O-ring (B) and the clutch master cylinder seal (C) from the master cylinder. 7. Install the clutch master cylinder in the reverse order of removal. Install a new O-ring. Tighten the master cylinder mounting nuts to 13 Nm (1.3 kgf-cm, 9.4 ft. lbs.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Page 4184 8. Make sure the hose clamps (A) are positioned on the master cylinder (B) and reservoir (C) as shown. 9. To prevent the retaining clip (A) from coming off, pry to open the tip of the retaining clip (B) with a screwdriver. 10. Bleed the clutch master hydraulic system (see step 11). NOTE: The reservoir filling is covered in the bleeding procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 air cleaner housing (see step 6). 3. Remove the intake air duct (see step 7). 4. Remove the battery tray. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 4188 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-cm, 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-cm, 6 ft. lbs.); do not overtighten it. ^ Refill the clutch master cylinder with fluid when done. ^ Always use only Honda DOT 3 or 4 brake fluid. 12. Install the intake air duct (see step 37). 13. Install the air cleaner housing (see step 38). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4197 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4198 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4199 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4205 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4206 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4207 ^ If the noise is still present, look for other causes. 7. Test-drive the vehicle to check for proper clutch operation. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch pedal Height from floor Standard or new 200 mm Stroke Standard or new 125 - 135 mm Play Standard or new 6 - 17 mm Disengagement height from floor Standard or new 112 mm minimum Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 4211 Clutch Pedal Assembly: Adjustments Clutch Pedal and Clutch Pedal Position Switch Adjustment NOTE: ^ To check the clutch pedal position switch. ^ To check the clutch interlock switch. ^ Remove the driver's side floor mat before adjusting the clutch pedal. ^ The clutch is self-adjusting to compensate for wear. ^ If there is no clearance between the master cylinder piston and push rod, the release bearing 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 push-rod locknut (D), and turn the push rod (E) in or out to get the specified height (F), stroke (G), free play (H) and disengagement height (I) at the clutch pedal. Clutch Pedal Stroke: 125 - 135 mm (4.92 - 5.31 inch) Clutch Pedal Free Play: 6 - 17 mm (0.24 - 0.67 inch) Clutch Pedal Height: 200 mm (7.87 inch) Clutch Pedal Disengagement Height: 112 mm (4.41 inch) 3. Tighten the clutch push-rod 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. Press the clutch pedal to the floor. 8. 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. 9. Tighten the clutch interlock switch locknut (J). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations 43. Under Left Side of Dash (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4215 Clutch Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 4216 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector (A). 2. Remove the clutch interlock switch (B). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure plate Warpage Standard or new 0.03 mm maximum Service limit 1.5 mm Height of diaphragm spring fingers measured with special tool and feeler gauge Standard or new 0.6 mm maximum Service limit 0.8 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4220 Pressure Plate: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4221 Pressure Plate: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Clutch, M/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4240 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4241 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4247 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4248 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4261 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 4270 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > Customer Interest: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 4271 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 4277 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 Cr-v 4wd Workshop Manual (L4-2.4L (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: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 4278 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns Differential Clutch: All Technical Service Bulletins Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4284 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4285 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4291 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4292 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns Differential Clutch: Customer Interest Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns > Page 4306 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns > Page 4307 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns Differential Clutch: All Technical Service Bulletins Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4313 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4314 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Mount > Component Information > Diagrams > Page 4318 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns Fluid - Differential: Customer Interest Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns > Page 4327 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 07-024 > May > 10 > Drivetrain Rear Differential Moaning/Groaning On Turns > Page 4328 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns Fluid - Differential: All Technical Service Bulletins Drivetrain - Rear Differential Moaning/Groaning On Turns 07-024 May 14, 2010 Applies To: 2002-06 CR-V - ALL with 4WD 2007 CR-V - From VIN 5J6RE4...7L000001 thru 5J6RE4...7L019269 2007 CR-V - From VIN JHLRE4...7C000001 thru JHLRE4...7C068888 Moan or Groan From the Rear Differential (Supersedes 07-024, dated August 12, 2009, to revise the information marked by the black bars and asterisks) *REVISION SUMMARY Under WARRANTY CLAIM IN FORMATION, the flat rate time was revised after the operation was reviewed and validated.* BACKGROUND A moaning or groaning comes from the rear differential when making a sharp or tight turn at low speeds. PROBABLE CAUSE Contamination in the rear differential fluid. CORRECTIVE ACTION Replace the rear differential fluid, and burnish the rear differential clutches. REQUIRED MATERIALS Honda Dual Pump System Fluid II: P/N 08200-9007 2002-04 models: 1.1 quarts per vehicle per replacement (2.2 quarts total) 2005-07 models: 1.3 quarts per vehicle per replacement (2.6 quarts total) WARRANTY CLAIM INFORMATION The normal warranty applies. Operation Number: 2191N7 *Flat Rate Time: 10 hour* Failed Part: P/N 41011-PNZ-307 Defect Code: 08103 Symptom Code: 04216 Skill Level: Repair Technician REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: ^ Refer to page 15-13 of the 2002-04 OH-V Service Manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4334 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. ^ With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes. 7. Replace the rear differential fluid: ^ Refer to page 15-13 of the service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 8. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 8. REPAIR PROCEDURE: 2005-07 MODELS 1. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Turn off the VSA. 5. Burnish the rear differential clutches: Automatic transmission models ^ Set the parking brake, and shift the transmission to R. Let the engine idle for 5 minutes. ^ Shift the transmission to D. Release the parking brake, and keep the wheel speed at 10 mph for 5 minutes. ^ Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 6. Manual transmission models ^ With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, then keep the wheel speed at 20 mph for 5 minutes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 07-024 > May > 10 > Drivetrain - Rear Differential Moaning/Groaning On Turns > Page 4335 ^ Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, then keep the wheel speed at 10 mph for 5 minutes. ^ Shift the transmission into neutral, then apply the brakes to stop the wheels. ^ Repeat the bulleted steps one more time, then go to step 6. 6. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 7. Let the rear differential cool for 10 minutes. 8. Replace the rear differential fluid: ^ Refer to the Rear Differential section of the appropriate service manual, or ^ Online, enter keywords REAR DIFF and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 9. To confirm the repair, test-drive the vehicle for 2 miles, making as many turns as possible (at least 20). If the noise is still there, repeat steps 2 thru 9. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Change ................................................................................................................................................ .............................................................. 1.0L (1.1 Qt) Total ................................................................ .................................................................................................................................................. 1.2L (1.3 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4338 Fluid - Differential: Fluid Type Specifications Differential Fluid Type ..................................................................................................................................................... ........................................... Honda Dual Pump Fluid Do NOT use Automatic Transmission Fluid (ATF). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4339 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4340 Fluid - Differential: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4341 Fluid - Differential: Service and Repair Inspection and Replacement 1. With the vehicle on level ground, inspect the differential fluid with engine OFF. 2. Remove the oil filler plug (A) and sealing washer (B), then check the condition of the fluid, and make sure the fluid is at the proper level (C). 3. The fluid level must be up to the fill hole. If it is below the hole, add the recommended fluid until it runs out, then reinstall the oil filler plug with a new sealing washer. 4. If the differential fluid is dirty, remove the drain plug (A), and drain the fluid. 5. Clean the drain plug, then reinstall it with a new sealing washer, and refill the differential with the recommended fluid to the proper level. NOTE: If you disassembly the differential, check the fluid level again after the 4WD system check is finished. Add fluid if necessary. Fluid Capacity 1.0 L (1.1 US qt., 0.9 Imp qt.) at fluid change 1.2 L (1.3 US qt., 1.1 Imp qt.) at overhaul Recommended fluid: Honda Dual Pump Fluid 6. Reinstall the oil filler plug with a new sealing washer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair Constant Velocity Joint: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Axle Shaft Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4350 Universal Joint: Service and Repair Intermediate Shaft Removal 1. Remove the right driveshaft. 2. Remove the heat shield. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4351 3. Remove the flange bolt (A) and two dowel bolts (B). 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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4352 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. 4. Press the intermediate shaft bearing (A) out of the bearing support (B) using the special tools and a press. Intermediate Shaft Reassembly Special Tools Required ^ Drive 07749-0010000 ^ Attachment, 52 x 55 mm 07746-0010400 ^ Attachment, 35 mm I.D. 07746-0030400 ^ Oil seal driver 07GAD-PH70201 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4353 2. Press the intermediate shaft bearing (A) into the bearing support (B) using the special tools and a press. 3. Seat the internal snap ring into the groove of the bearing support. 4. Press the intermediate shaft (A) into the shaft bearing (B) using the special tool and a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4354 5. 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. 7. Install the set ring. Intermediate Shaft Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Diagrams > Page 4355 1. Use solvent or carburetor 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). 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Wheel Bearings - Humming Or Growling Wheel Bearing: Technical Service Bulletins Wheel Bearings - Humming Or Growling SOURCE: Honda Service News November 2003 TITLE: Humming or Growling? Check the Wheel Bearings APPLIES TO: 1998-04 Accord, 2001-04 CR-V, 2003 Element, 1999-04 Odyssey SERVICE TIP: A bad front wheel bearing(s) can make a humming or growling that's easily mistaken for a noisy bearing or gear in the A/T. Before you order a reman A/T, test-drive the vehicle to make sure the A/T is really the problem. Listen carefully as you accelerate and decelerate during your test-drive. Shift into neutral. Varying throttle position and shifting into neutral changes the load on the A/T bearings and gears. If the A/T has a bad bearing or gear, the change in load will affect its noise level. If that's what you find, then go ahead and order a reman A/T. If the noise level isn't affected by changes in throttle position or shifting into neutral, then the culprit could be a bad front wheel bearing(s). Since the wheel bearings aren't mounted on shafts being spread apart by gears, they're not affected by changes in load. Also, since Honda uses angular contact wheel bearings, you won't normally hear a change in noise level when you swerve the vehicle from side to side. Hook up a STEELMAN® ChassisEAR (T/N JSP SM06600) to the front knuckles, and test-drive the vehicle again. Refer to S/B 00-063, STEELMAN ChassisEAR Diagnostic Tool, for more info. If you hear humming or growling from one or affected wheel bearing(s), and then test-drive the vehicle to make sure the noise is gone. If you don't hear any noise from the front wheel bearings, the problem could be from tire noise or vibration. Swap the front wheels and tires with a known-good vehicle. Testdrive the vehicle, and check if the noise or vibration goes away. STEELMAN(R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Front > Page 4362 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Diagrams > Page 4363 Wheel Bearing: Testing and Inspection Inspection 1. Raise the vehicle, and make sure it is securely supported. 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. 3. Set up the dial gauge against the hub cap as shown, and measure the bearing end play by 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Special Tools Required Hub disassembly tool 07GAF-SD40100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle and Hub Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4366 2. Remove the wheel cap, wheel nuts, and front wheel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4367 8. With ABS: 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 clip (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the clip into the ball joint pin from the inside to the outside of the vehicle. The closed end of the clip must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4368 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. 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. - First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specific torques. Do not place the jack against the ball joint pin of the lower arm. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the clip hole. Do not align the castle nut by loosening it. - Install a new clip 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. - Replace the self-locking nuts, damper pinch bolts and nuts with new ones. 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. Wheel Bearing Replacement 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4369 3. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 5. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 6. 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. NOTE (with ABS): Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4370 7. Install the snap ring (A) securely in the knuckle (B). 8. Install the splash guard (C), and tighten the screws (D) to the specified torque. 9. Press a wheel bearing (A) onto the hub (B) using the special tools and a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4371 Wheel Bearing: Service and Repair Rear Knuckle/Hub/Wheel Bearing Special Tools Required Hub disassembly tool 07965-SA70100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4372 2. Release the parking brake lever. 3. Remove the brake hose mounting bolt (A). 4. 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. 5. Remove the brake disc retaining screw (A), and screw two 8 x 1.25 mm bolts into the brake disc/ drum (B) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the brake disc/drum excessively. Remove the brake disc/drum. 6. Raise the stake (A), and remove the spindle nut (B). Remove the rear axle shaft (C) from vehicles with 2WD. 7. Remove the parking brake shoes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4373 8. Remove the parking brake cable (A) from the backing plate. NOTE: The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. 9. Remove the wheel sensor (A) from the knuckle (if equipped with ABS). 10. Place a floor jack under the trailing arm (A) to support it. NOTE: Do not place the jack against the plate section of the lower arm. Be careful not to damage any suspension components. 11. Remove the flange bolt, and disconnect the upper arm (B) from the knuckle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4374 12. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), then remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 13. Remove the flange bolt (D). 14. Remove the knuckle (A) while pushing in the driveshaft and holding the driveshaft outboard joint (B) (4WD only). 15. 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 and adjusting cam with the marked positions when tightening. - Use a new self-locking nut on reassembly. - 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/drum, clean the mating surfaces of the rear hub and the inside of the brake disc/drum. - Before installing the wheel, clean the mating surfaces of the brake disc/drum and the inside of the wheel. - Check the rear wheel alignment, and adjust it if necessary. Wheel Bearing Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4375 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with a press attachment (C) or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. Remove the brake hose mounting bracket (A). 3. Remove the backing plate (B), and snap ring (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press. 5. Press the wheel bearing inner race (A) from the hub (B) using the special tool, a commercially available bearing separator (C), and a press. 6. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4376 7. 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. Be careful not to damage the sleeve of the pack seal. NOTE (with ABS) Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. 8. Install the snap ring (A), backing plate (B), and brake hose mounting bracket (C). Tighten the flange nuts and bolts to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 4377 9. Install the hub (A) on the knuckle (B) using the special tools and a hydraulic press. Be careful not to deform the backing plate (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Diagrams > Front > Page 4382 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection Drive/Propeller Shaft: Testing and Inspection Propeller Shaft Inspection Universal Joint and Boots 1. Shift the transmission to Neutral. 2. Raise the vehicle off the ground, and support it with safety stands in the proper locations. 3. Check the center support bearing (A) for excessive play or rattle. If the center support has excessive play or rattle, replace the propeller shaft assembly (B). 4. Check the universal joint boots (C) for damage and deterioration. If the boots are damaged or deteriorated, replace the propeller shaft assembly. 5. Check the universal joints for excessive play or rattle. If the universal joints have excessive play or rattle, replace the propeller shaft assembly. Propeller Shaft Runout 6. Install a dial indicator with its needle on the center of the No. 1 or No. 2 propeller shaft. 7. Turn the other propeller shaft slowly, and check the runout. Repeat this procedure for the other propeller shaft. 8. If the runout on either propeller shaft exceeds the service limit, replace the propeller shaft assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Drive Shafts Drive/Propeller Shaft: Service and Repair Drive Shafts For further information regarding this component and the system that it is part of, please refer to Axle Shaft Assembly; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Drive Shafts > Page 4389 Drive/Propeller Shaft: Service and Repair Propeller Shaft Propeller Shaft Removal 1. Raise the vehicle off the ground, and support it with safety stands in the proper locations. 2. Remove the No. 2 propeller shaft protector. 3. Make a reference mark (A) across the propeller shaft (B) and transfer companion flange (C). 4. Separate the propeller shaft from the transfer assembly. 5. Remove the center support bearing mounting bolts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Drive Shafts > Page 4390 6. Make a reference mark (A) across the propeller shaft (B) and rear differential companion flange (C). 7. Separate the propeller shaft from the rear differential, then remove the propeller shaft. Propeller Shaft Installation 1. Install the propeller shaft (A) onto the rear differential (B) by aligning the reference mark (C). 2. Install the center support bearing mounting bolts. Make sure you use new bolts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Drive Shafts > Page 4391 3. Install the propeller shaft (A) onto the transfer assembly (B) by aligning the reference mark (C). 4. Install the No. 2 propeller shaft protector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Testing and Inspection Universal Joint: Testing and Inspection For further information regarding this component and the system that it is part of, please refer to Drive/Propeller Shaft; Testing and Inspection; Procedures. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Testing and Inspection > Page 4395 Universal Joint: Service and Repair For further information regarding this component and the system that it is part of, please refer to Drive/Propeller Shaft; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Torque Flywheel: Specifications Torque Flywheel Runout on clutch mating surface Standard or New ....................................................................................................................................................... 0.05 mm (0.002 inch) maximum Service Limit .................................................................................... ......................................................................................... 0.15 mm (0.006 inch) Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Torque > Page 4400 Flywheel: Specifications Flywheel Runout on clutch mating surface Standard or new 0.05 mm maximum Service limit 0.15 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications Countershaft: Specifications Countershaft Diameter of needle bearing contact area (clutch housing side) Standard or new 35.000 - 35.015 mm Service limit 34.95 mm Diameter of distance collar contact area Standard or new 39.937 - 39.950 mm Service limit 39.88 mm Diameter of ball bearing contact area (transmission housing side) Standard or new 30.020 - 30.033 mm Service limit 29.97 mm Runout Standard or new 0.02 mm maximum Service limit 0.05 mm 35 mm shim-to-bearing inner race clearance Standard or new 0.04 - 0.10 mm Service limit Adjust Countershaft 1st gear I.D. Standard or new 52.010 - 52.029 mm Service limit 52.08 mm End play Standard or new 0.06 - 0.16 mm Service limit 0.25 mm Thickness Standard or new 22.92 - 22.97 mm Service limit 22.87 mm Countershaft 2nd gear I.D. Standard or new 52.010 - 52.029 mm Service limit 52.08 mm End play Standard or new 0.06 - 0.16 mm Service limit 0.25 mm Thickness Standard or new 27.92 - 27.97 mm Service limit 27.87 mm Countershaft 1st gear distance collar I.D. Standard or new 39.95 - 39.96 mm Service limit 39.97 mm O.D. Standard or new 46.989 - 47.000 mm Service limit 46.94 mm Length Standard or new 23.03 - 23.08 mm Countershaft 2nd gear distance collar I.D. Standard or new 39.95 - 39.96 mm Service limit 39.97 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications > Page 4405 O.D. Standard or new 46.989 - 47.000 mm Service limit 46.94 mm Length Standard or new 28.03 - 28.08 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 I.D. Standard or new 18.010 - 18.028 mm Carrier-to-pinion shaft clearance Standard or new 0.027 - 0.057 mm Service limit 0.1 mm Driveshaft contact area I.D. Standard or new 28.025 - 28.045 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 I.D. Standard or new 18.042 - 18.066 mm Pinion gear-to-pinion shaft clearance Standard or new 0.059 - 0.095 mm Service limit 0.15 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 ................................................................................................................................ ............................................................................... 2.0 Qt (1.9L) Overhaul ......................................... .............................................................................................................................................................. ...... 2.4 Qt (2.3L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4417 Fluid - M/T: Fluid Type Specifications M/T Fluid Type ..................................................................................................................................................... ............... Honda Manual Transmission Fluid (MTF) If not available you may use 10W-30 or 10W-40 motor oil with an API certification seal that says "For Gasoline Engines" as a temporary replacement. However, motor oil does not contain the proper additives and continued use can cause stiffer shifting. Replace with Honda MTF as soon as it is convenient. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 4418 Fluid - M/T: Testing and Inspection 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 1.9 L (2.0 US qt., 1.7 Imp qt.) at fluid change 2.3 L (2.4 US qt., 2.01 Imp qt.) at overhaul Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives. 5. Reinstall the oil filler plug with a new washer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 4419 Fluid - M/T: Service and Repair For further information, refer to Testing and Inspection; Procedures. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Service limit 0.4 mm Double cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear Standard or new 0.70 - 1.19 mm Service limit 0.3 mm Synchro cone-to-gear clearance Ring pushed against gear Standard or new 0.50 - 1.04 mm Service limit 0.3 mm Outer synchro ring-to-gear cone clearance Ring pushed against gear Standard or new 0.95 - 1.68 mm Service limit 0.6 mm Triple cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear Standard or new 0.70 - 1.19 mm Service limit 0.3 mm Synchro cone-to-gear clearance Ring pushed against gear Standard or new 0.50 - 1.04 mm Service limit 0.3 mm Outer synchro ring-to-gear cone clearance Ring pushed against gear Standard or new 0.95 - 1.68 mm Service limit 0.6 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft, M/T > Component Information > Specifications Mainshaft: Specifications Mainshaft End play Standard or new 0.11 - 0.17 mm Service limit Adjust Diameter of bushing surface Standard or new 20.80 - 20.85 mm Service limit 20.75 mm Diameter of distance collar Standard or new 31.984 - 32.000 mm Service limit 31.93 mm Diameter of ball bearing contact area (clutch housing side) Standard or new 27.977 - 27.990 mm Service limit 27.94 mm Diameter of needle bearing contact area Standard or new 38.984 - 39.000 mm Service limit 38.93 mm Diameter of ball bearing contact area (transmission housing side) Standard or new 27.987 - 28.000 mm Service limit 27.94 mm Runout Standard or new 0.02 mm maximum Service limit 0.05 mm Mainshaft 3rd, 4th and 5th gears I.D. Standard or new 44.009 - 44.025 mm Service limit 44.08 mm End play Standard or new 0.06 - 0.16 mm Service limit 0.25 mm Thickness Standard or new 23.92 - 23.97 mm Service limit 23.80 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse idler gear I.D. Standard or new 20.016 - 20.043 mm Service limit 20.90 mm Gear-to-reverse gear shaft clearance Standard or new 0.036 - 0.084 mm Service limit 0.16 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Fork-to-synchro sleeve clearance Standard or new 0.35 - 0.65 mm Service limit 1.0 mm Reverse shift fork Finger thickness Standard or new 13.4 - 13.7 mm Fork-to-synchro sleeve clearance Standard or new 0.20 - 0.59 mm Service limit 1.2 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Shift arm I.D Standard or new 13.973 - 14.000 mm Shift fork diameter at contact area Standard or new 16.9 - 17.0 mm Shift arm-to-shift lever clearance Standard or new 0.2 - 0.5 mm Service limit 0.6 mm Select lever Finger width Standard or new 14.85 - 14.95 mm Shift lever Shaft-to-select lever clearance Standard or new 0.05 - 0.25 mm Service limit 0.5 mm Groove (to select lever) Standard or new 15.00 - 15.10 mm Shift-to-shift arm clearance Standard or new 0.013 - 0.07 mm Service limit 0.1 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Diagrams > Page 4439 Shift Linkage: Service and Repair Gearshift Mechanism Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns Transmission Mount: Customer Interest Engine, M/T, A/T - Grind/Rattle on L/H Turns 04-005 July 30, 2005 *Applies To: 2002-05 CR-V - See VEHICLES AFFECTED* Noise When Turning Left (Supersedes 04-005, dated January 30, 2004) Updated information is shown with black bars and asterisks. SYMPTOM A rattle, grind, or growl can be heard from the A-pillar or right front side of the vehicle when turning left. VEHICLES AFFECTED PROBABLE CAUSE There is not enough clearance between the right transmission mount bracket and the engine, causing them to rub together. CORRECTIVE ACTION Move the engine away from the right transmission mount bracket. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112321 Flat Rate Time: 0.3 hour Failed Part: P/N 50821-S9A-023 H/C 7095599 Defect Code: 07404 Symptom Code: 04201 Template ID: 04-005A Skill Level: Repair Technician Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 4448 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop Transmission Mount: Customer Interest A/T, M/T - Vibration Accelerating From a Stop 04-070 November 19, 2004 Applies To Noise or Vibration When Accelerating From a Stop SYMPTOM There is a noise or vibration when accelerating from a stop. PROBABLE CAUSE The transmission mount limiter tabs are out of position. CORRECTIVE ACTION Reposition the limiter tabs, and glue them to the transmission mount. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112002 Flat Rate Time: 0.2 hour Failed Part: P/N 50805-S9A-983 H/C 7114614 Defect Code: 02502 Symptom Code: 04216 Template ID: 04-070A 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. INSPECTION PROCEDURE Inspect the transmission mount. The limiter tabs should be positioned as shown in step 2 of the REPAIR PROCEDURE. If the limiter tabs are out of position, proceed with REPAIR PROCEDURE. If the tabs are in the correct position, troubleshoot for other causes. REPAIR PROCEDURE 1. Open the hood. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4453 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4454 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns Transmission Mount: All Technical Service Bulletins Engine, M/T, A/T - Grind/Rattle on L/H Turns 04-005 July 30, 2005 *Applies To: 2002-05 CR-V - See VEHICLES AFFECTED* Noise When Turning Left (Supersedes 04-005, dated January 30, 2004) Updated information is shown with black bars and asterisks. SYMPTOM A rattle, grind, or growl can be heard from the A-pillar or right front side of the vehicle when turning left. VEHICLES AFFECTED PROBABLE CAUSE There is not enough clearance between the right transmission mount bracket and the engine, causing them to rub together. CORRECTIVE ACTION Move the engine away from the right transmission mount bracket. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112321 Flat Rate Time: 0.3 hour Failed Part: P/N 50821-S9A-023 H/C 7095599 Defect Code: 07404 Symptom Code: 04201 Template ID: 04-005A Skill Level: Repair Technician Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-005 > Jul > 05 > Engine, M/T, A/T - Grind/Rattle on L/H Turns > Page 4460 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. Loosen the transmission mount bracket mounting support bolt and nuts. 2. Using a prybar, push the engine toward the left side of the vehicle. 3. Retighten the bolt and nuts to 54 Nm (40 lb-ft). 4. Make sure there is a gap between the rubber bumper on the frame and the metal tab on the upper bracket. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop Transmission Mount: All Technical Service Bulletins A/T, M/T - Vibration Accelerating From a Stop 04-070 November 19, 2004 Applies To Noise or Vibration When Accelerating From a Stop SYMPTOM There is a noise or vibration when accelerating from a stop. PROBABLE CAUSE The transmission mount limiter tabs are out of position. CORRECTIVE ACTION Reposition the limiter tabs, and glue them to the transmission mount. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 112002 Flat Rate Time: 0.2 hour Failed Part: P/N 50805-S9A-983 H/C 7114614 Defect Code: 02502 Symptom Code: 04216 Template ID: 04-070A 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. INSPECTION PROCEDURE Inspect the transmission mount. The limiter tabs should be positioned as shown in step 2 of the REPAIR PROCEDURE. If the limiter tabs are out of position, proceed with REPAIR PROCEDURE. If the tabs are in the correct position, troubleshoot for other causes. REPAIR PROCEDURE 1. Open the hood. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4465 2. With your hands, rotate the limiter tabs until they are positioned as shown. 3. With your finger, roll back the upper loop of the limiter tab, and put a dab of commercially available super glue (cyanoacrylate adhesive) between the loop and the mount. Do this for both limiter tabs. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 04-070 > Nov > 04 > A/T, M/T - Vibration Accelerating From a Stop > Page 4466 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4472 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 4478 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 4479 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4483 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 4486 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 4490 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 4491 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4495 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4496 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4497 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4498 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4499 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4500 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4509 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4510 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4516 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4517 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4518 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4519 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4520 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4521 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4522 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4523 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4524 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4529 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4533 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4534 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4535 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4536 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4546 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4547 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4553 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4554 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Automatic Trans and Transfer Transfer Case Change ................................................................................................................................................ ......................................................................... 3.1 Qt Overhaul ......................................................... .............................................................................................................................................................. 7.2 Qt Manual Trans and Transfer Transfer Case Change................................................................................................................................................. .............................................................. 1.9L (2.0 Qt) Overhaul........................................................... .................................................................................................................................................. 2.3L (2.4 Qt) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4564 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............. Honda Manual Transmission Fluid (MTF). Do not use motor oil. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations 19. Transmission Housing 140. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4571 Pressure Regulating Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection Shift Interlock Solenoid: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4575 Shift Interlock Solenoid: Service and Repair Shift Lock Solenoid Test/Replacement 1. Remove the driver's dashboard lower cover, and the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Connect the battery positive terminal to the No. 4 terminal of the O/D switch/shift lock solenoid/park pin switch connector, and connect the battery negative terminal to the No. 3 terminal. NOTE: Do not connect the battery positive terminal to the No. 3 terminal or you will damage the diode inside the solenoid. 4. Check that the shift lever can be moved from the P position. Release the battery terminals, move the shift lever back to P, and make sure it locks. If the shift lock solenoid works properly, connect the connector and install the removed parts. If the shift lock solenoid is faulty, go to step 5 for replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable end holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), and remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4576 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry up the tabs on the O/D switch/shift lock solenoid/park pin switch connector (A) to release the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever cover. 15. Remove the shift lock solenoid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4577 16. Install the shift lock solenoid plunger (A) and plunger spring (B) in the new shift lock solenoid (C). 17. Install the shift lock solenoid by aligning the joint of the shift lock solenoid plunger with the tip of the shift lock stop (D). 18. Route the harnesses, and clamp them as shown. 19. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 20. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 21. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity and the RED harness terminal (D) in the No. 4 cavity. Make sure that all six terminals lock securely, then install the lock (E) securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4578 22. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. 23. Install the shift lever cover. 24. Install the shift lever assembly. 25. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 26. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 27. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4579 28. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever is secured in the R position. 29. Rotate the socket holder (A) on the shift cable (B) to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 30. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection > Page 4580 31. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 32. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 33. Connect the O/D switch/shift lock solenoid/park pin switch connector. 34. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 35. Check that the shift lock solenoid operates. 36. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4584 Shift Solenoid: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4585 Shift Solenoid: Testing and Inspection Shift Solenoid Valves Test 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure shift solenoid valves resistance between the shift solenoid harness connector terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4586 No. 1, No. 2, No. 3, No. 5 and body ground. Shift solenoid valve A: No. 5 terminal (BLU) Shift solenoid valve B: No. 2 terminal (ORN) Shift solenoid valve C: No. 1 terminal (GRN) Shift solenoid valve E: No. 3 terminal (RED) STANDARD: 12 - 25 Ohms 9. If the resistance is out of standard, disconnect the shift solenoid valve connector, and measure its resistance at the solenoid valve connector. Replace the shift solenoid valve if the resistance is out of standard. 10. Connect the battery positive terminal to the shift solenoid harness connector terminals, and connect the battery negative terminal to body ground individually. A clicking sound should be heard. 11. If no sound is heard, connect the battery positive terminal to the shift solenoid valve connector terminal, and check the clicking sound is heard. Replace the shift solenoid valve if no sound is heard. 12. Replace the solenoid harness if the tests results are OK. 13. Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4587 Shift Solenoid: Service and Repair Shift Solenoid Valves Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 5. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 6. Disconnect the shift solenoid valve connectors. 7. Remove the bolts, and hold the shift solenoid valve body, then remove them. Do not hold the connector to remove. 8. Install the new O-rings (two O-rings per solenoid valve) (F) on the good solenoid valve. The replacement solenoid valve comes with new O-rings. 9. Install shift solenoid valve A, C, and E by holding the shift solenoid valve body; be sure to install the solenoid valves until their mounting bolt brackets contact the servo body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4588 10. Install shift solenoid valve B by holding the shift solenoid valve body; be sure to install the solenoid valve until its mounting bolt bracket contacts to the bracket of installed solenoid. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. 11. Connect shift solenoid valve A connector (G) with the ATF temperature sensor. 12. Connect solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the shift solenoid valve cover with the new gasket and dowel pins. 14. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 15. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 16. Remove the transmission jack. 17. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valve A Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Measure A/T clutch pressure control solenoid valve A resistance at the solenoid valve A connector. STANDARD: About 5 Ohms 4. If the resistance is out of standard, replace A/T clutch pressure control solenoid valve A. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valve A. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valve A connector to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure the A/T clutch pressure control solenoid valve moves. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valve A body. 10. If the valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valve A. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Testing and Inspection > A/T Clutch Pressure Control Solenoid Valve A Test > Page 4593 Torque Converter Clutch Solenoid: Testing and Inspection A/T Clutch Pressure Control Solenoid Valves B and C Test Test 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Measure A/T clutch pressure control solenoid valve B resistance at the solenoid valve B connector, and measure A/T clutch pressure control solenoid valve C resistance at the solenoid valve C connector. STANDARD: About 5 Ohms 4. If the resistance of either of the A/T clutch pressure control solenoid valves is out of standard, replace A/T clutch pressure control solenoid valves B and C. 5. Connect the battery positive terminal to the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors, and connect the battery negative terminal to the No. 2 terminal. A clicking sound should be heard. 6. If no sound is heard, remove A/T clutch pressure control solenoid valves B and C. 7. Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt. 8. Connect the No. 1 terminal of the A/T clutch pressure control solenoid valves B and C connectors to the battery positive terminal, and connect the No. 2 terminal to the battery negative terminal. Make sure A/T clutch pressure control solenoid valves B and C move. 9. Disconnect one of the battery terminals, and check valve movement. NOTE: You can see valve movement through the fluid passage in the mounting surface of the A/T clutch pressure control solenoid valves B and C body. 10. If either valve binds or moves sluggishly, or if the solenoid valve does not operate, replace A/T clutch pressure control solenoid valves B and C. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valve A Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valve A connector. 3. Remove the mounting bolts and A/T clutch pressure control solenoid valve A. 4. Remove the ATF pipe (B), ATF joint pipes (C), O-rings (D), and gasket (E). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valve A and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF pipe and ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valve A. 9. Check the A/T clutch pressure control solenoid valve A connector for rust, dirt, and oil, then connect it securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > A/T Clutch Pressure Control Solenoid Valve A Replacement > Page 4596 Torque Converter Clutch Solenoid: Service and Repair A/T Clutch Pressure Control Solenoid Valves B and C Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the A/T clutch pressure control solenoid valves B and C connectors. 3. Remove the mounting bolts, harness clamp brackets (A), and A/T clutch pressure control solenoid valves B and C. 4. Remove the ATF joint pipes (D), O-rings (E), and gasket (F). 5. Clean the mounting surface and fluid passage of A/T clutch pressure control solenoid valves B and C and the transmission housing. 6. Install the new gasket on the transmission housing, and install the ATF joint pipes. 7. Install the new O-rings over the ATF joint pipes. 8. Install the new A/T clutch pressure control solenoid valves B and C, and harness clamp brackets. 9. Check the A/T clutch pressure control solenoid valves B and C connectors for rust, dirt, and oil, then connect them securely. 10. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Relay > Component Information > Locations > Page 4602 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 4608 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Countershaft Sensor, A/T > Component Information > Locations > Page 4609 Countershaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations 19. Transmission Housing 141. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4613 Fluid Pressure Sensor/Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement Fluid Pressure Sensor/Switch: Service and Repair 2ND Clutch Pressure Switch Replacement Replacement 1. Remove the air cleaner housing. 2. Disconnect the connector from the 2nd clutch pressure switch (A). 3. Remove the 2nd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 4. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. 5. Install the air cleaner housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 2ND Clutch Pressure Switch Replacement > Page 4616 Fluid Pressure Sensor/Switch: Service and Repair 3RD Clutch Pressure Switch Replacement Replacement 1. Disconnect the connector from the 3rd clutch pressure switch (A). 2. Remove the 3rd clutch pressure switch and use a new sealing washer (B). Tighten the switch on the metal part, not the plastic part. 3. Reconnect the connector, making sure there is no water, oil, dust, or foreign particles inside it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations 19. Transmission Housing (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 4620 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Mainshaft Sensor, A/T > Component Information > Locations > Page 4621 Mainshaft Sensor: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Transmission Speed Sensor, A/T; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair Overdrive Switch: Service and Repair O/D Switch Test/Replacement 1. Remove the driver's dashboard lower cover, the instrument panel. 2. Disconnect the O/D switch/shift lock solenoid/park pin switch connector. 3. Check for continuity between the No. 5 and No. 6 terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch, and when the switch is released. 4. If the O/D switch is OK, connect the connector and install the removed parts. If the switch is faulty, go to step 5 for the O/D switch replacement. 5. Shift the shift lever to the R position. 6. Slide the lock tab (A) down on the shift cable and holder (B). 7. Grasp the shift cable lock (C) in the middle (D) with needle-nose pliers (E), then remove it from the shift cable end and shift cable end holder. NOTE: Do not pry the shift cable lock with a screwdriver, it may damage the shift cable end holder. 8. Separate the shift cable end from the shift cable end holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4625 9. Rotate the socket holder (A) on the shift cable (B) a quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E). Then slide the holder to remove the shift cable from the socket holder bracket. NOTE: Do not remove the shift cable by twisting the shift cable guide (F) and damper (G). 10. Remove the shift lever assembly. 11. Remove the harness from the harness clamp on the shift lever bracket base, and remove the harness band from the harness. 12. Pry the lock tabs on the back of the O/D switch/shift lock solenoid/park pin switch connector (A), and remove the lock (B). 13. Remove the terminal (C) from the connector by pushing the lock tab (D) up in the connector using a thin blade screwdriver (E). Remove all six terminals. 14. Remove the shift lever knob (A), then remove the O/D switch (B) from the knob. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4626 15. Remove the O/D switch connector terminals by pushing the lock tabs in the connector with a thin blade screwdriver. 16. Pull the O/D switch harness wires (A) from shift lever bracket side, and remove them. Leave the harness tube (B) and remove only the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4627 17. Install the shift lever knob (A) on the shift lever (B), and align the opening (C) of the switch so it is inclined 50° (D) toward the vertical axis (E). 18. Insert the new O/D switch harness wires (A) in the original harness tube (B), then tie a string (C) around the tube to secure the terminals in the tube. 19. Pull the old tube out of the shift lever knob side to install the O/D switch harnesses. 20. Remove the old harness tube from the O/D switch harness terminals. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4628 21. Install the O/D switch harness terminals in the new O/D switch. Either harness terminal can be installed in either cavity. 22. Install the new O/D switch in the shift lever knob. 23. Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Either O/D switch harness terminal can be installed in the No. 5 and No. 6 cavities. 24. Install the park pin switch harness terminals (B) in the No. 1 and No. 2 cavities. Either park pin switch harness terminal can be installed in the No. 1 and No. 2 cavities. 25. Install the BLU harness terminal (C) of the shift lock solenoid in the No. 3 cavity, and the RED harness terminal (D) in the No. 4 cavity. Make sure that the all six terminals lock securely, then install the lock (E) securely in place. 26. Align the marks (A) on the harnesses, and tie the harness band (B) over the marks. Clamp the O/D switch harness (C) 15 mm (0.6 inch) (D) from the harness band. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4629 27. Install the shift lever assembly. 28. Turn the ignition switch ON (II), and verify that the R position indicator comes on. 29. If necessary, push the shift cable until it stops, then release it. Pull the shift cable back one step so that the shift cable is in R. Do not hold the shift cable guide (A) to adjust the shift cable (B). 30. Turn the ignition switch OFF. 31. Insert a 6.0 mm (0.24 inch) pin (A) into the positioning holes (B) on the shift lever bracket base and through the positioning hole (C) on the shift lever. The shift lever must be in the R position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Page 4630 32. Rotate the socket holder (A) on the shift cable (B) to place the tab (C) on the holder opposite of the opening (D) in the socket holder bracket (E). Align the holder with the opening in the bracket, then slide the holder into the bracket. Rotate the holder a quarter turn to secure the shift cable. Do not install the shift cable by twisting the shift cable guide (F) and damper (G). 33. Install the shift cable end (A) in the shift cable end holder (B). Keep the shift cable end and end holder free of grease. 34. Install the new shift cable lock (A) to secure the shift cable end and shift cable end holder, then push the lock tab (B) up until it stops to lock the joint. 35. Remove the 6.0 mm (0.24 inch) pin that was installed to hold the shift lever. 36. Connect the O/D switch/shift lock solenoid/park pin switch connector. 37. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch. 38. Check that the O/D switch operates. 39. Install the instrument panel and the driver's dashboard lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4639 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4640 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4646 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4647 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4648 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4649 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4650 Transmission Position Switch/Sensor: Testing and Inspection Transmission Range Switch Test 1. Remove the transmission range switch harness connector (A) from the connector bracket (B), then disconnect the connector. Connector Terminal Specification 2. Check for continuity between terminals at the harness connector. There should be continuity between the terminals in the following table for each switch position. 3. If there is no continuity between any terminals, remove the transmission range switch cover, and disconnect the connect at the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4651 Connector Terminal Specification 4. Check for continuity between terminals at the switch connector. There should be continuity between the terminals in the following table for each switch position. 5. If there is no continuity between any terminals, check the transmission range switch installation. If the transmission range switch installation is OK, replace the switch. If the transmission range switch continuity check was OK, replace the faulty transmission range switch harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4652 Transmission Position Switch/Sensor: Service and Repair Transmission Range Switch Replacement 1. Raise the vehicle, and make sure it is securely supported. 2. Shift to the N position. 3. Remove the transmission range switch cover. 4. Disconnect the transmission range switch connector. 5. Remove the old transmission range switch, and install the new switch. 6. Make sure that the control shaft is in the N position. If necessary, move the shift lever to the N position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4653 7. Align the cutout (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 inch) feeler gauge blade (D) in the cutouts to hold it in the position. NOTE: Be sure to use a 2.0 mm (0.08 inch) blade or equivalent to hold the switch in the N position. 8. Install the transmission range switch (A) gently on the control shaft (B) while holding the N position with the 2.0 mm (0.08 inch) blade (C). 9. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4654 10. Connect the connector securely, then install the transmission range switch cover (A). 11. Turn the ignition switch ON (II). Move the shift lever through all gear positions, and cheek the transmission range switch synchronization with the A/T gear position indicator. 12. Check that the engine can start in the P and N positions, and cannot start in any other shift lever position. 13. Check that the back-up lights come on when the shift lever is in the R position. 14. Allow the wheels to rotate freely, then start the engine, and check the shift lever operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 > Page 4659 Transmission Speed Sensor: Service and Repair Mainshaft and Countershaft Speed Sensors Replacement 1. Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector. 2. Remove the mainshaft speed sensor (A) and countershaft speed sensor (B). 3. Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing. 4. Install the new O-ring (D) on the countershaft speed sensor, and install the countershaft speed sensor in the transmission housing. 5. Check the connectors for rust, dirt, and oil, then connect the connectors securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations 139. In Transmission (A/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4663 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4664 Transmission Temperature Sensor/Switch: Testing and Inspection For further information, refer to Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4665 Transmission Temperature Sensor/Switch: Service and Repair ATF Temperature Sensor Test/Replacement 1. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). 2. Reinstall the drain plug with a new sealing washer (B). 3. Place the transmission jack under the transmission, and lift it up to create clearance between the transmission and front sub-frame. 4. Disconnect the shift solenoid harness connector. 5. Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing washers (F). 6. Remove the shift solenoid valve cover, gasket (G), and dowel pins (H). 7. Remove the bolt (A), and remove the shift solenoid harness connector (B). 8. Measure ATF temperature sensor resistance between the No. 6 and No. 7 terminals of the shift solenoid harness connector. STANDARD: 50 Ohms - 25 k Ohms Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4666 9. If the resistance is out of standard, replace the shift solenoid harness. The ATF temperature sensor is not available separately from the shift solenoid harness. 10. Disconnect the connectors from the shift solenoid valves. 11. Connect the shift solenoid valve A connector (BLU wire) with the ATF temperature sensor (F) on the new solenoid harness. 12. Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and solenoid valve E connector (RED wire). 13. Install the new O-ring (G) on the shift solenoid harness connector (H), and install the connector in the transmission housing. 14. Install the shift solenoid valve cover with the new gasket and dowel pins. 15. Install the ATF cooler inlet line with the line bolt and the new sealing washers. Create clearance with the jack between the transmission and the front sub-frame to tighten the line bolt with the torque wrench. 16. Install the bracket of the ATF cooler inlet line on the shift solenoid valve cover with the bolt. 17. Check the connector for rust, dirt, or oil, then connect the connector securely. 18. Remove the transmission jack. 19. Refill the transmission with the recommended fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4676 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4677 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4683 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4684 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations 46. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4694 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4695 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4696 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. 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. At the insulator cutout, measure the pedal height (B) from the middle of the pedal pad (C). 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Page 4697 4. 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 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. 5. Check the brake pedal free play. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 4701 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. - Take care 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. Disconnect negative cable from the battery. 3. Pull up the lock (A) of the ABS control unit 47P connector (B), then disconnect the connector. 4. Disconnect the six brake lines. 5. Remove the ABS modulator-control unit /bracket (C/D) from the body. 6. Remove the two 6 mm shoulder bolts and 6 mm bolt from the bracket, then remove the ABS modulator-control unit from the bracket. Installation 1. Install the ABS modulator-control unit on the bracket, then tighten the two 6 mm shoulder bolts and 6 mm bolt. 2. Install the ABS modulator-control unit/bracket on the body. 3. Align the connecting surface of the ABS control unit 47P connector. 4. Push in the lock of the ABS control unit 47P connector, then connect the connector. 5. Connect the six brake lines. 6. Bleed the brake system, starting with the front wheels. 7. Start the engine, and check that the ABS indicator and brake system indicator go off. 8. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations 3. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 4705 (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations > Page 4706 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. - Take care not to damage or deform the bake 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 47P connector (B), then disconnect the connector. 3. Disconnect the six brake lines. 4. Remove the ABS modulator-control unit / bracket (C/D) from the body. 5. Remove the two 6mm shoulder bolts and the 6mm bolt from the bracket, then remove the ABS modulator-control unit from the bracket. Installation 1. Install the ABS modulator-control unit on the bracket, then tighten the two 6mm shoulder bolts and the 6mm bolt. 2. Install the ABS modulator-control unit/bracket on the body. 3. Align the connecting surface of the ABS control unit 47P connector. 4. Push in the lock of the ABS control unit 47P connector, then the connector. 5. Connect the six brake lines. 6. Bleed the brake system, starting with the front wheels. 7. Start the engine, and check that the ABS indicator and the brake system indicator go off. 8. Disconnect the Honda PGM tester. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel sensor Standard Front/Rear 0.5 - 1.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4710 Wheel Speed Sensor: Locations 138. Left Side of Engine Compartment 143. Right Side of Engine Compartment 145. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4711 148. Under Right Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4712 Wheel Speed Sensor: Diagrams (EX; Canada: EX-L) (EX; Canada: EX-L) (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4713 (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4714 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. The wheel sensors detect changing of magnetic polarity on the magnetic encoder. The ABS control unit calculates the wheel speed based on signals received from the wheel sensor. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4715 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Remove the appropriate front driveshaft or rear driveshaft. 2. Check the magnetic encoder after cleaning the encoder. If necessary, replace the encoder. 3. Measure the air gap between the wheel sensor and the magnetic encoder all the way around while rotating the encoder. Standard: Front/Rear: 0.5 - 1.5 mm (0.02 - 0.06 inch) Note: - Install the wheel brearing with the magnetic encoder (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Be carful not to damage the encoder surface when you insert them wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 4716 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Fluid type Honda DOT3 brake fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications > Page 4720 Brake Bleeding: Service and Repair Brake System Bleeding NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. - Do not reuse the drained fluid. - Always use Honda DOT3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Loosen the left-front brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications > Page 4721 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal Pedal height (carpet removed) 173 mm Free play 1 - 5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4725 Brake Pedal Assy: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. 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. At the insulator cutout, measure the pedal height (B) from the middle of the pedal pad (C). 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 4726 4. 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 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. 5. Check the brake pedal free play. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Indicator Does Not Come on Brake Warning Indicator: Testing and Inspection Brake System Indicator Does Not Come on Brake system indicator does not come on 1. Disconnect the negative cable from the battery. 2. Disconnect the multiplex control unit 13P connector and the ABS control unit 47P connector. 3. Check for continuity between the ABS control unit 47P connector terminal No. 13 and body ground. Is there continuity? YES - Repair short to body ground in the wire between the multiplex control unit and the ABS control units. NO - Go to multiplex control system troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Indicator Does Not Come on > Page 4763 Brake Warning Indicator: Testing and Inspection Brake System Indicator Does Not GO Off Brake system indicator does not go off 1. Start the engine. 2. Release the parking brake. Does the brake system indicator go off? YES - The system is OK at this time. NO - Go to step 3. 3. Check the brake fluid level. Is there level OK? YES - Go to step 4. NO - Refill the brake fluid, and rechecks 4. Check the ABS indicator. Does the ABS indicator stay on? YES - Read the ABS DTC, and do the applicable troubleshooting for the DTC. NO - Go to step 5. 5. Turn the ignition switch OFF. 6. Disconnect the negative cable from the battery. 7. Disconnect the ABS control unit 47P connector. 8. Reconnect the battery cable. 9. Connect the ABS control unit 47P connector terminal No. 13 and body ground with a jumper wire. 10. Start the engine. 11. Check the brake system indicator. Does the brake system indicator go off? YES - Replace the ABS modulator-control unit. NO - Go to step 12. 12. Turn the ignition switch OFF. 13. Connect the multiplex control unit 13P connector terminal No. 1 and body ground with a jumper wire. 14. Start the engine. 15. Check the brake system indicator. Does the brake system indicator go off? YES - Repair open in the wire between the multiplex control unit and the ABS control unit. NO - Go to multiplex control system troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise Brake Caliper: Technical Service Bulletins Brakes - Rear Brake Grinding Noise 04-006 April 16, 2004 Applies To Grinding Noise From Rear Brakes (Supersedes 04-006, dated February 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM A grinding noise from the rear brakes PROBABLE CAUSE Corrosion between the rear caliper bracket and the pad retainers. CORRECTIVE ACTION Clean the caliper bracket, and apply lubricant between the caliper bracket and the pad retainers. REQUIRED MATERIALS M-77 Assembly Paste: P/N 08798-9010, H/C 4503793 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. *Operation Number: 411003* Flat Rate Time: 0.7 hour Failed Part: P/N 43244-SG0-003 *H/C2590131* Defect Code: 00801 Symptom Code: 04213 *Template ID: 04-006A* 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. REPAIR PROCEDURE 1. Remove both rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise > Page 4769 2. Hold the caliper pins with a wrench, being careful not to damage the pin boots. Remove the caliper bolts and caliper body from the caliper bracket. 3. Remove the pads and pad retainers from the caliper bracket. 4. Remove any corrosion from the caliper bracket surfaces under the upper and lower pad retainers. NOTE: If the corrosion cannot be removed, replace the caliper assembly. 5. Apply M-77 Assembly Paste to the areas indicated by the arrows. 6. Clean the upper and lower pad retainers; remove any corrosion. NOTE: The upper and lower pad retainers are different; the lower one has two holes. Make sure you install the pad retainers correctly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise > Page 4770 7. Install the upper and lower pad retainers. 8. Thoroughly clean the shims and the brake pad backing plates. Apply M-77 Assembly Paste to the brake pad backing plates and shims in the areas indicated by the arrows. Wipe off any excess paste; do not get any paste on the disc pad surfaces. 9. Install the pads in their original positions. 10. Install the caliper body on the caliper bracket, and torque the caliper bolts to 22 Nm (16 lb-ft). 11. Repeat steps 2 through 10 for the other rear caliper. 12. Install the rear wheels; torque the wheel nuts to 108 Nm (80 lb-ft). Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Diagrams > Front > Page 4773 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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. - When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. - Do not reuse drained brake fluid. - Always use Honda DOT3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. - Do not mix different brands of brake fluid as they may not be compatible. - Coat the piston, piston seal groove, and caliper bore with clean brake fluid. - Make sure no grease or oil gets on the brake discs or pads. - Replace all rubber parts with new ones whenever disassembled. - After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4776 Brake Caliper: Service and Repair Rear 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. - 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 dirt and other foreign particles. - Replace parts with new ones as specified in the illustration. - Make sure no dirt or other foreign matter gets in 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. - Always use Honda DOT3 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. - Coat the piston, piston seal groove, and caliper bore with clean brake fluid. - Replace all rubber parts with new ones. - After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Standards and Service Limits Brake Pad: Specifications Brake pads Thickness Front Standard or new 11.0 mm Service limit 1.6 mm Rear Standard or new 9.0 mm Service limit 1.0 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Standards and Service Limits > Page 4781 Brake Pad: Specifications Brakes Type of service brake Front Power-assisted self-adjusting ventilated disc Rear Power-assited self-adjusting solid disc Type of parking brake Mechanical actuating, rear wheels Pad friction surface area Front 42 cm2 x 2 Rear 21 cm2 x 2 Shoe friction surface area Rear 49.0 cm2 x 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Pads Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the front of the vehicle, and make sure it is securely supported. 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 pads as a set. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection > Front > Page 4784 Brake Pad: Testing and Inspection Rear Rear Brake Pads Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Check the thickness of the inner (A) and outer pads (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Pads Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Remove the flange bolt (A). NOTE: The pad springs are installed on the pads to prevent brake drag. Be careful when pivoting up the caliper body fully, or the spring could be flipped out of the position. 2. Pivot the caliper slightly so the pads do not come out of position, and hold the pads on both sides firmly with your fingers. Remove the pad springs (A) from the pads. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4787 3. Pivot the caliper up out of the way, and remove the pads (A). 4. Remove the pad shims (B). 5. Check the hose and pin boots for damage and deterioration. 6. Remove the pad retainers (A). 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 Dow Corning Molykote M77 grease to both sides of the pad shim (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 11. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4788 12. Push in the piston (A) so the caliper will fit over the 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. Hold the pads on both sides firmly with your fingers, and install the new pad springs (A) on the pads. Holding the pads, set the caliper over the pads by pivoting if down slowly. NOTE: Insert the pad spring ends into the pad installation holes securely. 14. Pivot the caliper (A) down into position. Be careful not to damage the pin boots. 15. Install the flange bolt (B), and tighten it to the specified torque. 16. 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 have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 17. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4789 Brake Pad: Service and Repair Rear Rear Brake Pads Inspection and Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Replacement 1. Hold the pins (B) with a wrench, being careful not to damage the pin boots. Remove the caliper bolts (A), and remove the caliper (C) from the caliper bracket. 2. Remove the pad shims (A) and pads (B). 3. Remove the pad retainers (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4790 4. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 5. Check the brake disc for damage and cracks. 6. Install the pad retainers. 7. Apply Dow Corning Molykote M77 grease to both sides of the pad shims (A), the back of the pads (B), and the other areas indicated by the arrows. Wipe excess grease off the shim. Contaminated brake discs and pads reduce stopping ability. Keep grease off the discs and pads. 8. Install the brake pads and pad shims correctly. Install the pads with the wear indicators (C) on the inside. If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 9. Push in the piston (A) so that the caliper will fit over the pads. Check the brake fluid level. The brake fluid may overflow if the reservoir is too full. Make sure that the piston boot is in position to prevent damaging it when installing the caliper. 10. Apply Dow Corning Molykote M77 grease to the piston edges (B) on their mating surfaces against the inner pad shim. 11. Install the brake caliper (C) and caliper bolts (D), and torque them to the specified torque while holding the pin (E). Be careful not to damage the pin boots. 12. Press the brake pedal several times to make sure the brakes work, then test-drive. NOTE: Engagement of the brake may require a greeter pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 13. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4795 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4796 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4797 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4798 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4799 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4800 Brake Rotor/Disc: Specifications Brake disc Thickness Front Standard or new 23.0 mm Service limit 21.0 mm Rear Standard or new 9.0 mm Service limit 7.0 mm Runout Front Service limit 0.10 mm Rear Service limit 0.10 mm Parallelism Front and rear Service limit 0.015 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front Disc Brake Rotor Brake Rotor/Disc: Testing and Inspection Front Disc Brake Rotor Front Brake Disc Inspection Runout 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake pads. 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly, and remove all rust. 4. Install suitable flat washers (A) and wheel nuts, and tighten the nuts to the specified torque to hold the brake disc securely against the hub. 5. Set up the dial gauge against the brake disc as shown, and measure the runout at 10 mm (0.4 inch) from the outer edge of the disc. Brake Disc Runout: Service Limit: 0.10 mm (0.004 inch) 6. If the disc is beyond the service limit, refinish the brake disc. Maximum Refinish Limit: 21.0 mm (0.83 inch) NOTE: If the brake disc is beyond the service limit for refinishing, replace it. - A new disc should be refinished if its runout is greater than 0.10 mm (0.004 inch). Thickness and Parallelism 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake pads. 3. Using a micrometer, measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 inch) in from the outer edge of the disc. 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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Front Disc Brake Rotor > Page 4803 Brake Rotor/Disc: Testing and Inspection Rear Disc Brake Rotor Rear Brake Disc Inspection Runout 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Remove the brake pads. 3. Inspect the disc surface for damage and cracks. Clean the disc thoroughly and remove all rust. 4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial indicator (B) as shown, and measure the runout at 10 mm (0.4 inch) from the outer edge of the disc. 5. If the disc is beyond the service limit, refinish the brake disc. Maximum Refinishing Limit: 8.0 mm (0.31 inch) NOTE: A new disc should be refinished if its runout is greater than 0.10 mm (0.004 inch). Thickness and parallelism 1. Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported. Remove the rear wheels. 2. Remove the brake pads. 3. Using a micrometer (A), measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 inch) in from the outer edge of the disc. 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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Fluid type Honda DOT3 brake fluid Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications > Page 4808 Brake Bleeding: Service and Repair Brake System Bleeding NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. - Do not reuse the drained fluid. - Always use Honda DOT3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A). 2. Slide a piece of clear plastic hose over the first bleed screw, and submerge the other end in a container of new brake fluid. 3. Have someone slowly pump the brake pedal several times, then apply steady pressure. 4. Loosen the left-front brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 5. Repeat the procedure for each wheel in the sequence shown until air bubbles no longer appear in the fluid. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications > Page 4809 6. Refill the master cylinder reservoir to the MAX (upper) level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise Brake Caliper: Technical Service Bulletins Brakes - Rear Brake Grinding Noise 04-006 April 16, 2004 Applies To Grinding Noise From Rear Brakes (Supersedes 04-006, dated February 20, 2004) Updated information is shown with asterisks and black bars. SYMPTOM A grinding noise from the rear brakes PROBABLE CAUSE Corrosion between the rear caliper bracket and the pad retainers. CORRECTIVE ACTION Clean the caliper bracket, and apply lubricant between the caliper bracket and the pad retainers. REQUIRED MATERIALS M-77 Assembly Paste: P/N 08798-9010, H/C 4503793 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. *Operation Number: 411003* Flat Rate Time: 0.7 hour Failed Part: P/N 43244-SG0-003 *H/C2590131* Defect Code: 00801 Symptom Code: 04213 *Template ID: 04-006A* 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. REPAIR PROCEDURE 1. Remove both rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise > Page 4814 2. Hold the caliper pins with a wrench, being careful not to damage the pin boots. Remove the caliper bolts and caliper body from the caliper bracket. 3. Remove the pads and pad retainers from the caliper bracket. 4. Remove any corrosion from the caliper bracket surfaces under the upper and lower pad retainers. NOTE: If the corrosion cannot be removed, replace the caliper assembly. 5. Apply M-77 Assembly Paste to the areas indicated by the arrows. 6. Clean the upper and lower pad retainers; remove any corrosion. NOTE: The upper and lower pad retainers are different; the lower one has two holes. Make sure you install the pad retainers correctly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Brakes - Rear Brake Grinding Noise > Page 4815 7. Install the upper and lower pad retainers. 8. Thoroughly clean the shims and the brake pad backing plates. Apply M-77 Assembly Paste to the brake pad backing plates and shims in the areas indicated by the arrows. Wipe off any excess paste; do not get any paste on the disc pad surfaces. 9. Install the pads in their original positions. 10. Install the caliper body on the caliper bracket, and torque the caliper bolts to 22 Nm (16 lb-ft). 11. Repeat steps 2 through 10 for the other rear caliper. 12. Install the rear wheels; torque the wheel nuts to 108 Nm (80 lb-ft). Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Diagrams > Front > Page 4818 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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. - When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency. - Do not reuse drained brake fluid. - Always use Honda DOT3 brake fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. - Do not mix different brands of brake fluid as they may not be compatible. - Coat the piston, piston seal groove, and caliper bore with clean brake fluid. - Make sure no grease or oil gets on the brake discs or pads. - Replace all rubber parts with new ones whenever disassembled. - After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4821 Brake Caliper: Service and Repair Rear 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. - 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 dirt and other foreign particles. - Replace parts with new ones as specified in the illustration. - Make sure no dirt or other foreign matter gets in 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. - Always use Honda DOT3 Brake Fluid. Non-Honda brake fluid can cause corrosion and shorten the life of the system. - Coat the piston, piston seal groove, and caliper bore with clean brake fluid. - Replace all rubber parts with new ones. - After installing the caliper, check the brake hose and line for leaks, interference, and twisting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4825 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4826 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations 23. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4830 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4831 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Hoses and Lines Inspection 1. Inspect the brake hoses, for damage, deterioration, leaks, interference, and twisting. 2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. 3. Check for leaks at hose and line joints or connections, and retighten if necessary. 4. Check the master cylinder and ABS modulator unit (if equipped) for damage and leakage. NOTE: Replace the brake hose clip whenever the brake hose is serviced. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Page 4835 Brake Hose/Line: Service and Repair Brake Hose Replacement NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off immediately with water. - To prevent dripping, cover disconnected line joints with rags or shop towels. - Before reassembling, check that all parts are free of dust and other foreign particles. - Replace parts with new ones whenever specified to do so. 1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks. 2. Disconnect the brake hose from the brake line (B) using a 10 mm flare nut wrench (C). 3. Remove the flange bolt (A), and remove the brake hose brackets from the damper. 4. Remove and discard the hose clip (B). 5. Remove the banjo bolt (C), and remove the brake hose from the caliper. 6. Install the brake hose bracket (A) on the damper with the flange bolt (B) first, then connect the brake hose to the caliper with the banjo bolt (C) and new sealing washers (D). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Page 4836 7. Install the hose onto the hose bracket on the body with a new hose clip (A). 8. Connect the brake line to the brake hose. 9. After installing the brake hose, bleed the brake system. 10. Do the following checks: - Check the brake hose and line joint for leaks, and tighten if necessary. - Check the brake hoses for interference and twisting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations 3. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 4840 (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Locations > Page 4841 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. - Take care not to damage or deform the bake 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 47P connector (B), then disconnect the connector. 3. Disconnect the six brake lines. 4. Remove the ABS modulator-control unit / bracket (C/D) from the body. 5. Remove the two 6mm shoulder bolts and the 6mm bolt from the bracket, then remove the ABS modulator-control unit from the bracket. Installation 1. Install the ABS modulator-control unit on the bracket, then tighten the two 6mm shoulder bolts and the 6mm bolt. 2. Install the ABS modulator-control unit/bracket on the body. 3. Align the connecting surface of the ABS control unit 47P connector. 4. Push in the lock of the ABS control unit 47P connector, then the connector. 5. Connect the six brake lines. 6. Bleed the brake system, starting with the front wheels. 7. Start the engine, and check that the ABS indicator and the brake system indicator go off. 8. Disconnect the Honda PGM tester. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master cylinder Piston-to-pushrod clearance 0 - 0.4 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 4845 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal/Installation Brake Master Cylinder: Service and Repair Removal/Installation 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. Release the engine wire harness clips on the strut brace (A), and remove the strut brace. With M/T: Remove the clutch reservoir bracket from the strut brace, and move it aside. Do not disconnect the clutch hose from the reservoir. 2. Remove the reservoir cap and brake fluid from the master cylinder reservoir. 3. Remove the brake fluid level sensor connector (A). 4. Disconnect the brake lines (B) from the master cylinder (C). To prevent spills, cover the hose joints with rags or shop towels. 5. Remove the master cylinder mounting nuts (D) and washers. 6. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. 7. Remove the rod seal (F) from the master cylinder. 8. Install the master cylinder in the reverse order of removal, and note these items: - Replace all the rubber parts with new ones whenever the master cylinder is removed. - Check the pushrod clearance before installing the master cylinder, and adjust it if necessary. - Use a new rod seal on reassembly. - Coat the inner bore lip and outer circumference of the new rod seal with the recommended seal grease in the master cylinder set. - Install the rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. - Check the brake pedal height and free play after installing the master cylinder, and adjust it if necessary. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal/Installation > Page 4848 Brake Master Cylinder: Service and Repair Bleeding the Master Cylinder For further information regarding this component and the system that it is a part of, please refer to Brake Bleeding; Service and Repair. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 4853 Parking Brake Cable: Service and Repair Parking Brake Cable Replacement 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. Raise the rear of the vehicle, and make sure it is securely supported. 2. Release the parking brake lever fully. Move the driver's seat all the way forward. 3. Pull back the carpet under the driver's seat. Remove the screw and bolt for the parking brake equalizer cover (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 4854 4. Remove the return spring (A). 5. Back off the adjusting nut (A) in the equalizer, and disconnect the parking brake cable ends (B) from the equalizer. 6. Remove the cable guide base (C). 7. Remove the rear brake shoes, and disconnect the parking brake cable from the shoe. 8. Remove the flange bolts (A) and parking brake cable (B) from the backing plate (C). 9. Reinstall the parking brake cable in the reverse order of removal, and note these items. - Be careful not to bend or distort the cable. - Do the major parking brake adjustment. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications Parking Brake Drum: Specifications Parking brake Brake drum I.D. Standard or new 170 mm Service limit 171 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 4858 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 4859 Parking Brake Drum: Testing and Inspection Parking Brake Drum 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. 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Release the parking brake, and remove the rear brake caliper and disc/drum. 3. Check the parking brake linings (A) for cracking, glazing, wear, and contamination. 4. Measure the parking brake lining thickness (B). Measurement does not include brake shoe thickness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 4860 Parking brake lining thickness: Standard: 3.2 mm (0.126 inch) Service limit: 1.0 mm (0.04 inch) 5. If the brake lining thickness is less than the service limit, replace all the parking brake shoes as a set. 6. Check the bearings in the hub unit for smooth operation. 7. Measure the inside diameter of the parking brake drum with inside vernier calipers. 8. If the inside diameter of the parking brake drum is more than service limit, replace the rear brake disc/drum. 9. Check the parking brake drum for scoring, grooves, and cracks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking brake lever Distance travelled when lever pulled with 196 N (20 kgf, 44 lbs.) of force 5 - 9 clicks Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications Parking brake Brake shoe lining thickness Standard or new 3.2 mm Service limit 1.0 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4867 Parking Brake Shoe: Testing and Inspection Parking Brake Drum 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. 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Release the parking brake, and remove the rear brake caliper and disc/drum. 3. Check the parking brake linings (A) for cracking, glazing, wear, and contamination. 4. Measure the parking brake lining thickness (B). Measurement does not include brake shoe thickness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4868 Parking brake lining thickness: Standard: 3.2 mm (0.126 inch) Service limit: 1.0 mm (0.04 inch) 5. If the brake lining thickness is less than the service limit, replace all the parking brake shoes as a set. 6. Check the bearings in the hub unit for smooth operation. 7. Measure the inside diameter of the parking brake drum with inside vernier calipers. 8. If the inside diameter of the parking brake drum is more than service limit, replace the rear brake disc/drum. 9. Check the parking brake drum for scoring, grooves, and cracks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4869 Parking Brake Shoe: Service and Repair Parking Brake Shoes Replacement CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles - Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Disassembly 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Release the parking brake, and remove the rear brake caliper and brake disc/drum. 3. Disconnect and remove the upper return springs (A). 4. Remove the tension pins (A) by pushing the retainer springs (B) and turning the pins. 5. Disconnect the rod spring (A), and remove the connecting rod (B). 6. Lower the parking brake shoe assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4870 7. Remove the forward brake shoe by removing the lower return spring (A) and adjuster assembly (B). 8. Remove the rearward brake shoe by disconnecting the parking brake cable (A) from the parking brake lever (B). 9. Remove the U-clip (A), wave washer (B), parking brake lever (C), and pivot pin (D) from the brake shoe. Reassembly Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4871 1. Apply Molykote 44 MA grease to the sliding surface of the pivot pin (A), and insert the pin into the rearward brake shoe (B). 2. Install the parking brake lever (C) and wave washer (D) on the pivot pin, and secure with a new U-clip (E). - Install the wave washer with its convex side facing out. - Pinch the U-clip securely to prevent the pivot pin from coming out from the brake shoe. 3. Connect the parking brake cable (A) to the parking brake lever (B). Apply silicone grease to the cable contact surface (C) on the backing plate. 4. Apply Molykote 44 MA grease to the shoe ends (A), sliding surfaces (B), and opposite edges of the parking brake shoe (C) as shown. Wipe off Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4872 any excess. Don't get grease on the brake linings. 5. Clean the threaded portions of clevis A, and coat the threads of the clevis with grease. Clean the sliding surface of clevis B. and coat the sliding surface of clevis B with grease. Install clevises A and B on the adjuster (C), and shorten clevis A by turning the adjuster. 6. Reinstall the brake shoe adjuster assembly (D), and hook the lower return spring (E) on the parking brake shoes. 7. Hook the rod spring (A) to the connecting rod (B) first with the spring end pointing downward. Then hook the rod spring to the parking brake shoe , and install the connecting rod on the parking brake shoes. 8. Reinstall the tension pins (A) and retainer springs (B). Make sure the tension pin does not contact the parking brake lever. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4873 9. Reinstall the upper return springs (A). 10. Install the rear brake disc/drum and rear brake caliper. 11. Do the major adjustment for the parking brake. Parking Brake Shoe Lining Break-in NOTE: Break-in the parking brake shoe linings after replacing the shoes or the rear brake disc/drum. WARNING: Do this operation in a safe area. 1. Park the vehicle on a firm, level surface. 2. Do the major parking brake adjustment. 3. Do the minor parking brake adjustment. 4. Drive the vehicle at no more than 31 mph (50 km/h). 5. Pull the parking brake lever two to four clicks while driving the vehicle for 400 m (1/4 mile). 6. Stop the vehicle, and release the parking brake lever for 5 - 10 minutes to allow the drums to cool. Repeat steps 4 through 6 three more times. 7. Do the major parking brake adjustment. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4877 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4878 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake booster pushrod clearance adjustment Clearance 0 - 0.4 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4883 Vacuum Brake Booster: Testing and Inspection Brake Booster Test Functional Test 1. With the engine stopped, press the brake pedal several times to deplete the vacuum reservoir, then press the pedal hard, and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, proportioning control valve, or calipers) is leaking. 2. Start the engine with the pedal pressed. If the pedal sinks slightly, the vacuum booster is working properly. If the pedal height does not vary, the booster or check valve is faulty. 3. With the engine running, press the brake pedal lightly. If the brake pedal sinks more than 10 mm (3/8 inch) in 3 minutes, the master cylinder is faulty. A slight change in pedal height when the A/C compressor cycles on and off is normal. (The A/C compressor load changes the vacuum available to the booster.) Leak Test 1. Press the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while pressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty. 2. With the engine stopped, press the brake pedal several times using normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, the pedal height should gradually rise. If the pedal position does not vary, check the booster check valve. 3. Disconnect the brake booster vacuum hose (check valve built-in) 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 and check valve, and retest. 6. Turn the ignition switch OFF, and wait 30 seconds. Press the brake pedal several times using normal pressure. When the pedal is first pressed, it should below. On consecutive applications, the pedal height should gradually rise. - If the pedal position does not vary, replace the brake booster. - If the pedal position varies, replace the brake booster vacuum hose/check valve assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4884 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 mm Hg, 30 inch Hg) to the booster's engine vacuum supply, and maintain an engine speed that will deliver 66 kPa (500 mm Hg, 20 inch Hg) vacuum. 5. With a feeler gauge (A), measure the clearance between the gauge body and the adjusting nut (B) as shown. If the clearance between the gauge body and the adjusting nut is 0.4 mm (0.02 inch), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and the adjusting nut is 0 mm, the pushrod-to-piston clearance is 0.4 mm (0.02 inch) or more. Therefore it must be adjusted and rechecked. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4885 6. If the clearance is incorrect, loosen the star locknut (A), and turn the adjuster (B) in or out to adjust. - Adjust the clearance while the specified vacuum is applied to the booster. - Hold the clevis (C) while adjusting. 7. Tighten the star locknut securely. 8. Remove the special tool (D). 9. Check the pushrod length (A) as shown if the booster is removed. If the length is incorrect, loosen the pushrod locknut (B), and turn the clevis (C) in or out to adjust. 10. Install the master cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4886 Vacuum Brake Booster: Service and Repair Brake Booster Replacement 1. Remove the master cylinder. 2. Remove the air cleaner assembly (A). 3. Remove the master cylinder brake lines (A) from the brake line clip. 4. Disconnect the vacuum hose (B) from the brake booster. 5. Remove the clip (A) and the joint pin (B), and disconnect the yoke from the brake pedal. 6. Remove the brake booster mounting nuts (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4887 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 bent 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 clip whenever installing. - After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 4895 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. - Take care 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. Disconnect negative cable from the battery. 3. Pull up the lock (A) of the ABS control unit 47P connector (B), then disconnect the connector. 4. Disconnect the six brake lines. 5. Remove the ABS modulator-control unit /bracket (C/D) from the body. 6. Remove the two 6 mm shoulder bolts and 6 mm bolt from the bracket, then remove the ABS modulator-control unit from the bracket. Installation 1. Install the ABS modulator-control unit on the bracket, then tighten the two 6 mm shoulder bolts and 6 mm bolt. 2. Install the ABS modulator-control unit/bracket on the body. 3. Align the connecting surface of the ABS control unit 47P connector. 4. Push in the lock of the ABS control unit 47P connector, then connect the connector. 5. Connect the six brake lines. 6. Bleed the brake system, starting with the front wheels. 7. Start the engine, and check that the ABS indicator and brake system indicator go off. 8. Test-drive the vehicle, and check that the ABS indicator and brake system indicator do not come on. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations 23. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4900 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4901 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations 46. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4905 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4906 Braking Sensor/Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4907 Braking Sensor/Switch: Adjustments Brake Pedal and Brake Pedal Position Switch Adjustment Pedal Height 1. 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. At the insulator cutout, measure the pedal height (B) from the middle of the pedal pad (C). 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Page 4908 4. 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 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. 5. Check the brake pedal free play. Pedal Free Play 1. With the engine off, inspect the play (A) on the pedal pad (B) by pushing the 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4912 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4913 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel sensor Standard Front/Rear 0.5 - 1.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4917 Wheel Speed Sensor: Locations 138. Left Side of Engine Compartment 143. Right Side of Engine Compartment 145. Under Left Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4918 148. Under Right Rear of Vehicle Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4919 Wheel Speed Sensor: Diagrams (EX; Canada: EX-L) (EX; Canada: EX-L) (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4920 (EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4921 Wheel Speed Sensor: Description and Operation Wheel Sensors The wheel sensors are the magnetic contact less type. The wheel sensors detect changing of magnetic polarity on the magnetic encoder. The ABS control unit calculates the wheel speed based on signals received from the wheel sensor. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure. The pump motor starts at this time. As the wheel speed is restored, the inlet valve opens momentarily to increase the caliper fluid pressure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4922 Wheel Speed Sensor: Testing and Inspection Wheel Sensor Inspection 1. Remove the appropriate front driveshaft or rear driveshaft. 2. Check the magnetic encoder after cleaning the encoder. If necessary, replace the encoder. 3. Measure the air gap between the wheel sensor and the magnetic encoder all the way around while rotating the encoder. Standard: Front/Rear: 0.5 - 1.5 mm (0.02 - 0.06 inch) Note: - Install the wheel brearing with the magnetic encoder (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Be carful not to damage the encoder surface when you insert them wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 4923 Wheel Speed Sensor: Service and Repair Wheel Sensor Replacement NOTE: Install the sensors carefully to avoid twisting the wires. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations 43. Under Left Side of Dash (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4929 Clutch Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 4930 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector (A). 2. Remove the clutch interlock switch (B). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4936 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4937 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4938 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4939 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4940 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4941 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4942 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4943 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4944 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 4945 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4949 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4954 Starter Relay: Testing and Inspection 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. Starter Cut Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair Jump Starting Jump Starting with an Auxiliary (Booster) Battery CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children. Jump Starting Procedure 1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the "PARK" position. If the vehicle is equipped with a manual transmission, place the shift lever in the "NEUTRAL" position. Turn "OFF" the ignition. Turn "OFF" all lights and any other accessory requiring electrical power. 2. Look at the built-in hydrometer. If the indication area of the built-in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned "OFF". 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 4959 Be sure to first disconnect the negative cable from the vehicle with the discharged battery. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Electrical - Battery Replacement Precautions > Page 4964 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations 13. Right Side of Engine Comp. (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Exploded Views Exploded View Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Exploded Views > Page 4971 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4972 Alternator: Description and Operation Alternator Control The alternator signals the ECM during charging. The ECM then controls the voltage generated at the alternator according to the electrical load determined by the ELD (Electrical Load Detector) and driving mode. This reduces engine load to improve fuel economy. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator and Regulator Circuit Test Alternator: Testing and Inspection Alternator and Regulator Circuit Test Alternator and Regulator Circuit Test 1. Be sure the battery is sufficiently charged and in good condition. 2. Raise the hoist to full height. 3. Hook up the ammeter, 0 - 400 A, to the starter sub-harness. 4. Lower the hoist. 5. Hook up the voltmeter, 0 - 20 V (accurate within 0.1 V), to T101. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or Neutral) until the radiator fan comes on then let it idle. 7. Raise the engine speed to 2,000 rpm, and hold it there. 8. Turn the headlights (high beam) on, and measure voltage at the under-hood fuse/relay box terminal. Is the voltage between 13.9 and 15.1 V? YES - Go to step 9. NO - Repair or replace the alternator. 9. Read the amperage at 13.5 V. NOTE: Adjust the voltage by turning the blower motor, rear window defogger, brake lights, etc. ON. Is the amperage 60 A or more? YES - Alternator/regulator operation is OK. NO - Repair or replace the alternator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator and Regulator Circuit Test > Page 4975 Alternator Control System Test 1. Check for proper operation of the electrical load detector(ELD) by checking the malfunction indicator lamp (MIL). 2. Disconnect the engine wire harness 8P connector from the starter sub-harness 8P connector. 3. Start the engine, and turn the headlights (high beam) ON. 4. Measure voltage between the engine wire harness 8P connector terminal No.3 and the positive terminal of the battery. Is there 1 V or less? YES - Go to step 8. NO - Go to step 5. 5. Turn the headlights and ignition switch OFF. 6. Disconnect the negative cable from the battery. 7. Disconnect engine control module (ECM)/ powertrain control module (PCM) connector B (24P). 8. Check for continuity between ECM/PCM connector terminal B18 and body ground. Is there continuity? YES - Repair short in the wire between the alternator and the ECM/PCM. NO - Check that the terminals are firmly seated at the connector. If OK, substitute a known-good ECM/PCM, and recheck. If the prescribed voltage is now available, replace the original ECM/PCM. 9. Turn the headlights and ignition switch OFF. 10. Disconnect ECM/PCM connector B (24P). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator and Regulator Circuit Test > Page 4976 11. Check for continuity between ECM/PCM connector terminal B18 and engine wire harness 8P connector terminal No.3. Is there continuity? YES - Repair or replace the alternator. NO - Repair open in the wire between the alternator and the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator and Regulator Circuit Test > Page 4977 Alternator: Testing and Inspection Alternator FR Signal Circuit Troubleshooting Alternator FR Signal Circuit Troubleshooting 1. Disconnect the alternator 4P connector. 2. Turn the ignition switch ON (II). 3. Measure voltage between ECM/PCM connector terminals A24 and B13. Is there about 5 V? YES - Go to step 4. NO - Go to step 14. 4. Turn the ignition switch OFF. 5. Reconnect the alternator 4P connector. 6. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on, then let it idle. 7. Measure voltage between ECM/PCM connector terminals A24 and B13. Does the voltage decrease when the headlights and rear window defogger are turned on? YES - The ALT FR signal is OK. NO - Go to step 8. 8. Turn the ignition switch OFF. 9. Disconnect the negative cable from the battery. 10. Disconnect ECM/PCM connector B (24P). 11. Disconnect the alternator 4P connector. 12. Connect alternator 4P connector terminal No.4 to body ground with a jumper wire. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Alternator and Regulator Circuit Test > Page 4978 13. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Test the alternator. NO - Repair open in the wire between the ECM/PCM (B13) and the alternator. 14. Turn the ignition switch OFF. 15. Disconnect the negative cable from the battery. 16. Disconnect ECM/PCM connector B (24P). 17. Check for continuity between body ground and ECM/PCM connector terminal B13. Is there continuity? YES - Repair short in the wire between the ECM/PCM (B13) and the alternator. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation Alternator: Service and Repair Removal and Installation Alternator Replacement 1. Disconnect the battery negative cable, then disconnect the positive cable. 2. Remove the bolt (A) securing the battery clamp, then remove the bulkhead cover (B). 3. Remove the upper brackets and cushions. 4. Remove the drive belt. 5. Remove the auto-tensioner. 6. Remove the three bolts securing the alternator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4981 7. Disconnect the alternator connector (A) and BLK wire (B), and remove the harness clamp (C) from the alternator. 8. Remove the alternator 9. Install the alternator and drive belt in the reverse order of removal. 10. Install the upper brackets and cushions, make sure they are set securely. 11. Connect the battery positive cable and negative cable to the battery. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4982 Alternator: Service and Repair Disassembly and Reassembly Alternator Overhaul Exploded View Exploded View Special Tools Required - Driver 07749-0010000 - Attachment, 52 x 55 mm 07746-0010400 NOTE: Refer to the Exploded View as needed during this procedure. 1. Test the alternator and regulator before you remove them. 2. Remove the alternator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4983 3. Remove the four through bolts 4. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (129 - 140 °F, 50 - 60 °C). 5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. NOTE: Be careful not to damage the stator with the tip of the screwdriver. 6. Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4984 7. If you are not replacing the front bearing and/or rear bearing, go to step 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut. 8. Remove the rotor using a puller as shown. 9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks. - If either the rotor or drive-end housing is damaged, replace the alternator. - If both the rotor and the drive-end housing are OK, goto step 10. 10. Remove the rear bearing using the puller as shown. 11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4985 12. Remove the front bearing retainer plate. 13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift and hammer. 14. With a hammer and the special tools, install a new front bearing in the drive-end housing. Alternator Brush Inspection Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4986 15. Measure the length of both brushes with a vernier caliper. - If either brush is shorter than the service limit, replace the rear housing assembly. - If brush length is OK, go to step 16. Rotor Slip Ring Test 16. Check that there is continuity between the slip rings (A). - If there is continuity, go to step 17. - If there is no continuity, replace the rotor assembly. 17. Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C). - If there is no continuity, replace the rear housing assembly, and go to step 18. - If there is continuity, replace the rotor assembly. Alternator Reassembly 18. If you removed the pulley, put the rotor in the drive- end housing, then tighten its locknut to 111 N.m (11.3 kgf.m, 81.7 lbf.ft). 19. Remove any grease or any oil from the slip rings. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 4987 20. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold them there. 21. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (129 140 °F, 50 - 60 °C). 22. Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten the four through bolts (C) and pull out the pin (D). 23. After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise. 24. Install the alternator and drive belt. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations 43. Under Left Side of Dash (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4992 Clutch Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 4993 Clutch Switch: Testing and Inspection Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector (A). 2. Remove the clutch interlock switch (B). 3. Check for continuity between the terminals according to the table. - If the continuity is not as specified, replace the clutch interlock switch. - If OK, install clutch interlock switch and adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Ignition Lock Solenoid > Component Information > Description and Operation Ignition Lock Solenoid: Description and Operation Interlock System (A/T) How the Circuit Works Key Interlock When you push the key into the ignition switch, a ground signal is provided to the multiplex control unit. If the shift lever is in PARK, the multiplex control unit provides voltage to the key interlock solenoid, energizing the solenoid and allowing the key to be turned to the LOCK (0) position. Shift Position Interlock Battery voltage is supplied at all times through fuse 7 to the brake pedal position switch. With the ignition in ACC (I) or ON (II), battery voltage is supplied through fuse 8 (in the under-dash fuse/relay box) to the shift lock solenoid. When you push the brake pedal, battery voltage is applied through the WHT/BLK wire to the PCM. If, at the same time, you do not push the accelerator pedal, a low voltage signal is sent through the WHT/BLU wire to the multiplex control unit. The multiplex control unit then applies ground through the YEL/BLK wire to the shift lock solenoid. The solenoid is then energized allowing the shift lever to be moved from the PARK position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5003 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5004 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5005 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5006 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5007 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5008 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5009 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5010 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5011 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5012 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations 138. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5020 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Clicking Or Ratcheting Noise On Hard Right Turn Starter Motor: Technical Service Bulletins Clicking Or Ratcheting Noise On Hard Right Turn SOURCE: Honda Service News May 2004 TITLE: Clicking or Ratcheting Noise on Hard Right Turns APPLIES TO: 2002-04 CR-V, 2003-04 Accord SERVICE TIP: A faulty starter motor can cause a clicking or ratcheting noise when turning hard right. This noise can easily be mistaken for a tranny noise. To properly identify this noise, hook up a STEELMAN(R) ChassisEAR(R) diagnostic tool (T/N JSP-SM06600) to the starter motor, and test drive the vehicle. If the noise is loudest at the starter, replace the starter motor. STEELMAN(R) and ChassisEAR(R) are registered trademarks of J.S. Products, Inc. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 5025 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 5026 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Circuit Troubleshooting Starter Motor: Testing and Inspection Starter Circuit Troubleshooting Starter Circuit Troubleshooting NOTE: - Air temperature must be between 590 and 100 °F (150 and 38 °C) during this procedure. - After this test, or any subsequent repair, reset the engine control module (ECM)/powertrain control module (PCM) to clear any diagnostic trouble codes (DTCs). - The battery most be in good condition and fully charged. Recommended Procedure: - Use a starter system tester. - Connect and operate the equipment in accordance with the manufacturer's instructions. Alternate Procedure 1. Hook up the following equipment: - Ammeter, 0 - 400 A - Voltmeter, 0 - 20 V (accurate within 0.1 volt) - Tachometer, 0 - 1200 rpm 2. Remove the No.6 (15A) fuse from the under-hood fuse/relay box. 3. With the shift lever in [N] or [P] (A/T) or clutch pedal pressed (M/T), turn the ignition switch to start (III). Did the starter crank the engine normally? YES - The starting system is OK. NO - If starter will not crank the engine at all, go to step 4. If it cranks the engine erratically or too slowly, go to step 7. If it won't disengage from the flywheel or torque converter ring gear when you release the key, check for the following until you find the cause. Solenoid plunger and switch malfunction - Dirty drive gear or damaged overrunning clutch 4. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables and the starter for looseness and corrosion Then try starting the engine again. Did the starter crank the engine? YES - Repairing the loose connection repaired the problem. The starting system is OK. NO - Go to step 5. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Circuit Troubleshooting > Page 5029 5. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire (A) from the starter solenoid (B). Connect a jumper wire from the battery positive terminal to the solenoid terminal. Did the starter crank the engine? YES - Go to step 6. NO - Remove the starter, and repair or replace as necessary. 6. Check the following items in the order listed until you find the open circuit. - Check the BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter. - Check the ignition switch. - Check the transmission range switch and connector (A/T) or the clutch interlock switch and connector (M/T). - Check the starter cut relay. 7. Check the engine speed while cranking the engine. Is the engine speed above 100 rpm? YES - Go to step 8. NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause. Excessively worn starter brushes - Open circuit in commutator brushes - Dirty or damaged helical splines or drive gear - Faulty drive gear clutch 8. Check the cranking voltage and current draw. Is cranking voltage greater than or equal to 8.5 V and current draw less than or equal to 380 A? YES - Go to step 9. NO - Replace the starter, or remove and disassemble it, and check for the following until you find the cause. Open circuit in starter armature commutator segments - Starter armature dragging - Shorted armature winding - Excessive drag in engine 9. Remove the starter, and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Starter Circuit Troubleshooting > Page 5030 Starter Motor: Testing and Inspection Starter Performance Test Starter Performance Test 1. Disconnect the wire from the S terminal. 2. Make the connections 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. If the starter pinion moves out, it is working properly. 4. Disconnect the battery from the body. If the pinion retracts immediately, it is working properly. 5. Clamp the starter firmly in a vise. 6. Connect the starter to the battery as shown, and confirm that the motor starts and keeps rotating. 7. If the electric current and motor speed meet the specifications when the battery voltage is at 11.5 V, the starter is working properly. Specifications: Electric current: 80 A or less Motor speed: 2,300 rpm or more Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly Starter Motor: Service and Repair Disassembly and Reassembly Starter Overhaul Disassembly/Reassembly Armature Inspection and Test 1. Remove the starter. 2. Disassemble the starter as shown at the beginning of this procedure. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5033 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature. 4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B). 5. Check the commutator diameter. If the diameter is below the service limit, replace the armature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5034 6. Measure the commutator (A) runout. - If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. - If the commutator runout is not within the service limit, replace the armature. 7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D). 8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5035 9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature. 10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature. Starter Brush Inspection 11. Measure the brush length. If it is not within the service limit, replace the brush holder assembly. Starter Brush Holder Test Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5036 12. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is continuity, replace the brush holder assembly. Planetary Gear Inspection 13. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged. Overrunning Clutch Inspection 14. Holding the drive gear (A), turn the gear shaft (B) clockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover assembly. 15. Holding the drive gear, turn the gear shaft counterclockwise. The gear shaft should rotate freely. If the gear shaft does not rotate smoothly, replace the gear cover assembly. 16. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel or torque converter ring gear. Replace it if the starter drive gear teeth are damaged. Starter Reassembly Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5037 17. Install the brush into the brush holder, and set the armature (A) in the brush holder (B). NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator. 18. Squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E and F). 19. Install the armature and brush holder assembly into the housing. NOTE: Make sure the armature stays in the holder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Reassembly > Page 5038 Starter Motor: Service and Repair Removal And Installation Starter Replacement 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable. 3. Disconnect the knock sensor connector. 4. Disconnect the bolt securing the harness bracket. 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 battery positive cable and negative cable to the battery. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5042 Starter Relay: Testing and Inspection 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. Starter Cut Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations 14. Front of Engine (Intake Removed) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 5046 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Electrical - Auxiliary Power Socket Overload Auxiliary Power Outlet: Technical Service Bulletins Electrical - Auxiliary Power Socket Overload Dead Power Socket? Keep Electrical Load Below Max NOTE: This article applies to Japan-built 03-06 Accords, '05-06 Civic Hybrids, '02-6 CR-Vs, and '04-06 Insights. The accessory power socket is made to handle a maximum electrical load of 120 watts (10 amps). Exceed that limit over a period of time, and the socket could overheat and cause an open circuit. If you've got a vehicle in your shop with a dead accessory power socket, check for continuity between the center contact and the wire terminal. If you find an open circuit, remind your service customer to keep the electrical load below 120 watts or the problem could wind up happening again. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Page 5052 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Auxiliary Power Outlet: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Auxiliary Power Outlet: Electrical Diagrams Diagram 155 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5086 Auxiliary Power Outlet: Testing and Inspection Accessory Power Socket Test/Replacement Front: 1. Carefully pry the accessory power socket (A) out from the left rear side trim panel. 2. Disconnect the 2P connector (A) 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 to 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 (15A) fuse in the under-dash fuse/relay box. Rear: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5087 1. Carefully pry the accessory power socket (A) out from the left rear side trim panel. 2. Disconnect the 2P connector (A) 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 to 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 (G451, G601, G701). - an open in the wire. - blown No.18 (15A) fuse in the under-dash fuse/relay box. - blown No.2 (10 A) fuse in the under-dash fuse/relay box. - faulty rear accessory power socket relay. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Page 5091 Electronic Noise Suppressor: 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 measure the condenser capacity. 4. If not within the specifications, replace the noise condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 5096 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 5097 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse: Connector Views (Honda Accessory) (Honda Accessory) (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5102 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5103 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5108 Fuse Block: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5109 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5112 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5113 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5115 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5116 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5117 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and the under-dash fuse/relay box (A). 6. Disconnect the 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 dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams Multiple Junction Connector: Diagrams (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 5121 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5124 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5125 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5126 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5127 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5128 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5129 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5130 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5131 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5132 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5133 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5134 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5135 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5136 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5137 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5138 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5144 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5145 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5146 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5147 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5148 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5149 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5151 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5154 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5159 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5160 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5161 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5162 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5163 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5164 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5165 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5166 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5169 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Electrical - Auxiliary Power Socket Overload Auxiliary Power Outlet: Technical Service Bulletins Electrical - Auxiliary Power Socket Overload Dead Power Socket? Keep Electrical Load Below Max NOTE: This article applies to Japan-built 03-06 Accords, '05-06 Civic Hybrids, '02-6 CR-Vs, and '04-06 Insights. The accessory power socket is made to handle a maximum electrical load of 120 watts (10 amps). Exceed that limit over a period of time, and the socket could overheat and cause an open circuit. If you've got a vehicle in your shop with a dead accessory power socket, check for continuity between the center contact and the wire terminal. If you find an open circuit, remind your service customer to keep the electrical load below 120 watts or the problem could wind up happening again. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Technical Service Bulletins > Page 5175 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Auxiliary Power Outlet: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Auxiliary Power Outlet: Electrical Diagrams Diagram 155 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5209 Auxiliary Power Outlet: Testing and Inspection Accessory Power Socket Test/Replacement Front: 1. Carefully pry the accessory power socket (A) out from the left rear side trim panel. 2. Disconnect the 2P connector (A) 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 to 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 (15A) fuse in the under-dash fuse/relay box. Rear: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5210 1. Carefully pry the accessory power socket (A) out from the left rear side trim panel. 2. Disconnect the 2P connector (A) 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 to 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 (G451, G601, G701). - an open in the wire. - blown No.18 (15A) fuse in the under-dash fuse/relay box. - blown No.2 (10 A) fuse in the under-dash fuse/relay box. - faulty rear accessory power socket relay. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Page 5214 Electronic Noise Suppressor: 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 measure the condenser capacity. 4. If not within the specifications, replace the noise condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box Fuse: Locations Under-Dash Fuse/Relay Box Under-dash Fuse/Relay Box Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 5219 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Under-Dash Fuse/Relay Box > Page 5220 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Connector Views Fuse: Connector Views (Honda Accessory) (Honda Accessory) (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5225 Under-dash Fuse/Relay Box Part 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5226 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5231 Fuse Block: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5232 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5235 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5236 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5237 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5238 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5239 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5240 Fuse Block: Service and Repair Removal and Installation SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. Removal 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least 3 minutes. 3. Remove the dashboard lower cover. 4. Disconnect the connectors from the fuse side of the under-dash fuse/relay box. 5. Remove the mounting bolt and the under-dash fuse/relay box (A). 6. Disconnect the 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 dashboard lower cover. 3. Connect both the negative cable and positive cable to the battery. 4. Enter the anti-theft code for the radio, then enter the customer's radio station presets. 5. Confirm that all systems work properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams Multiple Junction Connector: Diagrams (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 5244 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5247 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5248 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5249 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5250 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5251 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5252 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5253 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5254 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5255 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5256 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5257 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5258 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5259 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5260 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Service and Repair > How To Replace Connector Terminals > Page 5261 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5267 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5268 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5269 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5270 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5271 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5272 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5273 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5274 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5277 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations Relay Box: Component Locations 24. Left Side of Engine Compartment 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5282 Relay Box: Connector Locations 49. Under Left Side of Dash (Honda Accessory) 54. Under Left Side of Dash (A/T: Honda Accessory) 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 5283 56. Under Left Side of Dash (Honda Accessory) 57. Under Left Side of Dash (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5284 Relay Box: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5285 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5286 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5287 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5288 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5289 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Under-Dash Fuse/Relay Box > Page 5292 Under-hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5302 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5303 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5304 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5305 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5306 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5307 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5308 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5309 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5310 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5316 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5317 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5318 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5319 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5320 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5321 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5322 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5323 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5324 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5329 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative Expansion Valve: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5335 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5336 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5337 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5338 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5339 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5340 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5341 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5342 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5343 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5344 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5345 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5346 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5347 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5348 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5349 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5350 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5351 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5352 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5353 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5354 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5355 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5356 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5357 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5358 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5359 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5360 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5361 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5362 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5363 DIAGNOSTIC WORKSHEET REPAIR PROCEDURE A Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5364 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5365 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5366 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5367 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5368 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Alignment: Specifications Wheel alignment Camber Front 0 deg 00' +/- 45' Rear -1 deg 00' +/- 45' Caster Front 1 deg 45' +/- 1 deg Total Toe Front 0 +/- 2 mm Rear IN 2 [+2/-1] mm Front wheel turning angle Inside wheel 39 deg 45' +/- 2 deg Outside wheel 32 deg 30' (Reference) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment > Page 5371 Alignment: Specifications Trim Height Honda Motor Company does not list ride height/trim height specifications. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5372 Alignment: Service and Repair Wheel Alignment The suspension can be adjusted for front camber, front toe, and rear toe. However, each of these adjustments are interrelated to each other. For example, when you adjust toe, the camber changes. Therefore, you must adjust the front wheel alignment whenever you adjust camber or toe. Pre-Alignment Checks For proper inspection and adjustment of the wheel alignment, do these checks: 1. Release the parking brake to avoid an incorrect measurement. 2. Make sure the suspension is not modified. 3. Check the tire size and tire pressure. Tire size: Front/rear: 205/70R15 95S Tire pressure: Front/rear: 180 kPa (1.8 kgf/cm2, 26 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 manufacture's instructions. Check the caster angle. If the caster angle is not within the specification, check for bent or damaged suspension components. Front caster angle: 1°45' ± 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: 0°00' ± 45' Front Camber Adjustment The front camber can be adjusted by exchanging one or both of the damper pinch bolts with the smaller diameter adjusting bolt(s). The difference between the adjusting bolt diameter and the pinch bolt hole diameter allows a small range of adjustment. 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5373 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 nuts 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 make sure it is securely supported. 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 it, 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: -1°00'± 45' NOTICE: Do not loosen the special bolts on the trailing arm. Front Toe Inspection/Adjustment 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 ± 2 mm (0 ± 0.08 inch) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5374 3. Loosen the locknut (A) while holding the tie-rod end (B). 4. Turn the tie-rod arm (C) until the toe is correct. NOTE: Adjust both the right and left wheels at the same time by the same amount in opposite directions to obtain the correct toe and to keep the steering wheel straight. 5. After adjusting, tighten the locknut while holding the tie-rod arm. Make sure the toe setting does not change. Rear Toe Inspection/Adjustment 1. Release the parking brake. 2. Check the toe. If it is not within the specification, go to step 3. Rear toe-in: 2 [+2 -1] mm (0.08 [+0.08 -0.04] inch) 3. Loosen the self-locking nut (A) while holding the adjusting bolt (B). NOTICE: Do not loosen the special bolts (C) on the trailing arm. 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. 5. Turn the adjusting bolt until the toe is correct. Rear toe-in: 2 [+2 -1] mm (0.08 [+0.08 -1] 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5375 1. Turn the steering wheel fully to the right and left while applying the brakes, and check the turning angles of both front wheels. If the turning angle is not within the specification or the inward turning angles differ between the right and left side, go to step 2. 2. Check the toe. If it is correct, but the turning angle is not within the specification, check for bent or damaged suspension components. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5381 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5382 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5383 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5384 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5385 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications TORQUE SPECIFICATIONS Splash Guard Screw ............................................................................................................................ .......................................... 4.9 Nm (58.8 inch lbf.) Castle Nut ............................................................ ................................................................................................................... 49 - 59 Nm (36 - 43 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power steering fluid Capacity For fluid change ................................................................................................................................... ...................................... 0.26 L (0.27 US qt.) For system overhaul ..................................................... .............................................................................................................. 0.75 L (0.79 US qt.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 5395 Power Steering Fluid: Fluid Type Specifications Power steering fluid ........................................................................................................................................................... Use Honda Power Steering Fluid Do not use ATF Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5396 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 5397 Power Steering Fluid: Service and Repair Replacement Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather. 1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once. 2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. 3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid. 4. Reinstall the return hose on the reservoir. 5. Fill the reservoir to the upper level line (C}. 6. Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system. 7. Recheck the fluid level and add more if necessary. Do not fill the reservoir beyond the upper level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Replacement Note these items during installation: ^ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ^ Check all clamps for deterioration or deformation; replace the clamps with new ones if necessary. ^ Add the recommended power steering fluid to the specified level on the reservoir and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Pump Output pressure with shut-off valve closed 7,460 - 8,140 kPa Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5404 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Replacement 1. Place a suitable container under the vehicle. 2. Drain the power steering fluid from the reservoir. 3. Remove the drive belt (A) from the pump pulley. 4. Remove the pump mounting bolts (B). 5. Cover the auto-tensioner, alternator, and A/C compressor with several shop towels to protect them from spilled power steering fluid. Disconnect the pump inlet hose (C) and pump outlet hose (D) from the pump (E), and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once. Do not turn the steering wheel with the pump removed. 6. Cover the opening of the pump with a piece of tape to prevent foreign material from entering the pump. 7. Connect the pump inlet hose and pump outlet hose. 8. Loosely install the pump in the pump bracket with the mounting bolts, then tighten the pump fittings securely. 9. Install the drive belt (A). Note these item during belt installation: ^ Make sure that the belt is properly positioned on the pulleys (B). ^ Do not get power steering fluid or grease on the auto-tensioner, alternator, A/C compressor, and drive belt or pulley faces. Clean off any fluid or grease before installation. 10. Tighten the pump mounting bolts to the specified torque. 11. Fill the reservoir to the upper level line. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5407 Power Steering Pump: Service and Repair Overhaul Overhaul Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged. Special Tools Required ^ Attachment, 32 x 35 mm 07746-0010100 ^ Driver 07749-0010000 ^ Pulley holder 07ZAB-S5A0100 Disassembly NOTE: Refer to the Exploded View as needed during the following procedure. 1. Remove the power steering pump. 2. Drain the fluid from the pump. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5408 3. Hold the steering pump (A) in a vise with soft jaws, hold the pulley (B) with the special tool (C), and remove the pulley nut (D) and pulley. Be careful not to damage the pump housing with the jaws of the vise. 4. Remove the inlet joint and O-ring. 5. Remove the pressure control valve cap, O-ring, valve spring, and pressure control valve. 6. Remove the pump housing cap, O-ring, and pump preload spring. 7. Remove the pump cover and pump cover seals. 8. Pull out the roll pin. 9. Remove the outer case, cam ring, rotor, vanes, and side plate. 10. Remove the rubber seal and slipper seal from the outer case. 11. Remove the O-rings from the bottom of the housing. 12. Remove the snap ring, then remove the drive shaft by tapping the shaft end with the plastic hammer 13. Remove the seal from the pump housing. Inspection 14. Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve. 15. Inspect the bore of the pressure control valve on the pump housing for scratches and wear. 16. Slip the pressure control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 17; if not, replace the pump as an assembly. The pressure control valve is not available separately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5409 17. Attach a hose (A) to the end of the pressure control valve (B) as shown. Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and blow in the hose. ^ If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm2, 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately. ^ If the pressure control valve is OK, set it aside for reassembly later. 18. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B). 19. Inspect each part shown with an asterisk in the Exploded View; if any of them are worn or damaged, replace the pump as an assembly. Reassembly 20. Install the new pump seal (A) (with its grooved side facing in) into the pump housing (B) by hand first, then drive it in using the special tools until there is no step at the top of the pump seal, and the seal is fully seated in the pump housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5410 21. Position the pump drive shaft (A) in the pump housing, then press it in with the appropriate size socket wrench (B) as shown. Do not apply more than 1,370 N (140 kgf, 308 lbs.) of pressure. 22. Install the 40 mm snap ring (C) with its radiuses side facing out. 23. Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it on the bottom (B) of the pump housing. 24. Coat the new cover seals (A) and (B) with power steering fluid, then position them into the grooves on the cover (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5411 25. Install the outer case (A) by aligning the slot (B) inside the outer case with the cover roll pin hole (C). Be sure that the slit (D) on the outer case is to the direction shown. 26. Apply power steering fluid to the rubber seal (E) (black), and install it in the slot (F) of the outer case. 27. Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you just installed. 28. Install the cam ring (A) by aligning the slot (B) with the slot (C) in the outer case. 29. Insert the roll pin (D) into the slots between the cam ring and outer case, then push the roll pin into the set hole (E). 30. Install the rotor (A) in the cam ring (B). 31. Set the 11 vanes (C) in the grooves in the rotor. Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5412 32. Place the side plate (A) on the cam ring, and align the roll pin set hole (B) with the roll pin (C). 33. Coat the new O-ring (D) with the power steering fluid, then position it into the groove on the side plate. 34. Install the pump housing (A) over the cover assembly (B). 35. Align the bolt holes in the cover (A) with the threaded holes in the pump housing. Install the flange bolts loosely first, then torque the flange bolts in a cries-cross pattern in two or more steps. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5413 36. Push in the cam ring (A) from the pump housing cap hole (B) with a flat-tip screwdriver to make sure the cam ring is fully seated against the outer case. 37. Install the pump preload spring (A) in the pump housing. 38. Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C). 39. Install the pump housing cap on the pump housing, and tighten it to specified torque. 40. Install the pressure control valve spring (A) in the pump housing. 41. Coat the pressure control valve (B) with power steering fluid, and install it in the pump housing. 42. Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the pressure control valve cap (D). 43. Install the pressure control valve cap on the pump housing, and tighten it to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5414 44. Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B). 45. Install the inlet joint on the pump housing. 46. Install the pulley (A), then loosely install the pulley nut (B). Hold the steering pump in a vise with soft jaws. Be careful not to damage the pump housing with the jaws of the vise. 47. Hold the pulley with the special tool, and tighten the pulley nut to the specified torque. 48. Check that the pump turns smoothly by turning the pulley. If it turns hard, loosen the four flange bolts on the cover, then retighten them as in step 35, and check the pump again. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Idle Control System - Component Location Index 12. Rear of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5419 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5420 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch The PSP switch signals the ECM/PCM when the power steering load is high. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5421 Power Steering Pressure Switch: Testing and Inspection PSP Switch Signal Circuit Troubleshooting 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Go to step 3 NO - Go to step 6. 3. Start the engine. 4. Turn the steering wheel to the full lock position. 5. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - The PSP switch signal is OK. NO - Go to step 13. 6. Turn the ignition switch OFF. 7. Disconnect the PSP switch 2P connector. 8. Turn the ignition switch ON (II). 9. At the harness side, connect PSP switch 2P connector terminals No.1 and No.2 with a jumper wire. 10. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there less than 1.0 V? YES - Replace the PSP switch. NO - Go to step 11. 11. Turn the ignition switch OFF. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5422 12. Check for continuity between PSP switch 2P connector terminal No.2 and body ground. Is there continuity? YES - Repair open in the wire between the PSP switch and ECM/PCM (E16). NO - Repair open in the wire between the PSP switch and G301. 13. Turn the ignition switch OFF. 14. Disconnect the PSP switch 2Pconnector. 15. Turn the ignition switch ON (II). 16. Measure voltage between ECM/PCM connector terminals A24 and E16. Is there battery voltage? YES - Replace the PSP switch. NO - Go to step 17. 17. Turn the ignition switch OFF. 18. Disconnect ECM/PCM connector E(31P). 19. Check for continuity between body ground and ECM/PCM connector terminal E16. Is there continuity? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5423 YES - Repair short in the wire between ECM/PCM (E16) and the PSP switch NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 5430 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 5431 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 5432 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 5433 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 5436 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 5437 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 5438 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 5439 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5442 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5443 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5444 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Gearbox Angle of rack guide screw loosened from locked position 20 deg Maxiumum Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5453 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5454 Steering Gear: Adjustments Adjustment Special Tools Required Locknut wrench, 40 mm 07916-SA50001 1. Set the wheels in the straight ahead position. 2. Loosen the rack guide screw locknut (A) with the special tool, then remove the rack guide screw (B). 3. Remove the old sealant from rack guide screw, and apply new sealant to the middle of the threads (A). Loosely install the rack guide screw in the steering gearbox. 4. Tighten the rack guide screw (A) to 25 Nm (2.5 kgf-cm, 18 ft. lbs.), then loosen it. 5. Retighten the rack guide screw to 6 Nm (0.6 kgf-cm, 4 ft. lbs.), then back it off to specified angle. Specified Return Angle: 20° Max. 6. Hold the rack guide screw stationary with a wrench, and tighten the locknut by hand until it's fully seated. 7. Install the special tool on the locknut (B), and hold the rack guide screw (A) stationary with a wrench. Tighten the locknut an additional 30° with Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5455 the special tool. 8. Check for unusual steering effort through the complete turning travel. 9. Check the steering wheel rotation play and the power assist. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation Removal Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 Note these items during removal: ^ Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air. ^ Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur. 1. Raise the front of vehicle, and make sure it is securely supported. 2. Remove the front wheels. 3. Remove the driver's airbag and the steering wheel. 4. Remove the driver's dashboard lower cover and under cover. 5. Remove the steering joint bolts, and disconnect the steering joint by moving the steering joint (A) toward the column. 6. Remove the air cleaner (A). 7. Remove the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5458 8. Separate the tie-rod ball joint and damper steering arm using the special tool. Repeat on the other side of the vehicle. 9. Loosen the adjustable hose clamp (A) and disconnect the return hose (B). 10. On the driver's side, loosen the 14 mm flare nut (A) and disconnect the feed line (B). Remove the bolts from the feed line clamps (C). Remove the P/S return line bracket bolt (D). 11. On the passenger's side, remove the P/S return line bracket attaching bolt (A) and return line clamp (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5459 12. Remove the two 10 mm flange bolts and washers from the left side of gearbox. 13. Remove the 10 mm flange bolt and nut from the right side of the gearbox, then remove the mounting bracket (A). 14. Lower the steering gearbox, and rotate it so the pinion shaft points upward. 15. Remove the pinion shaft grommet (A) from the top of the valve body unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5460 16. Carefully move the steering gearbox (A) and tie rods (B) as an assembly toward the driver's side until the pinion shaft clears the wheel well opening (C) on the frame. 17. Remove the steering gearbox through the wheel well opening on the driver's side. Installation 1. Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheel well opening on the driver's side. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5461 2. Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheel well opening on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. NOTE: Make sure the power steering return hose is routed between the gearbox and right tie-rod. 3. Install the pinion shaft grommet (A). 4. Install the mounting cushion on the cylinder side of the gearbox. 5. Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the mounting brackets. Be sure that the pinion shaft grommet is in place securely. 6. Loosely install the two 10 mm flange bolts and washers on the left side of the gearbox. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5462 7. Position the cutout (A) on the mounting cushion (B) as shown, and install it on the housing of the gearbox. Install the mounting bracket (C) over the mounting cushion. 8. Install the 10 mm flange bolt and nut loosely first, then torque the flange bolt and nut alternately in two or more steps. 9. Tighten the left side flange bolts to the specified torque value. 10. On the driver's side, connect the feed line (A), and tighten the 14 mm flare nut to specified torque. 11. Install the P/S return line bracket (B), then install the feed line clamps (C). Tighten the mounting bolts to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5463 12. Connect the return hose (A) securely, and tighten the adjustable hose clamp (B). 13. On the passenger's side, install the P/S return line bracket attaching bolt (A) and return line clamp (B) on the gearbox. Make sure that there is no interference between the feed and return lines and any other parts. Make sure the return line is routed between the gearbox and the right tie-rod. 14. Reinstall the air cleaner (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5464 15. Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the damper steering arms. Install the 10 mm nut (B), and tighten it to the specified torque. 16. Install a new cotter pin (C), and bend it as shown (D) or (E). 17. Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows: ^ Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole (D) with the flat portion (E) on the shah). ^ Slip the lower end of the steering joint onto the pinion shaft (C) (line up the bolt hole with the groove (F) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove in the pinion shaft. ^ Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it. Tighten the lower joint bolts to specified torque. 18. Install the driver's dashboard lower cover and under cover. 19. Install the front wheel, then set the wheels in the straight ahead position. 20. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two and half turns) until the arrow mark on the label points straight up. Reinstall the steering wheel. 21. Fill the system with power steering fluid, and bleed air from the system. 22. After installation, perform the following checks. ^ Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks. Perform the front toe inspection. ^ Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint / pinion shaft serrations, then adjust the front toe by turning the tie-rods, if necessary. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5465 Steering Gear: Service and Repair Overhaul Overhaul Special Tools Required ^ Cylinder end seal remover attachment 07NAD-SR30200 or 07NAD-SR3020A ^ Driver, 27 mm 07ZAF-S5A0100 ^ Valve seal ring sizing tool 07NAG-SR30900 or 07NAG-SR3090A ^ Sleeve seal ring guide 07YAG-S2X0100 ^ Sleeve seal ring sizing tool 07ZAG-S5A0100 ^ Attachment, 32 x 35 mm 07746-0010100 ^ Driver 07749-0010000 ^ Piston seal ring guide, 42 mm 07ZAG-S7A0100 ^ Piston seal ring sizing tool, 42 mm 07ZAG-S7A0200 ^ Pilot collar 07GAF-PH70100 ^ Locknut wrench 07ZAA-S5A0100 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5466 ^ Driver handle 07NAD-SR30101 ^ Cylinder end seal slicer, 23 mm 07974-6890801 or 07974-689080A ^ Valve seal ring guide 07ZAG-S5A0200 Pincers, Oetiker 1098 or equivalent, commercially available. NOTE: Refer to the Exploded View as needed during this procedure. Removal 1. Remove the steering gearbox. Disassembly 2. Remove cylinder lines (A) and return line joint (B) from the gearbox. 3. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth. 4. Unbend the lock washers (A). 5. Hold the bracket (A) with one wrench, and unscrew both rack ends (B) with another wrench. Remove the lock washers. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5467 6. Remove the stop washer (A), the 12 mm flange bolts (B), O-rings (C), and bracket (D) from the steering gearbox. 7. Remove the boot guard (A) by removing the 8 mm flange bolt (C) on the rack end. 8. Remove the boot band (D) and clip (E). Pull the boot (B) away from the end of the steering gearbox. Remove the rack end plug (F). 9. Loosen the locknut (A), then remove the rack guide screw (B), spring (C), and rack guide (D) from the steering gearbox. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5468 10. Remove the snap ring (A) and backup ring (B) from the cylinder housing. 11. Remove the valve body unit (A) from the steering gearbox. Remove the O-ring (B) and discard it. 12. Remove the two boot bands (B) from boot (A). Compress boot (A) by hand, and apply vinyl tape (C) so the boots stay collapsed and pulled back. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5469 13. Hold the gearbox housing using a C-clamp (commercially available) (A) and the wooden blocks (B) as shown. Do not clamp the cylinder housing or gearbox housing in the vise. 14. Install the special tool (A) on the lock screw (B), then loosen and remove the lock screw from inside of the gearbox housing (C). 15. Remove the special tool. 16. Pull on the cylinder to remove it from the gearbox housing. Remove boot (A) and the slider guide (B) from the cylinder. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5470 17. Check the slider guide for damage and cracks. Use vernier calipers to measure the thickness of the slider guide. If the thickness is less than the service limit, replace the slider guide. 18. Remove and discard the stop ring (A) on the cylinder by expanding it with snap ring pliers. Remove and discard the lock screw (B). 19. Set the cylinder housing (A) in a press so the cylinder side points downward, then press the cylinder end seal (B) and steering rack (C) out of the cylinder. Hold the rack to keep it from falling when pressed clear. 20. Remove the cylinder end seal from the steering rack. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5471 21. Insert the special tools into the cylinder. Make sure the attachment (A) of the special tools is securely positioned on the bushing edges (B). 22. Place the cylinder in a press, then remove the cylinder end seal (C), backup ring (D), and bushing (B) from the cylinder by pressing on the special tool end. Note the items when pressing the cylinder end seal: ^ Keep tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal. ^ Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the cylinder. 23. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring. 24. Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft. 25. Separate the valve housing from the pinion shaft/ valve using a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5472 26. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it. NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped. 27. Check for wear, burrs, and other damage to the edges of the grooves in the sleeve. NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set. 28. Remove the snap ring (A) and sleeve (B) from the pinion shaft. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5473 29. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and the outer surface when removing the seal rings. 30. Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the groove (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring. 31. Remove the valve oil seal (A) and wave washer (B) from the pinion shaft. Note these items during disassembly: ^ Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play, replace the pinion shaft and sleeve as an assembly. ^ The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5474 32. Press the valve oil seal (A) and roller bearing (B) out of the valve housing using a hydraulic press and special tool. Reassembly 33. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with the power steering fluid. 34. Install the wave washer (B). Coat the inside surface of the new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). Remove the vinyl tape. 35. Install the special tool over the pinion, and coat the surface of the tool with power steering fluid. Slip the new O-ring (A) and new valve seal ring (B) over the special tool, and expand them. 36. Fit the O-ring in the groove of the pinion shaft. Then slide the valve seal ring over the shaft and in the groove on the pinion shaft. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5475 37. Remove the special tool, and apply power steering fluid to the surface of the valve seal ring (A). 38. Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring, and move the special tool up and down several times to make the valve seal ring fit in the pinion shaft groove. 39. Remove the special tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fit snugly in the pinion shaft groove. 40. Apply power steering fluid to the surface of the special tool. Slip two new seal rings (A) over the special tool from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B). Note these items when installing the seal rings: ^ Do not over-expand the seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal rings using the special tool (sizing tool). ^ There are two types of sleeve seal rings: black and brown. Do not mix the different types of rings, as they are not compatible. 41. Align the special tool with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily. 42. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool. 43. Move the sleeve back and forth several times to make the seal rings snugly fit in the sleeve. Be sure that the seal rings are not twisted. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5476 44. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve. 45. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and special tools. Install the seal with its grooved side facing the tool. 46. Press the roller bearing (C) into the valve housing with a hydraulic press and special tool. 47. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid. 48. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C) and valve oil seal sealing lip (D). 49. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5477 50. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it. 51. Coat the special tool with power steering fluid, then slide it onto the rack, big end first. 52. Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly: ^ Do not over expand the resin seal ring. Install the resin seal ring with care so as not to damage it. After installation, be sure to contract the seal ring using the special tool (sizing tool). ^ Replace piston's O-ring and seal ring as a set. 53. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring. 54. Coat the piston seal ring (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring. 55. Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5478 56. Set the new bushing (A) on the special tool, and insert the special tools into the cylinder housing (B). 57. Set the cylinder in a press, and install the bushing (A) into the bottom of the cylinder by pressing on the tool with press. Do not push on the tool with excessive force as it may damage the new bushing. 58. Coat the sliding surface of the special tool (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the special tool with its grooved side (C) facing opposite the special tool. 59. Apply a thin coat of grease to the inside of the special tool. 60. Install the cylinder end seal (A) onto the steering rack (B) with its grooved side (C) toward the piston (D). Make sure the gap in the special tool is opposite of rack teeth. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5479 61. Separate the cylinder end seal from the special tool, then remove the special tool. 62. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C). 63. Mark (A) a position on the steering rack surface with a felt-tip marker, 7.7 mm (0.3 inch) from the rack end. 64. Grease the steering rack teeth, then insert the steering rack (A) into the cylinder (B). Be careful not to damage the inner surface of the cylinder wall and bushing with the rack edges. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5480 65. Set the cylinder (A) in a press, then press the cylinder end seal (B) into the bottom of the cylinder until the mark (C) on the rack meets the edges (D) of the cylinder. 66. Coat the inside and outside surfaces of the new cylinder end seal (A) with power steering fluid. 67. Install the cylinder end seal onto the steering rack (B) with its grooved side (C) toward the piston. Push in the cylinder end seal with your finger. 68. Place the backup ring (D) on the cylinder end seal with its flat side facing upward. Then drive the backup ring in with the appropriate size socket wrench until the surface is below the snap ring groove (E). Install the snap ring (F) in the groove. 69. Install the new lock screw (A) on the cylinder. 70. Install the new stop ring (B) in the groove (C) on the cylinder by expanding it with snap ring pliers. Be careful not to scratch or damage on the cylinder surface with the stop ring edges. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5481 71. Coat the housing surface with multipurpose grease as shown. 72. Set the new boot bands (B) on the band installation grooves of boot (A) by aligning the tabs (C) with the holes (D) of the band. Do not close the ear portion of the boot band yet. 73. Compress boot (A) by hand, and apply vinyl tape (E) to the bellows so the boots stay collapsed and pulled back. Pass boot (A) over the cylinder so the smaller diameter end of the boot faces the gearbox housing. 74. Apply multipurpose grease to the sliding surface of the slider guide (A). Keep grease off of the rack-to-slider guide matching surfaces and the boot-to-slider guide matching surfaces. Slide the steering rack all the way to left, and place the slider guide on the steering rack by aligning the bolt holes (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5482 75. Hold the gearbox housing using a C-clamp (A) and the wooden block (B) as shown. 76. Push the cylinder (A) into the gearbox housing (B) so the notch (C) is aligned with the pin (D) inside of the gearbox housing. 77. Tighten the lock screw (A) by hand first, then install the special tool (B) on the lock screw. Lightly tighten the lock screw. Do not tighten the lock screw to specified torque yet. 78. Remove the special tool. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5483 79. Coat the new O-ring (A) with grease, and carefully fit it on the valve housing. 80. Apply grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections). Tighten the flange bolts (D) to the specified torque. 81. Grease the sliding surface and circumference of the rack guide (A), and install it into the gearbox housing. Wipe the grease off the threaded section of the housing. 82. Install the spring (B). Apply sealant to the middle of the threads on the rack guide screw (C), then install and tighten it to 25 Nm (2.5 kgf-cm, 18 ft. lbs.). Loosely install the locknut (D). 83. Center the steering rack within its stroke, and align the slider guide (B) with the holes (C) in boot (A). Fit the slider guide to boot (A) by pressing around the edges of the holes securely. 84. Before installing the bracket (D), clean the mating surface of the 12 mm flange bolts (E) and bracket. Coat the new O-rings (F) with grease, and install them on the 12 mm flange bolts. 85. Loosely install the bracket on the steering rack by tightening the 12 mm flange bolts to 25 Nm (2.5 kgf~m, 18 ft. lbs.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5484 86. Hold the gearbox housing using a C-clamp, then install the special tool on the lock screw (A). Retighten the lock screw to specified torque values. Remove the special tool. 87. Retighten the 12 mm flange bolts (A) to specified torque values. 88. After tightening the 12 mm flange bolts, install a new stop washer (B) over one of the bolt heads (C). Be sure the tabs (D) of the stop washer are aligned with the flat surfaces (E) of the bolt head. 89. Clean off any grease or contamination from the boot installation grooves around on the housing. 90. Expand boot (A) by removing the vinyl tape, and fit the boot ends (B) in the installation grooves on the cylinder housing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5485 91. Close the ear portion (A) of the bands (B) with a commercially available pincers, Oetiker 1098 or equivalent (C ). 92. Install the rack end plug (A). 93. Clean off any grease or contamination from the boot installation grooves (C) around on the housing. 94. Slide the steering rack, and adjust the distance between the cylinder housing end and the end of the rack end plug to 70.5 mm (2.8 inch). Install boot (B), and set the boot end in the installation grooves in the cylinder housing and rack end plug properly. Install the clip (D) and boot guard (E). Install the new boot band (F) in the band grooves of boot (B) by aligning the tabs (G) with the holes (H) in the band. 95. Close the ear portion (A) of the band (B) with a commercially available pincers, Oetiker 1098 or equivalent (C). Slide the rack right and left to be certain that the boots are not deformed or twisted. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 5486 96. Install a new lock washer (A) on the tie-rod (B) with the radiused side of the washer toward the tie-rod, and screw the tie-rod into the bracket (C). Repeat this step for the other tie-rod. Hold the bracket with one wrench, and tighten both tie-rods to the specified torque with another wrench. 97. Bend the lock washer against the flat spots on the bracket with a large pair of pliers. 98. Install the cylinder lines (A) and return line joint (B). Note these items during reassembly: ^ Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material. ^ Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque. 99. Adjust the rack guide screw. After adjusting, check that the rack moves smoothly by sliding it right and left. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Standards and Service Limits Steering Wheel: Specifications Steering wheel Rotational play measured at outside edge with engine running 0 - 10 mm Starting load measured at utside edge with engine running 29 N Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Standards and Service Limits > Page 5491 Steering Wheel: Specifications Steering Type Power-assisted rack and pinion Overall ratio 15.06 Turns, lock-to-lock 2.64 Steering wheel diameter 360 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 5492 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 5493 Steering Wheel: Service and Repair Removal SRS components are located in this area. Review the SRS component locations and precautions and procedures in Restraint Systems 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 horn switch connector (B). 3. Loosen the steering wheel bolt (C). 4. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller. Note these items when removing the steering wheel: ^ Do not tap on the steering wheel or the steering column shaft when removing the steering wheel. ^ If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt. 5. Remove the steering wheel puller, then remove the steering wheel bolt and steering wheel from the steering column. Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 5494 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 on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel. 3. Install the steering wheel bolt (A), and tighten it to the specified torque. Connect the horn and cruise control set/resume switch connectors. Make sure the wire harness is routed and fastened properly. 4. Install the driver's airbag, and confirm that the system is operating properly. 5. Check the horn and turn signal canceling for proper operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair Replacement Special Tools Required Attachment, 42 mm 07QAD-P0A0100 1. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. 2. Pack the lower area of the ball pin (A) with fresh multipurpose grease. 3. Pack the interior of the new boot (B) and lip (C) with fresh multipurpose grease. Note these items when installing new grease: ^ Keep grease off the boot mounting area (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications TORQUE SPECIFICATIONS Castle Nut Upper.................................................................................................................................. ................................... 39 - 47 Nm (29 - 35 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Ball Joint: Service and Repair Ball Joint 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 of the adjusting bolt (B) is in the position shown to allow the jaw (C) to pivot. 5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the steering arm or knuckle. If necessary, apply penetrating type lubricant to loosen the ball joint pin. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint > Page 5508 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 joint boot, and replace it if damaged. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint > Page 5509 Ball Joint: Service and Repair Dust Cover, Wheel Hub Replacement Special Tools Required Front hub disassembly tool 07965-SA50500 1. Remove the boot. Check for a gap between the ball joint (A) and the knuckle. If there is a gap, replace the knuckle assembly. Do not press the ball joint back into the knuckle. 2. Pack the interior and lip (B) of a new boot with fresh grease. Keep the grease off of the boot-to-knuckle mating surfaces (C). 3. Wipe the grease off the tapered section of the pin (D), and pack fresh grease onto the base (E). 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension Control Arm: Service and Repair Front Suspension Replacement Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 1. Raise the front of the vehicle, and make sure it is securely supported. 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 clip (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the clip into the ball joint pin from the inside to the outside of the vehicle. The closed end of the clip 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 5514 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. ^ 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. Do not place the jack on the lower arm ball joint. ^ Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the clip hole. Do not align the castle nut by loosening it. ^ Install a new clip 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension > Page 5515 Control Arm: Service and Repair Rear Suspension Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. 2. Place a floor jack under the trailing arm, and support the suspension. 3. Remove the wheel sensor harness bracket (A) (with ABS) from the upper arm (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications TORQUE SPECIFICATIONS Splash Guard Screw ............................................................................................................................ .......................................... 4.9 Nm (58.8 inch lbf.) Castle Nut ............................................................ ................................................................................................................... 49 - 59 Nm (36 - 43 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar Stabilizer Bar: Service and Repair Stabilizer Bar Front Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Disconnect the stabilizer links from the stabilizer bar on the right and left. 3. Remove the flange bolts (A) and bushing holders (B), then remove the bushings (C) and the stabilizer bar (D). 4. Install the stabilizer bar in the reverse order of removal, and note these items: ^ Use new self-locking nuts on reassembly. Note the right and left direction of the stabilizer bar. ^ Align the ends of the paint marks (A) on the stabilizer bar with each end of the bushings (B). ^ Note the before/after direction of the bushing holders. Rear Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar > Page 5523 2. Disconnect the stabilizer links from the stabilizer bar (A) on the right and left. 3. Remove the flange bolts and bushing holders (B), then remove the bushings (C) and the stabilizer bar. 4. Install the stabilizer bar in the reverse order of removal, and note these items: ^ Use new self-locking nuts on reassembly. Make sure the right and left ends of the stabilizer bar are installed on their respective sides of the vehicle. ^ Align the ends of the paint marks (A) on the stabilizer bar with the bushings (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar > Page 5524 Stabilizer Bar: Service and Repair Stabilizer Link Front Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), and remove the stabilizer link (E). 3. Install the stabilizer link on the stabilizer bar and lower arm with the joint pins set at the center of 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 ball joint pin. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar > Page 5525 6. Tighten the new 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. Rear Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar > Page 5526 3. Install the stabilizer link on the stabilizer bar and trailing arm with the joint pins 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 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 new 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair Removal Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 5530 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse M/T: Leave the transmission mount bracket attached to the front side frame. A/T: When replacing the front wheelhouse, support the wheelhouse and transmission mount bracket as an assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 5531 - Check the damper housing position, and check for damage. - If necessary, remove the Wheelhouse upper member, and replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimension. 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. - Weld the damper housing and front side frame. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 5532 - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, and damper housing extension lower. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 5533 - From the dashboard upper side, plug weld the holes in the damper housing extension upper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair > Page 5534 - Weld the front wheelhouse, damper housing, and front side frame. - Weld the wheelhouse upper member. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter > Page 5539 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Page 5540 Subframe: Service and Repair Subframe Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Page 5541 Subframe Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Diagrams > Front > Page 5546 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Replacement Special Tools Required Ball joint remover, 28 mm 07MAC-SL00200 Removal 1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5549 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) (with ABS) 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5550 7. Lower the lower arm, and remove the damper assembly (A). Disassembly/Inspection 1. Compress the damper spring with the 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5551 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. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5552 7. Check that the cutout (B) in the side of the upper spring seat (A) is in position shown. Note that there are two types of dampers, A type and B type, and the cutout position is different from type to type. A type damper: A/T models B type damper: M/T models If the cutout is out of position, remove all the components from the spring compressor. Go to step 2, and reassemble the spring and upper spring seat accordingly. 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. Installation 1. Lower the lower arm, and position the damper assembly in the body. Turn the damper mounting base so that the "[triangle]L" or "[triangle]R" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5553 mark (A) faces toward the outside of the vehicle. 2. Loosely install 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) (with ABS) onto the damper, and tighten the bolt to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5554 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5555 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Removal 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5556 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the flange nuts (A) from the top of the damper in the cargo area. 4. Remove the damper assembly from the body. Disassembly/Inspection 1. Compress the damper spring with the 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5557 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the damper mounting washer and self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the spring compressor. 4. Install the washer (A) and a new self-locking nut (B) on the damper shaft. 5. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 5558 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole on it is toward the 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 ................................................................................................................................ ............................... 59 N.m (6.0 kgf-m, 43 lbf-ft) Upper Flange Nut ................................................... .............................................................................................................................. 44 N.m (33 ft.lbs.) 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) Damper Pinch Bolt ......................................................................................................................................................... 157 N.m (16.0 kgf-m, 116 ft-lb) Tie-rod to Steer Arm Nut .................................................................................................................................................... 43 N.m (4.4 kgf-m, 32 lbf-ft) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 5563 Suspension Strut / Shock Absorber: Specifications Rear TIGHTENING SPECIFICATIONS Damper Shaft Nut ................................................................................................................................ ............................... 29 N.m (3.0 kgf-m, 22 lbf-ft) Upper Flange Nut ............................................................................................................................................................. 74 N.m (7.5 kgf-m, 54 lbs-ft..) Damper Bottom Bolt ............................................................................................................................................................ 93 N.m (9.5 kgf-m, 69 ft-lb) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 5564 Suspension Strut / Shock Absorber: Specifications Suspension Shock absorber Front Telescopic, hydraulic, nitrogen gas-filled Rear Telescopic, hydraulic, nitrogen gas-filled Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5565 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5566 Suspension Strut / Shock Absorber: Service and Repair Removal 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5567 2. Remove the flange bolt (A) from the bottom of the damper. 3. Remove the flange nuts (A) from the top of the damper in the cargo area. 4. Remove the damper assembly from the body. Disassembly/Inspection 1. Compress the damper spring with the 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5568 2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. 3. Reassemble all the parts, except for the spring. 4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced. 5. Check for oil leaks, abnormal noises, or binding during these tests. Reassembly 1. Install all the parts except the damper mounting washer and self-locking nut onto the damper unit by referring to the Exploded View. Align the bottom of the spring (A) and the stepped part of the lower spring seat (B), and align the damper mounting base as shown. 2. Install the damper assembly on a commercially available strut spring compressor (C). 3. Compress the damper spring with the spring compressor. 4. Install the washer (A) and a new self-locking nut (B) on the damper shaft. 5. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque. Installation Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 5569 1. Position the damper assembly in the body. Note the direction of the damper mounting base so that the small hole on it is toward the 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Page 5573 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 too 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Wheel Bearings - Humming Or Growling Wheel Bearing: Technical Service Bulletins Wheel Bearings - Humming Or Growling SOURCE: Honda Service News November 2003 TITLE: Humming or Growling? Check the Wheel Bearings APPLIES TO: 1998-04 Accord, 2001-04 CR-V, 2003 Element, 1999-04 Odyssey SERVICE TIP: A bad front wheel bearing(s) can make a humming or growling that's easily mistaken for a noisy bearing or gear in the A/T. Before you order a reman A/T, test-drive the vehicle to make sure the A/T is really the problem. Listen carefully as you accelerate and decelerate during your test-drive. Shift into neutral. Varying throttle position and shifting into neutral changes the load on the A/T bearings and gears. If the A/T has a bad bearing or gear, the change in load will affect its noise level. If that's what you find, then go ahead and order a reman A/T. If the noise level isn't affected by changes in throttle position or shifting into neutral, then the culprit could be a bad front wheel bearing(s). Since the wheel bearings aren't mounted on shafts being spread apart by gears, they're not affected by changes in load. Also, since Honda uses angular contact wheel bearings, you won't normally hear a change in noise level when you swerve the vehicle from side to side. Hook up a STEELMAN® ChassisEAR (T/N JSP SM06600) to the front knuckles, and test-drive the vehicle again. Refer to S/B 00-063, STEELMAN ChassisEAR Diagnostic Tool, for more info. If you hear humming or growling from one or affected wheel bearing(s), and then test-drive the vehicle to make sure the noise is gone. If you don't hear any noise from the front wheel bearings, the problem could be from tire noise or vibration. Swap the front wheels and tires with a known-good vehicle. Testdrive the vehicle, and check if the noise or vibration goes away. STEELMAN(R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Front > Page 5580 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Diagrams > Page 5581 Wheel Bearing: Testing and Inspection Inspection 1. Raise the vehicle, and make sure it is securely supported. 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. 3. Set up the dial gauge against the hub cap as shown, and measure the bearing end play by 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Special Tools Required Hub disassembly tool 07GAF-SD40100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle and Hub Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5584 2. Remove the wheel cap, wheel nuts, and front wheel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5585 8. With ABS: 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 clip (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the clip into the ball joint pin from the inside to the outside of the vehicle. The closed end of the clip must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5586 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. 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. - First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specific torques. Do not place the jack against the ball joint pin of the lower arm. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the clip hole. Do not align the castle nut by loosening it. - Install a new clip 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. - Replace the self-locking nuts, damper pinch bolts and nuts with new ones. 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. Wheel Bearing Replacement 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5587 3. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 5. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 6. 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. NOTE (with ABS): Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5588 7. Install the snap ring (A) securely in the knuckle (B). 8. Install the splash guard (C), and tighten the screws (D) to the specified torque. 9. Press a wheel bearing (A) onto the hub (B) using the special tools and a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5589 Wheel Bearing: Service and Repair Rear Knuckle/Hub/Wheel Bearing Special Tools Required Hub disassembly tool 07965-SA70100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5590 2. Release the parking brake lever. 3. Remove the brake hose mounting bolt (A). 4. 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. 5. Remove the brake disc retaining screw (A), and screw two 8 x 1.25 mm bolts into the brake disc/ drum (B) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the brake disc/drum excessively. Remove the brake disc/drum. 6. Raise the stake (A), and remove the spindle nut (B). Remove the rear axle shaft (C) from vehicles with 2WD. 7. Remove the parking brake shoes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5591 8. Remove the parking brake cable (A) from the backing plate. NOTE: The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. 9. Remove the wheel sensor (A) from the knuckle (if equipped with ABS). 10. Place a floor jack under the trailing arm (A) to support it. NOTE: Do not place the jack against the plate section of the lower arm. Be careful not to damage any suspension components. 11. Remove the flange bolt, and disconnect the upper arm (B) from the knuckle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5592 12. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), then remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 13. Remove the flange bolt (D). 14. Remove the knuckle (A) while pushing in the driveshaft and holding the driveshaft outboard joint (B) (4WD only). 15. 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 and adjusting cam with the marked positions when tightening. - Use a new self-locking nut on reassembly. - 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/drum, clean the mating surfaces of the rear hub and the inside of the brake disc/drum. - Before installing the wheel, clean the mating surfaces of the brake disc/drum and the inside of the wheel. - Check the rear wheel alignment, and adjust it if necessary. Wheel Bearing Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5593 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with a press attachment (C) or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. Remove the brake hose mounting bracket (A). 3. Remove the backing plate (B), and snap ring (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press. 5. Press the wheel bearing inner race (A) from the hub (B) using the special tool, a commercially available bearing separator (C), and a press. 6. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5594 7. 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. Be careful not to damage the sleeve of the pack seal. NOTE (with ABS) Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. 8. Install the snap ring (A), backing plate (B), and brake hose mounting bracket (C). Tighten the flange nuts and bolts to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5595 9. Install the hub (A) on the knuckle (B) using the special tools and a hydraulic press. Be careful not to deform the backing plate (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Diagrams > Front > Page 5600 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2. Raise the hoist a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid contact with the lift blocks. Safety Stands To support the vehicle on safety stands, use the same support points (B and C) as for a frame hoist. Always use safety stands when working on or under any vehicle that is supported only by a jack. Floor Jack 1. Set the parking brake. 2. Block the wheels that are not being lifted. 3. When lifting the rear of the vehicle, put the gearshift lever in reverse, or the automatic transmission in the P position. 4. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (B), center the jacking bracket in the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it. 5. Position the safety stands under the support points and adjust them so the vehicle is level. 6. Lower the vehicle onto the stands. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Tubless Tire Repair Information Tires: Technical Service Bulletins Tires - Tubless Tire Repair Information 06-082 December 15, 2006 Applies To: ALL Tubeless Tire Repair Information This service bulletin provides the resource information required to repair tubeless tires on Honda automobiles and light trucks. To properly repair a tire, follow the Rubber Manufacturers Association (RMA) "Puncture Repair Procedures for Passenger and Light Truck Tires" outlined on the RMA wall poster. One wall poster has been provided to your dealership. Additional posters can be ordered through Helm, the RMA website, www.rma.org, or the tire manufacturers. Michelin(R) PAX System(TM), tires can be repaired using the same repair procedures described on the RMA poster. Whenever you repair a PAX System tire, you must inspect the support ring. Refer to the PAX System support ring section of this service bulletin for inspection procedures. WARRANTY CLAIM INFORMATION Refer to the tire manufacturer for warranty information. REQUIRED MATERIALS ^ 1/8 inch Patch-plug with lead wire ^ 1/4 inch Patch-plug with lead wire ^ 1/8 inch Plugs (stem)* ^ 1/4 inch Plugs (stem)* ^ 1/4 inch Patches* ^ 3/4 inch Patches* ^ Chemical cement ^ Liquid buffer ^ Rim-bead sealer ^ Inner liner sealer REQUIRED TOOLS ^ Tire stitcher, 1-1/2 inch wheel ^ Tire crayons ^ Tire test tank ^ Awl or probe ^ Flexible blade skiving knife ^ 1/8 inch Carbide tire tool with adapter ^ 1/4 inch Carbide tire tool with adapter ^ Low speed buffer with quick release chuck and exhaust hose ^ Carbide buffing wheel with adapter Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tires - Tubless Tire Repair Information > Page 5609 ^ Reversible drill motor (800 RPM MAX) ^ Tire spreader ^ Inspection lamp * For repairable injuries that exceed 25 degrees TIRE REPAIR GUIDELINES Never repair tires worn below 2/32 inch of tread. Never repair a tire without removing the tire from the wheel for internal inspection. Never repair a tire with a tread injury larger than 1/4 inch (6 mm). Never use only a plug (stem) or a patch only to repair a tire injury. NOTE: If the angle of the tire injury exceeds 25 degrees, you must use the two-piece repair system as recommended by the RMA. MICHELIN PAX SYSTEM SUPPORT RING INSPECTION PAX System support rings are not repairable, under any circumstances, but they can be reused if no damage is found during a thorough inspection. If a PAX System tire ran flat or underinflated, dismount the tire from the wheel and inspect the wheel, tire, and support ring for damage. Refer to the Michelin PAX Support Rings Technical Bulletin in ISIS. Enter SEARCH BY PUBLICATION, select Job Aids, then select Michelin PAX Support Rings Technical Bulletin from the list. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Specifications Wheels: Specifications Wheel Aluminum wheel runout Axial Standard or new 0 - 0.7 mm Service limit 2.0 mm Radial Standard or new 0 - 0.7 mm Service limit 1.5 mm Steering wheel runout Axial Standard or new 0 - 1.0 mm Service limit 2.0 mm Radial Standard or new 0 - 1.0 mm Service limit 1.5 mm Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Wheel Bearings - Humming Or Growling Wheel Bearing: Technical Service Bulletins Wheel Bearings - Humming Or Growling SOURCE: Honda Service News November 2003 TITLE: Humming or Growling? Check the Wheel Bearings APPLIES TO: 1998-04 Accord, 2001-04 CR-V, 2003 Element, 1999-04 Odyssey SERVICE TIP: A bad front wheel bearing(s) can make a humming or growling that's easily mistaken for a noisy bearing or gear in the A/T. Before you order a reman A/T, test-drive the vehicle to make sure the A/T is really the problem. Listen carefully as you accelerate and decelerate during your test-drive. Shift into neutral. Varying throttle position and shifting into neutral changes the load on the A/T bearings and gears. If the A/T has a bad bearing or gear, the change in load will affect its noise level. If that's what you find, then go ahead and order a reman A/T. If the noise level isn't affected by changes in throttle position or shifting into neutral, then the culprit could be a bad front wheel bearing(s). Since the wheel bearings aren't mounted on shafts being spread apart by gears, they're not affected by changes in load. Also, since Honda uses angular contact wheel bearings, you won't normally hear a change in noise level when you swerve the vehicle from side to side. Hook up a STEELMAN® ChassisEAR (T/N JSP SM06600) to the front knuckles, and test-drive the vehicle again. Refer to S/B 00-063, STEELMAN ChassisEAR Diagnostic Tool, for more info. If you hear humming or growling from one or affected wheel bearing(s), and then test-drive the vehicle to make sure the noise is gone. If you don't hear any noise from the front wheel bearings, the problem could be from tire noise or vibration. Swap the front wheels and tires with a known-good vehicle. Testdrive the vehicle, and check if the noise or vibration goes away. STEELMAN(R) and ChassisEAR (R) are registered trademarks of J.S. Products, Inc. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Front > Page 5619 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Diagrams > Page 5620 Wheel Bearing: Testing and Inspection Inspection 1. Raise the vehicle, and make sure it is securely supported. 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. 3. Set up the dial gauge against the hub cap as shown, and measure the bearing end play by 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Special Tools Required Hub disassembly tool 07GAF-SD40100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle and Hub Replacement 1. Raise the front of the vehicle, and make sure it is securely supported. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5623 2. Remove the wheel cap, wheel nuts, and front wheel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5624 8. With ABS: 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 clip (A) from the lower arm ball joint, and remove the castle nut (B). NOTE: During installation, insert the clip into the ball joint pin from the inside to the outside of the vehicle. The closed end of the clip must be in the range shown. 11. Disconnect the lower arm from the knuckle using the special tool. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5625 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. 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. - First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specific torques. Do not place the jack against the ball joint pin of the lower arm. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the clip hole. Do not align the castle nut by loosening it. - Install a new clip 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. - Replace the self-locking nuts, damper pinch bolts and nuts with new ones. 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. Wheel Bearing Replacement 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5626 3. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press. 5. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 6. 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. NOTE (with ABS): Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. - Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5627 7. Install the snap ring (A) securely in the knuckle (B). 8. Install the splash guard (C), and tighten the screws (D) to the specified torque. 9. Press a wheel bearing (A) onto the hub (B) using the special tools and a press. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5628 Wheel Bearing: Service and Repair Rear Knuckle/Hub/Wheel Bearing Special Tools Required Hub disassembly tool 07965-SA70100 - Ball joint remover, 28 mm 07MAC-SL00200 - Attachment 62 x 68 mm 07746-0010500 - Driver 07749-0010000 - Support base 07965-SD90100 Knuckle Replacement 1. Raise the rear of the vehicle, and make sure it is securely supported. Remove the rear wheels. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5629 2. Release the parking brake lever. 3. Remove the brake hose mounting bolt (A). 4. 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. 5. Remove the brake disc retaining screw (A), and screw two 8 x 1.25 mm bolts into the brake disc/ drum (B) to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the brake disc/drum excessively. Remove the brake disc/drum. 6. Raise the stake (A), and remove the spindle nut (B). Remove the rear axle shaft (C) from vehicles with 2WD. 7. Remove the parking brake shoes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5630 8. Remove the parking brake cable (A) from the backing plate. NOTE: The parking brake cable must not be bent or distorted. This will lead to stiff operation and premature cable failure. 9. Remove the wheel sensor (A) from the knuckle (if equipped with ABS). 10. Place a floor jack under the trailing arm (A) to support it. NOTE: Do not place the jack against the plate section of the lower arm. Be careful not to damage any suspension components. 11. Remove the flange bolt, and disconnect the upper arm (B) from the knuckle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5631 12. Mark the cam positions of the adjusting bolt (A) and adjusting cam (B), then remove the self-locking nut (C), adjusting cam, and adjusting bolt. Discard the self-locking nut. 13. Remove the flange bolt (D). 14. Remove the knuckle (A) while pushing in the driveshaft and holding the driveshaft outboard joint (B) (4WD only). 15. 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 and adjusting cam with the marked positions when tightening. - Use a new self-locking nut on reassembly. - 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/drum, clean the mating surfaces of the rear hub and the inside of the brake disc/drum. - Before installing the wheel, clean the mating surfaces of the brake disc/drum and the inside of the wheel. - Check the rear wheel alignment, and adjust it if necessary. Wheel Bearing Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5632 1. Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with a press attachment (C) or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. Remove the brake hose mounting bracket (A). 3. Remove the backing plate (B), and snap ring (C). 4. Press the wheel bearing (A) out of the knuckle (B) using the special tools and a press. 5. Press the wheel bearing inner race (A) from the hub (B) using the special tool, a commercially available bearing separator (C), and a press. 6. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5633 7. 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. Be careful not to damage the sleeve of the pack seal. NOTE (with ABS) Install the wheel bearing with the magnetic encoder (E) (brown color) toward the inside of the knuckle. - Remove any oil, grease, dust, or other foreign material from the encoder surface. Keep magnetic tools away from the encoder surface. - Be careful not to damage the encoder surface when you insert the wheel bearing. 8. Install the snap ring (A), backing plate (B), and brake hose mounting bracket (C). Tighten the flange nuts and bolts to the specified torque. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5634 9. Install the hub (A) on the knuckle (B) using the special tools and a hydraulic press. Be careful not to deform the backing plate (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Diagrams > Front Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Diagrams > Front > Page 5639 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS Wheel Nuts .......................................................................................................................................... ............................................... 108 Nm (80 ft. lbs.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Accumulator HVAC: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5652 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5653 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5654 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5655 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5656 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5657 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5658 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5659 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5660 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5661 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5662 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5663 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5664 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5665 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Accumulator HVAC: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5671 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5672 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5673 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5674 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5675 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5676 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5677 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5678 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5679 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5680 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5681 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5682 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5683 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5684 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations 47. Under Left Side of Dash 83. Behind Glove Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5689 Air Door Actuator / Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7P connector from the air mix control motor. 2. Connect battery power to the No. 1 terminal of the air mix control motor, and ground the No.2 terminal; the air mix control motor should run, and stop at Max Hot. If it doesn't, reverse the connections; the air mix control motor should run, and stop at Max Cool. If the air mix control motor does not run, remove it, then check the air mix control linkage and door for smooth movement. If the linkage and door move smoothly, replace the air mix control motor. - If the linkage or door sticks or binds, repair them as needed. 3. Measure the resistance between the No.5 and No.7 terminals. It should be between 4.2 k to 7.8 kOhm. 4. Reconnect the air mix control motor 7P connector, then turn the ignition switch ON (II). 5. Measure the voltage between the No.3 and No.7 terminals. Max Cool-about 1 V Max Hot-about 4 V 6. If either the resistance or voltage readings are not as specified, replace the air mix control motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5692 Air Door Actuator / Motor: Testing and Inspection Mode Control Motor Test Mode Control Motor Test 1. Disconnect the 7P connector from the mode control motor. 2. Connect battery power to the No.1 terminal of the mode control motor, and ground the No.2 terminal; the mode control motor should run smoothly, and stop at Vent. If it doesn't, reverse the connections; the mode control motor should run smoothly, and stop at Defrost. When the mode control motor stops running, disconnect battery power immediately. 3. If the mode control motor does not run in step 2, remove it, then check the mode control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the mode control motor. - If the linkage or doors stick or bind, repair them as needed. 4. Use a digital multimeter with an output of 1 mA or less at the 20 kOhm range. With the mode control motor running as in step 2, check for continuity between the No. 3, 4, 5, 6 terminals and the No.7 terminal individually. There should be continuity for a moment at each terminal. 5. If there is no continuity for a moment at each terminal, replace the mode control motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5693 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Circuit Troubleshooting Recirculation Control Motor Circuit Troubleshooting 1. Check the No.14 (10A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 2. NO - Replace the fuse, and recheck. 2. Disconnect the recirculation control motor 7P connector. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.1 terminal of the recirculation control motor 7P connector and body ground. Is there battery voltage? YES - Go to step 5. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the recirculation control motor. 5. Turn the ignition switch OFF. 6. Test the recirculation control motor. Is the recirculation control motor OK? YES - Go to step 7. NO - Go to step 12. 7. Disconnect the heater control panel 30P connector. 8. Check for continuity between the No.29 and No.30 terminals of the heater control panel 30P connector 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5694 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 also may damage the heater control panel. Repair the short to power before replacing the healer control panel. NO - Goto step 10. 10. Turn the ignition switch OFF. 11. Check for continuity between the following terminals of the heater control panel 30P connector and the recirculation control motor 7P connector. Is there continuity? YES - Check for loose wires or poor connections at the heater control panel 30P connector and at the recirculation control motor 7P connector. If the connections are good, substitute a known-good heater control panel, and recheck. If the symptom/indication goes away, replace the original heater control panel. NO - Repair any open in the wire(s) between the heater control panel and the recirculation control motor. 12. Remove the recirculation control motor. 13. Check the recirculation control linkage and doors for smooth movement. Do the recirculation control linkage and doors move smoothly? YES - Replace the recirculation control motor. NO - Repair the recirculation control linkage or doors. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5695 Air Door Actuator / Motor: Testing and Inspection Recirculation Control Motor Test Recirculation Control Motor Test 1. Disconnect the 7P connector from the recirculation control motor. NOTE: Incorrectly applying power and ground to the recirculation control motor will damage it. Follow the instructions carefully. 2. Connect battery power to the No.1 terminal, and ground the No.5 and No.7 terminals; the recirculation control motor should run smoothly. To avoid damaging the recirculation control motor, do not reverse power and ground. Disconnect the No.5 or No.7 terminals from ground; the recirculation control motor should stop at Fresh or Recirculate. Don't cycle the recirculation control motor for a long time. 3. If the recirculation control motor does not run in step 2, remove it, then check the recirculation control linkage and doors for smooth movement. - If the linkage and doors move smoothly, replace the recirculation control motor. - If the linkage or doors stick or bind, repair them as needed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7P connector (A) from the air mix control motor (B). Remove the self-tapping screws and the air mix control motor from the heater unit. 3. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5698 Air Door Actuator / Motor: Service and Repair Mode Control Motor Mode Control Motor Replacement 1. Remove the ECM/PCM. 2. Disconnect the 7P connector (A) from the mode control motor (B). Remove the self-tapping screws and the mode control motor from the heater unit. 3. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 5699 Air Door Actuator / Motor: Service and Repair Recirculation Control Motor Recirculation Control Motor Replacement 1. Remove the ECM/PCM. 2. Remove the bolt and the bracket (A). Disconnect the 7P connector (B) and the harness clip (C) from the recirculation control motor (D). Remove the self-tapping screws and the recirculation control motor from the blower unit. 3. Install the motor in the reverse order of removal. After installation, make sure the motor runs smoothly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments Air Door 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 above. Hold the end of the heater valve cable housing against the stop (D), then snap the heater valve cable housing into the cable clamp (A). 5. From under the hood, turn the heater valve arm (C) to the fully closed position as shown, and hold it. Attach the heater valve cable (B) to the heater valve arm, and gently pull on the heater valve cable housing to take up any slack, then install the heater valve cable housing into the cable clamp (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Dashboard Side Vent Air Register: Service and Repair Dashboard Side Vent Dashboard Side Vent 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. 1. Carefully insert a trim tool next to the clips (A), and detach the clips by prying on the side vent (B). Take care not to scratch the dashboard and related parts. 2. Remove the vent by releasing the hooks (C). 3. Reinstall the hook portions of the vent first, then push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Dashboard Side Vent > Page 5707 Air Register: Service and Repair Rear Air Outlet Replacement Rear Air Outlet Replacement 1. Remove the rear bumper. 2. Detach the hooks (A), then remove the rear air outlet (B). Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5715 87. Under Right Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5718 Blower Motor: Description and Operation How the Circuit Works Blower Controls You can manually select the fan speed by turning the fan control dial clockwise, from the OFF position. Turning the dial further clockwise increases the fan's speed, which increases air flow. Battery voltage is applied through fuse 12 to the blower motor relay contacts at all times. With the ignition switch ON (II), the blower motor relay in the under-hood fuse/relay box is energized which feeds battery voltage to the blower motor. The blower power transistor controls the blower motor in all speeds except HIGH. The blower power transistor is controlled by the heater control unit-panel. When the control unit-panel requests HIGH blower speed, the blower power transistor grounds the blower motor which connects it directly to ground, making the blower run at high speed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1. Remove the passenger's dashboard lower cover, the right kick panel, and the glove box. 2. Cut the plastic cross brace in the glove box opening with diagonal cutters in the area shown. Remove and discard the plastic cross brace. 3. Remove the relays (A), then remove the bolts and the glove box frame (B). 4. Remove the ECM/PCM. 5. Disconnect the connectors (A) from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal and Installation > Page 5721 6. Fold the carpet and pad back toward you. Remove the mounting bolts, the mounting nut, and the blower unit. 7. Install the unit in the reverse order of removal. Make sure that there is no air leakage. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal and Installation > Page 5722 Blower Motor: Service and Repair Components Replacement Blower Unit Components Replacement Note these items when overhauling the blower unit. - The recirculation control motor (A), the power transistor (B), the blower motor (C), and the dust and pollen filters (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5726 Blower Motor Relay: Testing and Inspection 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. Blower Motor Relay Blower Motor Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 5730 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. 1. Open the glove box. Remove the glove box stop on each side, then hang the glove box down. 2. Remove the filter lid (A) from the blower unit, then pull out the first dust and pollen filter (B). Slide the second filter to the left, and pull it out. 3. Remove the filter (A) from the housing (B), and replace the filter. 4. Install the filters in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 outlet (B). Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Design Specifications Compressor Clutch: Specifications Air conditioning Compressor clutch Type Dry, dingle plate, foly-V belt drive Electrical power consumption at 68 deg F (20 deg C) 42W maximum at 12V Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Design Specifications > Page 5739 Compressor Clutch: Specifications Service Specifications Clearance ............................................................................................................................................ ............................. 0.5 ± 0.15 mm (0.020 ± 0.006 in.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Compressor Clutch Check Compressor Clutch: Testing and Inspection Compressor Clutch Check Compressor Clutch Check 1. Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set. 2. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag. 3. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance. Clearance: 0.5 ± 0.15 mm (0.020 ± 0.006 in.) NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. 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 262 °F (122 to 128 °C). When the temperature drops below 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Compressor Clutch Check > Page 5742 5. Check resistance of the field coil. If resistance is not within specifications, replace the field coil. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Compressor Clutch Check > Page 5743 Compressor Clutch: Testing and Inspection Compressor Clutch Circuit Compressor Clutch Circuit Troubleshooting 1. Check the No.1 (20A) fuse in the under-hood fuse/relay box, and the No. 14 (10A) 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 (use the Honda PGM Tester PGM-FI data list if possible). Is the coolant temperature above normal? YES - Troubleshoot and repair the cause of the high engine coolant temperature. NO - Go to step 3. 3. Remove the compressor clutch relay from the under-hood fuse/relay box, and test it. Is the relay OK? YES - Go to step 4. NO - Replace the compressor clutch relay. 4. Measure the voltage between the No.2 terminal of the compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 5. NO - Replace the under-hood fuse/relay box. 5. Connect the No.1 and No.2 terminals of the compressor clutch relay 4P socket with a jumper wire. Does the compressor clutch click ? Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Compressor Clutch Check > Page 5744 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 compressor clutch relay 4P socket and body ground. Is there battery voltage? YES - Go to step 9. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the compressor clutch relay socket. 9. Turn the ignition switch OFF. 10. Reinstall the compressor clutch relay. 11. Make sure the A/C switch is OFF. 12. Turn the ignition switch ON (II). 13. Measure the voltage between the No. 18 terminal of ECM/PCM connector E (31P) and body ground with the ECM/PCM connectors connected. Is there battery voltage? YES - Check for loose wires or poor connections at ECM/PCM connector E (31P). If the connections are good, substitute a known-good ECM/PCM, and recheck. If the symptom/indication goes away, replace the original ECM/PCM. NO - Repair open in the wire between the compressor clutch relay and the ECM/PCM. 14. Disconnect the jumper wire. 15. Disconnect the compressor clutch 1P connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Compressor Clutch Check > Page 5745 16. Check for continuity between the No.1 terminal of the compressor clutch relay 4P socket and the No.1 terminal of the compressor clutch 1P connector. Is there continuity? YES - Check the compressor clutch clearance, the thermal protector, and the compressor clutch field coil. NO - Repair open in the wire between the compressor clutch relay socket and the compressor clutch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 5746 Compressor Clutch: Service and Repair Compressor Clutch Overhaul Special Tool Required A/C clutch holder, Robinair 10204, Kent-Moore J37872, or Honda Tool and Equipment KMT-J33939, commercially available 1. Remove the center nut (A) while holding the armature plate with a commercially available A/C clutch holder (B). 2. Remove the armature plate (A) and shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and recheck its clearance. NOTE: The shims are available in four 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 and compressor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 5747 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 and compressor. 5. Reassemble the clutch in the reverse order of disassembly, and note these items. - Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the compressor. - Clean the rotor pulley and compressor sliding surfaces with contact cleaner or other non-petroleum solvent. - Install new snap rings, note the installation direction, and make sure they are fully seated in the groove. - Make sure that the rotor pulley turns smoothly after it's reassembled. - Route and clamp the wires properly or they can be damaged by the rotor pulley. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5751 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5752 Compressor Clutch Relay: Testing and Inspection 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. A/C Compressor Clutch Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Condenser HVAC: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5761 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5762 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5763 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5764 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5765 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5766 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5767 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5768 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5769 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5770 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5771 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5772 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5773 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5774 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Condenser HVAC: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5780 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5781 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5782 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5783 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5784 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5785 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5786 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5787 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5788 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5789 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5790 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5791 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5792 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5793 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5794 Heating And Air Conditioning - Component Location Index 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5795 Condenser HVAC: Service and Repair Condenser Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the front bumper. 3. Remove the bolts, then disconnect the discharge line (A) and the condenser line (B) from the condenser. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. 4. Remove the bolts and mounting brackets (A), then remove the condenser (B) by lifting it up. Be careful not to damage the radiator and condenser fins when removing the condenser. 5. Install the condenser in the reverse order of removal, and note these items: - If you're installing a new condenser, add refrigerant oil (KEIHIN SP-10). - Replace the O-ring with new ones at each fining, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-ring 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 and condenser fins when installing the condenser. - Charge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Locations 7. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions Condenser Fan: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Condenser Fan: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Fans Image 63 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Diagrams > Page 5832 Condenser Fan: Description and Operation How the Circuit Works Voltage is provided at all times to the radiator fan relay contacts through fuse 4 and to the A/C condenser fan relay contacts through fuse 1. With the ignition switch ON (II), voltage is provided to the coils of the relays through fuse 14 (in the under-dash fuse/relay box). The relays are grounded by either the radiator fan switch or by the ECM/PCM. Grounding the relays energizes their coils and applies battery voltage to the radiator and condenser fan motors. Both fans then run until ground is removed from the relay coils. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Testing and Inspection > Condenser Fan Circuit Troubleshooting Condenser Fan: Testing and Inspection Condenser Fan Circuit Troubleshooting Condenser Fan Circuit Troubleshooting 1. Check the No.1 (20A) fuse in the under-hood fuse/relay box, and the No.14 (10A) 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. Remove the condenser fan relay from the under-hood fuse/relay box, and test it. Is the relay OK? YES - Go to step 3. NO - Replace the condenser fan relay. 3. Measure the voltage between the No.2 terminal of the condenser fan relay 4P socket and body ground. Is there battery voltage? YES - Go to step 4. NO - Replace the under-hood fuse/relay box. 4. Connect the No.1 and No.2 terminals of the condenser fan relay 4P socket with a jumper wire. Does the condenser fan run? YES - Go to step 5. NO - Go to step 8. 5. Disconnect the jumper wire. 6. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Testing and Inspection > Condenser Fan Circuit Troubleshooting > Page 5835 7. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket and body ground. Is there battery voltage? YES - Replace the under-hood fuse/relay box. NO - Repair open in the wire between the No.14 fuse in the under-dash fuse/relay box and the condenser fan relay socket in the under-hood fuse/ relay box. 8. Disconnect the jumper wire. 9. Disconnect the condenser fan 2P connector. 10. Check for continuity between the No.1 terminal of the condenser fan relay 4P socket and the No.2 terminal of the condenser fan 2P connector. Is there continuity? YES - Go to step 11. NO - Repair open in the wire between the condenser fan relay socket in the under-hood fuse! relay box and the condenser fan. 11. Check for continuity between the No.1 terminal of the condenser fan 2P connector and body ground. Is there continuity? YES - Replace the condenser fan motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Testing and Inspection > Condenser Fan Circuit Troubleshooting > Page 5836 NO - Check for an open in the wire between the condenser fan and body ground. If the wire is OK, check for poor ground at G201. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Testing and Inspection > Condenser Fan Circuit Troubleshooting > Page 5837 Condenser Fan: Testing and Inspection Radiator and Condenser Fan Common Circuit Troubleshooting Radiator and Condenser Fans Common Circuit Troubleshooting 1. Check the No.1 (20A) and No.4 (20A) fuses in the under-hood fuse/relay box, and the No.14 (10A) 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. Remove the condenser fan relay from the under-hood fuse/relay box. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.3 terminal of the condenser fan relay 4P socket 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 condenser fan relay socket. 5. Turn the ignition switch OFF. 6. Reinstall the condenser fan relay. 7. Make sure the A/C switch is OFF. 8. Turn the ignition switch ON (II). 9. Measure the voltage between the No.6 terminal of ECM/PCM connector B (24P) and body ground with the ECM/PCM connectors connected. Is there battery voltage? YES - Check for loose wires or poor connections at ECM/PCM connector B (24P). If the connections are good, substitute a known-good ECM/PCM, and recheck. If the symptom/indication goes away, replace the original ECM/PCM. NO - Repair open in the wire between the radiator fan relay socket, the condenser fan relay socket, and the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Testing and Inspection > Page 5838 Condenser Fan: Service and Repair Radiator Fan Replacement 1. Drain the engine coolant. 2. Remove the bulkhead cover. (a) Removal the bolt (A) securing the battery clamp, then remove the bulkhead cover (B). 3. Remove the upper radiator hose. 4. Disconnect the condenser fan motor connectors. 5. Remove the condenser fan to radiator mounting bolts (6x1.0 mm) 6. Remove the condenser fan shroud assembly. 7. Install the condenser fan shroud assembly in reverse order of removal. 8. Install the bulkhead in reverse order of removal. Apply body paint to the bulkhead mounting bolts. 9. Fill the radiator with engine coolant and bleed the air. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Condenser Fan Motor Relay: Testing and Inspection 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. Condenser Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations 63. Under Middle of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Component Tests and General Diagnostics Control Assembly: Component Tests and General Diagnostics Heater Control Power and Ground Circuits Troubleshooting 1. Check the No.14 (10A) 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 heater control panel 30P connector. 3. Turn the ignition switch ON (II). 4. Measure the voltage between the No.15 terminal of the heater control panel 30P 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 heater control panel. 5. Turn the ignition switch OFF. 6. Check for continuity between the No.1 terminal of the heater control panel 30P connector and body ground. Is there continuity? YES - Check for loose wires or poor connections at the heater control panel 30P 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 - 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5849 Heater Control Panel Inputs And Outputs (30P Connector) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal and Installation Control Assembly: Service and Repair Removal and Installation Heater Control Panel Removal/Installation NOTE: Take care not to scratch the dashboard and related parts. 1. Remove the dashboard pocket. 2. Pull the parking brake lever. 3. Remove the screws (A), and pull out the heater control panel (B) to release the clips (C). Disconnect the heater control unit connector (D), then remove the heater control panel. 4. Install the panel in the reverse order of removal, and make sure the heater control unit connector is plugged in properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal and Installation > Page 5852 Control Assembly: Service and Repair Control Panel Bulb Heater Control Panel Bulb Replacement 1. Discharge the static electricity (which accumulated on you when you removed the climate control unit) by touching the door striker or other body parts. 2. Remove the self-tapping screws, then carefully separate the heater control panel display (A) from the control panel (B). Do not kink or pull on the wires between the display and the control panel. Do not touch the electronic components on the printed circuit board in the control panel. 3. Remove the bulb(s) with a flat-tip screwdriver. 4. Install the bulb(s) in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative Evaporator Core: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5861 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5862 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5863 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5864 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5865 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5866 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5867 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5868 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5869 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5870 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5871 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5872 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5873 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5874 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative Evaporator Core: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5880 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5881 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5882 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5883 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5884 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5885 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5886 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5887 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5888 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5889 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5890 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5891 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5892 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5893 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5894 Heating And Air Conditioning - Component Location Index 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5895 Evaporator Core: Service and Repair Evaporator Core Replacement 1. Recover the refrigerant with a recovery/recycling/charging station. 2. Remove the bolt, then disconnect the suction line (A) and the receiver line (B) from the evaporator core. 3. Remove the blower unit. 4. Remove the bolt and the ECM/PCM bracket (A). Remove the self-tapping screws and the expansion valve cover (B). 5. Carefully pull out the evaporator core without bending the pipes. 6. Install the core in the reverse order of removal, and note these items: - If you're installing a new evaporator core, add refrigerant oil (KEIHIN SP-10). - Replace the O-ring with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-ring 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations 51. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5899 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5900 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5901 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor clockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative Expansion Valve: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5910 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5911 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5912 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5913 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5914 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5915 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5916 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5917 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5918 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5919 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5920 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5921 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5922 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5923 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative Expansion Valve: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5929 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5930 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5931 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5932 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5933 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5934 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5935 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5936 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5937 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5938 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5939 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5940 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5941 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5942 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 5948 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Heater Control Valve Cable > Component Information > Technical Service Bulletins > Page 5949 Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5953 Heater Core: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5954 8. Remove the mounting nut from the heater unit, Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the ECM/PCM. 11. Disconnect the connectors (A) from the heater unit, then disconnect the drain hose (B). Remove the mounting bolts and nuts, then remove the blower-heater unit (C). 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 self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Locations > Page 5955 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. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - For evaporator core and A/C-related information, refer to evaporator core replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 5959 Heater Core Case: Service and Repair Heater Unit/Core Replacement SRS components are located in this area. Review the SRS component locations and precautions and procedures in the SRS section before performing repairs or service. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery. 3. Disconnect the suction and receiver lines from the evaporator core. 4. From under the hood, open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C). Turn the heater valve arm to the fully opened position as shown. 5. When the engine is cool, drain the engine coolant from the radiator. 6. Slide the hose clamps (A) back, then disconnect the inlet heater hose (B) and the outlet heater hose (C) from the heater core. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately. 7. Remove the mounting bolt and the heater valve as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 5960 8. Remove the mounting nut from the heater unit, Take care not to damage or bend the fuel lines and the brake lines, etc. 9. Remove the dashboard. 10. Remove the ECM/PCM. 11. Disconnect the connectors (A) from the heater unit, then disconnect the drain hose (B). Remove the mounting bolts and nuts, then remove the blower-heater unit (C). 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 self-tapping screws and the flange cover (C), then remove the grommet (D), and carefully pull out the heater core (E) so you don't bend the inlet and outlet pipes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Locations > Page 5961 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. - Be sure to connect the drain hose securely. - Adjust the heater valve cable. - Make sure that there is no coolant leakage. - Make sure that there is no air leakage. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. - For evaporator core and A/C-related information, refer to evaporator core replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Hose/Line HVAC: Customer Interest A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5973 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5974 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5975 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5976 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5977 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5978 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5979 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5980 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5981 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5982 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5983 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5984 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5985 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5986 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative Hose/Line HVAC: All Technical Service Bulletins A/C - System is Inoperative 09-076 October 14, 2010 Applies To: 2002-04 CR-V - ALL A/C System Does Not Work (Supersedes 09-076, dated July 23 2010; see REVISION SUMMARY) REVISION SUMMARY The DIAGNOSIS and REPAIR PROCEDURE sections were revised. American Honda recommends that you review these sections thoroughly. SYMPTOM The A/C system does not work. PROBABLE CAUSE The A/C compressor failed. CORRECTIVE ACTION Inspect the A/C compressor, the A/C compressor clutch, coil, and all other A/C system parts. Replace any parts that are internally contaminated or fails the service manual test. PARTS INFORMATION TOOL INFORMATION A/C Compressor Kit: 07MF-000A150 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5992 WARRANTY CLAIM INFORMATION The normal warranty applies. Failed Part: P/N 38810-PNB-006 Defect Code: 08103 Symptom Code: 03214 Skill Level: Repair Technician DIAGNOSIS NOTE: This procedure is in an outline form that you can also use as a checklist for the diagnosis/repair. If you need more details, bookmark the following procedures in the 2002-2004 OH-V Service Manual, or view them online: ^ Refrigerant Recovery/Recharging ^ Battery Disconnection/Reconnection ^ Front Bumper Removal ^ Radiator Reservoir Removal ^ A/C Compressor Clutch Check ^ A/C Compressor Clutch Overhaul ^ Drive Belt Replacement ^ Auto-Tensioner Replacement ^ A/C Condenser Replacement ^ ECM/PCM Removal/Installation 1. If the A/C compressor is operable, run the engine at idle speed, and let the A/C work for a few minutes, then shut the engine off. 2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets. 3. Make sure the ignition switch is in LOCK (0), then disconnect the negative cable from the battery. 4. Recover the refrigerant with a recovery/recycling/ charging station. 5. Remove the nut, then remove the discharge line from the A/C compressor. Swab the inside of the hose passage on the discharge port of the A/C compressor: ^ If you find metal particles or any gray or black residue, the A/C compressor must be replaced. Continue with step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5993 ^ If you do not find any metal particles or any gray or black residue, this service bulletin does not apply. Reinstall the discharge hose using a new 0-ring, then continue with normal troubleshooting. 6. Remove the nut, then remove the suction hose from the compressor. Swab the inside of the hose passage on the suction port of the compressor: ^ If you find any metal particles, or any dark gray or black residue, the entire NC system is contaminated. All A/C components must be replaced. Go to REPAIR PROCEDURE C. ^ If the suction port is clean or has a light gray residue, other components may be contaminated, go to step 7. 7. Remove the radiator reservoir. 8. Remove the drive belt. 9. Remove the auto-tensioner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5994 10. Disconnect the alternator connector and the BLK wire, then remove the harness clip from the alternator. 11. Remove the alternator (three bolts). 12. Remove the front bumper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5995 13. Remove the discharge hose bolt, then disconnect the discharge hose from the condenser. 14. Swab the inside of the discharge line and the condenser passage. ^ If you find any metal particles or other debris, the condenser and discharge line must be replaced. Go to step 15. ^ If no metal particles or debris is found, go to step 16. 15. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean or slightly contaminated, go to REPAIR PROCEDURE B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5996 ^ If the desiccant bag is heavily contaminated, go to REPAIR PROCEDURE C. 16. Remove the cap with 0-rings, the filter, and the desiccant bag from the receiver dryer. ^ If the desiccant bag is clean, go to REPAIR PROCEDURE A. ^ If the desiccant bag is slightly contaminated, go to REPARE PROCEDURE B. REPAIR PROCEDURE A (A/C SERVICE KIT A) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5997 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for desiccant/ filter and compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the desiccant and filter, the amount of oil drained from the new compressor needs to be reduced by 10 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5998 7. Install a new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reconnect the discharge line and the condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE B (A/C SERVICE KIT B) 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the NC compressor clutch as described in the service manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 5999 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Adjust the amount of refrigerant oil in the new A/C compressor. NOTE: The new compressor comes with 130 mL of SP-10 PAG oil. Calculate the amount of oil to be drained from the new compressor for the discharge hose, the condenser, the desiccant/filter and the compressor replacement. Compressor: Drain the PAG oil from the failed A/C compressor into an appropriate container and record the amount in mL. Subtract the volume of oil drained from the failed compressor from 130 mL (5-1/3 fl.oz.), and drain the calculated volume of oil from the new compressor: 130 mL (5-1/3 fl.oz.) - Volume of oil removed compressor = Volume to drain from new compressor. NOTE: Even if no oil is drained from the failed compressor, don't drain more than 50 mL (1-2/3 fl.oz.) from the new compressor. Example: When replacing the discharge hose, condenser, and desiccant/filter, the amount of oil drained from the new compressor needs to be reduced by 45 mL. 5. Install the new compressor, then torque its mounting bolts to 22 N.m (16 lb-ft). Connect the discharge line, the suction line, and the condenser line with new 0-rings, then torque the line nut and the bolts to 9.8 N.m (7.2 lb-ft). Reconnect the compressor clutch connector. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 6. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the old condenser. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6000 7. Install the new condenser, new desiccant bag, a new filter, and new 0-rings in the receiver dryer. NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 8. Install the new condenser, new discharge line, and the original condenser line with new 0-rings, then torque the bolts to 9.8 N.m (7.2 lb-ft). 9. Reinstall the A/C condenser and the upper mounting brackets, and torque the bolts to 9.8 N.m (7.2 lb-ft). 10. Reinstall the alternator. 11. Reinstall the drive belt. 12. Reinstall the auto-tensioner. 13. Reinstall the front bumper, and replace any damaged mounting clips. 14. Reconnect the battery cables to the battery, then do the battery reconnection procedure. 15. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. REPAIR PROCEDURE C (A/C SERVICE KIT C) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6001 1. Disconnect the connector, then remove the A/C compressor (four bolts). Be careful not to damage the radiator fins. 2. Check the A/C compressor clutch as described in the service manual. 3. If the clutch and the coil test good, remove and install them on the new compressor, or install a new clutch and coil if needed. 4. Disconnect the receiver line from the condenser. 5. Remove the bolts and mounting brackets, then remove the condenser by lifting it up. Be careful not to damage the radiator fins when removing the condenser. 6. Remove the suction hose, the discharge hose, the A/C line, receiver line A, and receiver line B. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6002 7. Remove the line bolt, then disconnect the suction line and the receiver line from the evaporator core. 8. Remove the passenger's dashboard undercover. Pull down on the front edge to release the clips. Pull the cover away to release the pins from the holders. 9. Remove the right kick panel and the glove box. 10. Cut the plastic cross brace in the glove box opening with diagonal cutters in the areas shown. Remove and discard the plastic cross brace. 11. Remove the relays, then remove the bolts and the glove box frame. 12. Remove the ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6003 13. Disconnect the connectors from the blower motor, the power transistor, and the recirculation control motor, then remove the wire harness clips. 14. Fold the carpet and the pad back toward you. Remove the mounting bolts, the mounting nuts, and the blower unit. 15. Remove the bolt and the ECM/PCM bracket. Remove the self-tapping screws and the expansion valve cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6004 16. Carefully pull out the evaporator. 17. Remove the bolts from the expansion valve. 18. Install the new expansion valve and new 0-rings on the new evaporator, then torque the bolts to 9.8 N.m (7.2 lb-ft). 19. Install a new evaporator, then reinstall the ECM/PCM bracket and the expansion valve cover. 20. Reinstall the blower unit. 21. Reinstall the ECM/PCM. 22. Reinstall the dashboard undercover. 23. Reinstall the relays. 24. Reinstall the kick panel and the glove box. 25. Install a new suction line and a new receiver line. Torque the line nuts to 9.8 N.m (7.2 lb-ft). 26. Install a new desiccant bag, a new condenser, a new condenser line, a new discharge hose, and new 0-rings. Torque the condenser bracket bolts to 9.8 N.m (7.2 lb-ft). Torque the condenser discharge lines to 9.8 N.m (7.2 lb-ft). NOTE: Apply a thin coat of refrigerant oil to the 0-rings before installation. 27. Install a new receiver line A and a new receiver line B. 28. Install a new clutch and coil (if needed) or the original to a new A/C compressor. Install the compressor, then torque the bolts to 22 N.m (16 lb-ft). 29. Install a new suction hose and a new discharge hose with new 0-rings to the compressor, and torque the line nuts to 9.8 N.m (7.2 lb-ft) 30. Reinstall the alternator, and torque its mounting bolts to 22 N.m (16 lb-ft). 31. Reinstall the auto-tensioner. 32. Reinstall the drive belt. 33. Reinstall the radiator. 34. Reinstall the front bumper. 35. Reconnect the battery. 36. Recharge the A/C system with a recovery/ recycling/recharge station. Recharging includes these steps: ^ Evacuate the system. ^ Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 09-076 > Oct > 10 > A/C - System is Inoperative > Page 6005 ^ Check for refrigerant leaks. ^ Check the A/C performance. ^ Do the ECM/PCM idle learn procedure. ^ Do the power window control unit reset procedure. ^ Enter the anti-theft codes for the audio system, then enter the customer's audio system presets. NOTE: A new compressor comes with enough oil for the entire system. However, the oil must be balanced in the system. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations Power Transistor HVAC: Locations 87. Under Right Side Of Dash Heating And Air Conditioning - Component Location Index 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations > Page 6009 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Power Transistor HVAC > Component Information > Locations > Page 6010 Power Transistor HVAC: Testing and Inspection Power Transistor Test 1. Disconnect the 4P connector from the power transistor. 2. Measure the resistance between the No.3 and No.4 terminals of the power transistor. It should be about 1.4 - 1.5 kOhm. - If the resistance is within the specifications, go to step 3. - If the resistance is not within the specifications, replace the power transistor. 3. Carefully release the lock tab on the No.1 terminal (BLU/YEL) (A) in the 4P connector, then remove the terminal and insulate it from body ground. 4. Reconnect the 4P connector to the power transistor. 5. Supply 12 volts to the No.1 cavity with a jumper wire. 6. Turn the ignition switch ON (II), and check that the blower motor runs. - If the blower motor does not run, replace the power transistor. - If the blower motor runs, the power transistor is OK. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations Heating And Air Conditioning - Component Location Index 2 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Locations > Page 6014 Receiver Dryer: Service and Repair Receiver/Dryer Desiccant Replacement 1. Remove the condenser. 2. Remove the cap (A) from the bottom of the condenser, then remove the O-ring (B), the filter (C) and the desiccant (D). 3. Install the desiccant in the reverse order of removal, and note these items: - Replace the O-ring with new ones, and apply a thin coat of refrigerant oil (KEIHIN SP-10) before installing them. - Be sure to use the right O-ring for HFC-134a (R-134a) to avoid leakage. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 6019 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 6020 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Leak Detection > Page 6021 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Type HFC - 134a (R-134a) Capacity of Systems 480 - 530 g (17 - 18.7 oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6024 Refrigerant: Fluid Type Specifications Refrigerant Type ..................................................................................................................................................... ........................................... HFC-134 a (R-134 a) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Performance Test Refrigerant: Testing and Inspection Performance Test A/C System Tests Performance Test CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. WARNING: - Compressed air mixed R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134 a service equipment or vehicle air conditioning systems. The performance test will help determine if the air conditioner system is operating within specifications. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions. 2. Insert a thermometer in the center air vent. Determine the relative humidity and air temperature. 3. Test conditions: - Avoid direct sunlight. - Open the hood. - Open the front doors. - Set the temperature control dial on Max Cool, the mode control dial on Vent and the recirculation control switch on Recirculate. - Turn the A/C switch on and the fan switch on Max. - Run the engine at 1,500 rpm. - No driver or passengers in vehicle. 4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low system pressure from the A/C gauges. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 6027 5. To complete the charts: - Mark the delivery temperature along the vertical line. - Mark the intake temperature (ambient air temperature) along the bottom line. - Draw a line straight up from the air temperature to the humidity. - Mark a point 10 % above and 10 % below the humidity level. - From each point, draw a horizontal line across the delivery temperature. - The delivery temperature should fall between the two lines. - Complete the low-side pressure test and high-side pressure test in the same way. - Any measurements outside the line may indicate the need for further inspection. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 6028 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Performance Test > Page 6029 Refrigerant: Testing and Inspection Refrigerant Leak Test Refrigerant Leak Test Special Tool Required Leak detector, Honda Tool and Equipment YGK-H-10PM, commercially available WARNING: - Compressed air mixed with R-134a forms a combustible vapor. - The vapor can burn or explode causing serious injury. - Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning system. CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with compressed air. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and remove the charging system couplers. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 480 to 530 g 1.48 to 0.53 kg 1.06 to 1.17 lbs 16.9 to 18.7 oz 3. Check the system for leaks using a R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. 4. If you find leaks that require the system to be opened (to repair or replace hoses, fittings, etc.), recover the system. 5. After checking and repairing leaks, the system must be evacuated. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery Refrigerant: Service and Repair Refrigerant Recovery Refrigerant Recovery CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery > Page 6032 Refrigerant: Service and Repair System Evacuation System Evacuation CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C system has been opened to the atmosphere, such as during installation or repair, it must be evacuated using a R-134a refrigerant recovery/recycling/charging station (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) 2. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. Evacuate the system. 3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in the system. Partially charge the system, and check for leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Recovery > Page 6033 Refrigerant: Service and Repair System Charging System Charging CAUTION: - Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. - Be careful when connecting service equipment. - Do not breathe refrigerant or vapor. Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. Connect a R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (8) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions. 2. Evacuate the system. 3. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only KEIHIN SP-10 refrigerant oil. 4. Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant capacity: 480 to 530 g 0.48 to 0.53 kg 1.06 to 1.17 lbs 16.9 to 18.7 oz 5. Check for refrigerant leaks. 6. Check for system performance. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Oil Type KEIHIN: SP-10 Capacity Of Components Condenser 5/6 fl. oz (0.9 imp. oz) Evaporator 1 1/3 fl. oz (1.4 imp. oz) Each Line and Hose 1/3 fl. oz (0.5 imp. oz) Reciever 1/3 fl. oz (0.4 imp. oz) Compressor 4 1/3 fl. oz (4.6 imp. oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6038 Refrigerant Oil: Fluid Type Specifications HVAC SYSTEM HVAC SYSTEM ITEM MEASUREMENT QUALIFICATION STANDARD OR NEW Refrigerant Oil Type KEIHIN: SP-10 Capacity Of Components Condenser 5/6 fl. oz (0.9 imp. oz) Evaporator 1 1/3 fl. oz (1.4 imp. oz) Each Line and Hose 1/3 fl. oz (0.5 imp. oz) Reciever 1/3 fl. oz (0.4 imp. oz) Compressor 4 1/3 fl. oz (4.6 imp. oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6039 Refrigerant Oil: Service and Repair A/C Refrigerant Oil Replacement Recommended PAGoil: KEIHIN SP-10: - PIN 38897-P931A01AH: 120 ml (4 fl.oz) - PIN 38899-P13A01: 40 ml (1 1/3 fl.oz) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6040 Add the recommended refrigerant oil in the amount listed if you replace any of the following parts: - To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. - Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. - Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 6045 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6050 Blower Motor Relay: Testing and Inspection 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. Blower Motor Relay Blower Motor Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6054 Compressor Clutch Relay: Description and Operation Air Conditioning (A/C) Compressor Clutch Relay When the ECM/PCM receives a demand for cooling from the A/C system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6055 Compressor Clutch Relay: Testing and Inspection 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. A/C Compressor Clutch Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Condenser Fan Motor Relay: Testing and Inspection 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. Condenser Fan Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations 51. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6066 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6067 Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Temperature Sensor Test 1. Dip the sensor in ice water, and measure the resistance between its terminals. 2. Then pour hot water on the sensor, and check for a change in resistance. 3. Compare the resistance readings with the specifications shown in the graph; the resistance should be within the specifications. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6068 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Replacement 1. Disconnect the 2P connector (A) from the evaporator temperature sensor (B), then remove the connector clip (C). Turn the evaporator temperature sensor clockwise to the stop, and carefully pull out it. 2. Install the sensor in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations 17. Front of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Locations > Page 6073 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Heating and Air Conditioning > Thermal Limiting Fuse > Component Information > Service and Repair Thermal Limiting Fuse: Service and Repair Compressor Thermal Protector Replacement 1. Remove the bolt, the ground terminal (A), and the holder (B). Disconnect the field coil connector (C), then remove the thermal protector (D). 2. Replace the thermal protector (A) with a new one, and apply silicone sealant (B) to the bottom of the thermal protector. 3. Install in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 SRS Component Replacement/Inspection After Deployment NOTE: Before doing any SRS repairs, use the PGM Tester SRS menu method to check for DTCs; refer to the DTC Troubleshooting Index for the less obvious deployed parts (seat belt tensioners, OPDS sensor, side airbag sensors, etc.) After a collision where the seat belt tensions deployed, replace these items: - Seat belt tensioners - Seat belt buckle tensioners - SRS unit - Front sensors After a collision where the frontal airbag(s) deployed, replace these items: - SRS unit - Deployed airbag(s) - Seat belt tensioners - Seat belt buckle tensioners - Front sensors After a collision where the side airbag(s) deployed, replace these items: - SRS unit - Deployed side airbag (s) - Side impact sensor (s) for side (s) deployed During the repair process, inspect these areas: - Inspect all the SRS wire harnesses.Replace, don't repair, any damaged harnesses. - Inspect the cable reel for heat damage.If there is any damage, replace the cable reelAfter the vehicle is completely repaired, turn the ignition switch on.If the SRS indicator comes on for about 6 seconds and then goes off, the SRS airbag system is OK. If the indicator does not function properly, use the PGM Tester SRS Menu Method to read the DTC (s).If this doesn't retrieve any codes, use the Tester's SCS menu method.If the SCS method doesn't work, you may need to install a known-good SRS unit to read the DTC(s).If you still cannot retrieve a code, go to SRS Indicator Circuit Troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6087 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6088 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6089 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6090 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6093 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6094 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6095 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6096 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6099 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6100 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6101 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Recalls for Air Bag Harness: > NHTSA04V255000 > Jun > 04 > Recall 04V255000: Air Bag Harness Defect Air Bag Harness: Recalls Recall 04V255000: Air Bag Harness Defect DEFECT: On certain sport utility vehicles, the wiring harness of the driver's front air bag was incorrectly wired. In the event of a crash, the air bag inflation rate will be incorrect, which could increase the risk of injury. REMEDY: Dealers will repair the wiring. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact Honda at 1-800-999-1009. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > NHTSA04V255000 > Jun > 04 > Recall 04V255000: Air Bag Harness Defect Air Bag Harness: All Technical Service Bulletins Recall 04V255000: Air Bag Harness Defect DEFECT: On certain sport utility vehicles, the wiring harness of the driver's front air bag was incorrectly wired. In the event of a crash, the air bag inflation rate will be incorrect, which could increase the risk of injury. REMEDY: Dealers will repair the wiring. The manufacturer has reported that owner notification is expected to begin during July 2004. Owners may contact Honda at 1-800-999-1009. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations 73. Under Middle of Dash 93. In Front Passenger's Seat (Side Airbag) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6119 Air Bag Control Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6120 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6121 Air Bag Control Module: Service Precautions Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6122 Air Bag Control Module: Description and Operation SRS Unit The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag and front passenger's airbag. Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the airbag inflators (and seat belt tensioners). 3. The inflators must ignite and deploy the airbags (and activate the tensioners). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6123 Air Bag Control Module: Service and Repair 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 5 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. Remove the right heater unit duct (A). 7. Pull down the carpet on the right side, then remove the Torx bolt (A) and the harness clip (B) from the SRS unit. 8. Pull down the carpet on the left side, then disconnect the connectors. Remove the Torx bolt (A), loosen the Torx bolt (B), then pull out the SRS unit from the right side. 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. Install the right heater unit duct. 3. Reinstall the dashboard center lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6124 4. Reconnect the driver's and front passenger's airbag connectors. 5. Reconnect the side airbag connectors. 6. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 7. Reconnect the battery negative cable. 8. Initialize the OPDS unit. 9. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement Clockspring Assembly / Spiral Cable: Recalls Recall - SRS Cable Reel Replacement 04-035 August 3, 2004 Applies To: 2002-03 CR-V - All VINs beginning with "SHSRD" 2004 CR-V 2WD - From VIN SHSRD68...4U200001 thru SHSDR68...4U206096 2004 CR-V 4WD - From VIN SHSRD7...4U200001 thru SHSRD7....4U238165 Safety Recall: CR-V SRS Cable Reel Connector (Supersedes 04-035, dated June 21, 2004) Updated information is shown by a black bar and asterisks. BACKGROUND The wire harness of the driver's front airbag was incorrectly wired. During specific crash conditions, the airbag inflation rate is incorrect, which could increase the risk of injury to the driver. CUSTOMER NOTIFICATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6133 All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown on your campaign responsibility report. ^ The vehicle is shown as eligible on an iN VIN status inquiry. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6134 Some vehicles affected by this recall may be in your new or used vehicle inventory. According to federal law, these vehicles cannot be sold or leased until they are repaired. To see if a vehicle is affected by this recall, do a VIN status inquiry before selling it. CORRECTIVE ACTION Inspect the cable reel connector wiring, and if necessary, replace the SRS cable reel 4P connector, and reposition the cable reel connector wires. PARTS INFORMATION SRS Connector Set: P/N 77978-S04-305, H/C 7806789 (Includes connector and lock tab) TOOL INFORMATION SRS Terminal Tool Set: T/N 070AZ-SCAA120 [Includes Terminal Tool A (two prongs) and Terminal Tool B (one prong)]. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 753103 Flat Rate Time: 0.3 hour Failed Part: P/N 77900-S5A-A14 H/C 6850176 Defect Code: 5AH Symptom Code: P34 Template ID: 04-035A Skill Level: Repair Technician REPAIR PROCEDURE NOTE: To avoid contaminating the SRS cable reel terminals, make sure your hands are clean while working on the cable reel connector. 1. Turn the ignition switch to ON (II), and watch the SRS indicator. ^ If the indicator goes off within 10 seconds, go to step 2. ^ If the indicator stays on, troubleshoot and repair the cause before continuing. If the required repair includes SRS cable reel replacement, go to step 19. Otherwise, go to step 2. *2. Turn the ignition switch to the LOCK (0) position, and remove the access panel from the steering wheel.* Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6135 *3. Detach the cable reel 4P connector from the steering wheel so it hangs free. DO NOT disconnect the 4P connector.* 4. Inspect the wire order going into the cable reel connector. With the cable reel connector positioned as shown below, the wire order, left to right, should be YELLOW, BLACK, GREEN, WHITE. * ^ If the wires are in the correct order, or if they are all the same color, go to step 5. ^ If the wires are not in the correct order, go to step 6.* *5. Reattach the cable reel 4P connector to the steering wheel, and reinstall the access panel on the steering wheel. Go to step 23.* 6. Make sure you have the anti-theft code for the radio. If you are working on a customer's vehicle write down the radio station presets. 7. Remove the negative cable from the battery, and wait at least 3 minutes. 8. Turn the steering wheel fully to the left, then remove the key from the ignition switch. 9. Disconnect the cable reel 4P connector from the driver's airbag connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6136 10. Using Terminal Tool A from the SRS Terminal Tool Set, remove the lock tab from the cable reel connector. 11. Using Terminal Tool B from the SRS Terminal Tool Set, remove the terminals from the original cable reel connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6137 * NOTE: If you cannot remove the terminals, go to step 19.* 12. Check the condition of the terminals: * ^ If any of the terminals are damaged or contaminated with oil or grease, go to step 19. ^ If no terminals are damaged or contaminated with oil or grease, go to step 13.* 13. Transfer the terminals to the new connector in the correct order: YELLOW, BLACK, GREEN, WHITE. 14. After transferring the terminals to the new connector, gently pull on each wire to make sure the terminals are engaged. 15. Insert a new lock tab into the connector. 16. Reconnect the cable reel 4P connector to the driver's airbag 4P connector, then reattach the cable reel connector. Reinstall the access panel on the steering wheel. 17. Reconnect the negative cable to the battery. 18. Turn the ignition switch to ON (II), and watch the SRS indicator. ^ If the indicator goes off within 10 seconds, go to step 20. ^ If the indicator does not go off within 10 seconds, go to step 19. 19. Replace the cable reel. ^ Refer to page 23-137 of the 2002-04 CR-V Service Manual. * ^ In ISIS, enter keyword REEL, and select Cable Reel Replacement from the list.* 20. 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 warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle fully closed and all electrical items off) for 10 minutes. 21. Initialize the driver's window auto-up feature: * ^ 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. 22. Enter the radio anti-theft code, and set the clock. If you are working on a customer's vehicle, enter the radio station presets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6138 23. Center-punch a completion mark above the 11th character of the engine compartment VIN. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall - SRS Cable Reel Replacement 04-035 August 3, 2004 Applies To: 2002-03 CR-V - All VINs beginning with "SHSRD" 2004 CR-V 2WD - From VIN SHSRD68...4U200001 thru SHSDR68...4U206096 2004 CR-V 4WD - From VIN SHSRD7...4U200001 thru SHSRD7....4U238165 Safety Recall: CR-V SRS Cable Reel Connector (Supersedes 04-035, dated June 21, 2004) Updated information is shown by a black bar and asterisks. BACKGROUND The wire harness of the driver's front airbag was incorrectly wired. During specific crash conditions, the airbag inflation rate is incorrect, which could increase the risk of injury to the driver. CUSTOMER NOTIFICATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6144 All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items: ^ The customer has a notification letter. ^ The vehicle is shown on your campaign responsibility report. ^ The vehicle is shown as eligible on an iN VIN status inquiry. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6145 Some vehicles affected by this recall may be in your new or used vehicle inventory. According to federal law, these vehicles cannot be sold or leased until they are repaired. To see if a vehicle is affected by this recall, do a VIN status inquiry before selling it. CORRECTIVE ACTION Inspect the cable reel connector wiring, and if necessary, replace the SRS cable reel 4P connector, and reposition the cable reel connector wires. PARTS INFORMATION SRS Connector Set: P/N 77978-S04-305, H/C 7806789 (Includes connector and lock tab) TOOL INFORMATION SRS Terminal Tool Set: T/N 070AZ-SCAA120 [Includes Terminal Tool A (two prongs) and Terminal Tool B (one prong)]. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 753103 Flat Rate Time: 0.3 hour Failed Part: P/N 77900-S5A-A14 H/C 6850176 Defect Code: 5AH Symptom Code: P34 Template ID: 04-035A Skill Level: Repair Technician REPAIR PROCEDURE NOTE: To avoid contaminating the SRS cable reel terminals, make sure your hands are clean while working on the cable reel connector. 1. Turn the ignition switch to ON (II), and watch the SRS indicator. ^ If the indicator goes off within 10 seconds, go to step 2. ^ If the indicator stays on, troubleshoot and repair the cause before continuing. If the required repair includes SRS cable reel replacement, go to step 19. Otherwise, go to step 2. *2. Turn the ignition switch to the LOCK (0) position, and remove the access panel from the steering wheel.* Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6146 *3. Detach the cable reel 4P connector from the steering wheel so it hangs free. DO NOT disconnect the 4P connector.* 4. Inspect the wire order going into the cable reel connector. With the cable reel connector positioned as shown below, the wire order, left to right, should be YELLOW, BLACK, GREEN, WHITE. * ^ If the wires are in the correct order, or if they are all the same color, go to step 5. ^ If the wires are not in the correct order, go to step 6.* *5. Reattach the cable reel 4P connector to the steering wheel, and reinstall the access panel on the steering wheel. Go to step 23.* 6. Make sure you have the anti-theft code for the radio. If you are working on a customer's vehicle write down the radio station presets. 7. Remove the negative cable from the battery, and wait at least 3 minutes. 8. Turn the steering wheel fully to the left, then remove the key from the ignition switch. 9. Disconnect the cable reel 4P connector from the driver's airbag connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6147 10. Using Terminal Tool A from the SRS Terminal Tool Set, remove the lock tab from the cable reel connector. 11. Using Terminal Tool B from the SRS Terminal Tool Set, remove the terminals from the original cable reel connector. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6148 * NOTE: If you cannot remove the terminals, go to step 19.* 12. Check the condition of the terminals: * ^ If any of the terminals are damaged or contaminated with oil or grease, go to step 19. ^ If no terminals are damaged or contaminated with oil or grease, go to step 13.* 13. Transfer the terminals to the new connector in the correct order: YELLOW, BLACK, GREEN, WHITE. 14. After transferring the terminals to the new connector, gently pull on each wire to make sure the terminals are engaged. 15. Insert a new lock tab into the connector. 16. Reconnect the cable reel 4P connector to the driver's airbag 4P connector, then reattach the cable reel connector. Reinstall the access panel on the steering wheel. 17. Reconnect the negative cable to the battery. 18. Turn the ignition switch to ON (II), and watch the SRS indicator. ^ If the indicator goes off within 10 seconds, go to step 20. ^ If the indicator does not go off within 10 seconds, go to step 19. 19. Replace the cable reel. ^ Refer to page 23-137 of the 2002-04 CR-V Service Manual. * ^ In ISIS, enter keyword REEL, and select Cable Reel Replacement from the list.* 20. 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 warm up to its normal operating temperature (the cooling fans cycle twice). ^ Let the engine idle (throttle fully closed and all electrical items off) for 10 minutes. 21. Initialize the driver's window auto-up feature: * ^ 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. 22. Enter the radio anti-theft code, and set the clock. If you are working on a customer's vehicle, enter the radio station presets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 04-035 > Aug > 04 > Recall - SRS Cable Reel Replacement > Page 6149 23. Center-punch a completion mark above the 11th character of the engine compartment VIN. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6150 Clockspring Assembly / Spiral Cable: Locations 34. In Steering Column Cover 36. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6151 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6152 Clockspring Assembly / Spiral Cable: Service Precautions Steering-related Precautions Cable Reel Alignment Misalignment of the cable reel could cause an open in the wiring, making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed. * Installation of the steering wheel * Installation of the cable reel * Installation of the steering column * Other steering-related adjustment or installation Do not disassemble the cable reel. Do not apply grease to the cable reel. If the cable reel shows any signs of damage, replace it with a new one. For example, it does not rotate smoothly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6153 Clockspring Assembly / Spiral Cable: Adjustments Cable Reel Alignment - Misalignment of the cable reel could cause an open in the wiring making the SRS system and the horns inoperative. Center the cable reel whenever the following is performed. Installation of the steering wheel - Installation of the cable reel - Installation of the steering column - Other steering-related adjustment or installation - Do not disassemble the cable reel. - Do not apply grease on the cable reel. - If the cable reel shows any signs of damage (for example, it does not rotate smoothly) replace it with a new one. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6154 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. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6155 8. Disconnect the dashboard wire harness B 4P connector (1) from the cable reel, then disconnect the dashboard wire harness B 5P connector (2) from the cable reel. 9. Release the tab (A), then remove the cable reel from the column. Installation 1. Before installing the steering wheel, align the front wheels straight ahead. 2. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6156 4. Carefully install the cable reel (A) on the steering column shaft. Then connect the 5P connector (1) to the cable reel, and connect the dashboard wire harness B 4P connector (2) to the cable reel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations 48. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 6160 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 96. Left B-Pillar (Right Similar) 130. Behind Right Side of Front Bumper 135. Behind Left Side of Front Bumper Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6164 Impact Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6165 Impact Sensor: Service Precautions SRS Unit, Front Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF. - During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit, front sensors, and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. - Do not disassemble the SRS unit or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit and side impact sensors are installed securely, with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit or the side impact sensors, and keep them away from dust. - Store the SRS unit and the side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6166 Impact Sensor: Service and Repair 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 and the B-pillar lower trim panel. 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 (1) to the side impact sensor (B). 2. Reconnect the negative battery 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. Front Sensor Replacement Removal 1. Disconnect the negative battery 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6167 4. Disconnect the engine compartment wire harness 2P connector (1), and remove the two Torx bolts (A) using a Torx T30 bit, then remove the front sensor (B). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (1) to the front sensor (B). 2. Reconnect the negative battery cable. 3. After installing the front 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6176 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6177 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6178 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6179 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6180 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6181 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6182 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6183 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6184 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6185 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6186 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6192 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6193 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6194 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6195 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6196 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6197 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6198 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6199 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6200 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6201 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6202 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6211 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6212 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6213 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6214 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6215 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6216 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6217 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6218 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6219 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6220 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6221 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6227 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6228 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6229 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6230 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6231 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6232 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6233 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6234 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6235 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6236 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6237 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams Side Air Bag: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag Side Air Bag: Service and Repair Side Airbag Removal and Installation Side Airbag Replacement NOTE: Review the seal 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 (1) 3. Remove the seat assembly and seat-back cover. 4. Remove the mounting nut (A) and the side airbag (B). Installation NOTE: - If the side airbag lid is secured by a tape, remove the tape. - Do not open the lid of the side airbag cover. - Use new mounting nuts tightened to the specified torque when you replace a side airbag. - Make sure that the seat-back cover is installed properly. Improper installation may prevent proper deployment. - Be sure to install the harness wires so that they are not pinched or interfering with other parts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6243 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. Initializing the OPDS Unit Special Tools Required SCS service connector 07PAZ-0010100 When a seat-back cover, seat-back cushion, and/or OPDS unit is replaced, initialize the OPDS by following the procedure below. NOTES: - Make sure the front passenger's seat is dry. Set the seat-back in the normal position, and make sure there is nothing on the front passenger's seat. -- Refer to TSB Number 02-052 for additional information on the ODPS initialization procedure. 1. Make sure the ignition switch is OFF. 2. Connect the Honda PGM Tester (A) to the DLC (16P) (1), and follow the Tester's prompts in the "SCS" menu to ground the SCS line (see the Honda PGM Tester Operator's Manual). 3. Connect the SCS service connector (B) to the MES connector (2P) (2). Do not use a jumper wire. 4. Turn the ignition switch ON (II). 5. The SRS indicator comes on for about 6 seconds and goes off. Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator went off. 6. The SRS indicator comes on again. Reconnect the SCS service connector to the MES connector within 4 seconds after the SRS indicator comes on. 7. The SRS indicator goes off. Remove the SCS service connector from the MES connector within 4 seconds. 8. Watch the SRS indicator. - If the indicator blinks two times and then stays on, the OPDS is initialized, but the DTCs need to be erased. Go to step 9, then erase the DTCs. - If the indicator blinks two times and then goes off, the OPDS unit is initialized. Go to step 9. - If the indicator stays on without first blinking, the OPDS is not initialized. Read the DTC. If DTC 15-1 is indicated, repeat the initialization procedure. If another DTC is indicated, go to the appropriate DTC Troubleshooting Index. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6244 9. Turn the ignition switch off, and disconnect the PGM Tester. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6245 Side Air Bag: Service and Repair Airbags/Seat Belt Tensioner Deployment and Disposal Deployment Tool Check Procedure Deployment Tool Check 1. Connect the yellow clips to both switch protector handles on the tool; connect the tool to a battery. 2. Push the operation switch: green means the tool is OK; red means the tool is faulty. 3. Disconnect the battery and the yellow clips. Deploying Airbags/Tensioner (Inside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Before scrapping any airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners (including those in a whole vehicle to be scrapped), the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners must be deployed. If the vehicle is still within the warranty period, the Honda District Service Manager must give approval and/or special instruction before deploying the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners. Only after the airbags, side airbags, seat belt tensioners, or seat belt buckle tensioners have been deployed (as the result of vehicle collision, for example), can they be scrapped. If the airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners appear intact (not deployed), treat them with extreme caution. Follow this procedure. Deploying Airbags in the Vehicle If an SRS equipped vehicle is to be entirely scrapped, its airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners should be deployed while still in the vehicle. The airbags, side airbags, seat belt tensioners, and seat belt buckle tensioners should not be considered as salvageable parts and should never be installed in another vehicle. 1. Turn the ignition switch OFF, then disconnect the battery negative cable, and wait at least 3 minutes. 2. Confirm that each airbag, side airbag, 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. Remove the access panel, then disconnect the front passenger's airbag 4P connector from dashboard wire harness. 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. Seat belt buckle tensioner: 8. Disconnect the seat belt buckle tensioner 4P connectors from the floor wire harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6246 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. 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. Deploying Airbags/Tensioner (Outside Vehicle) Airbag Disposal Special Tool Required Deployment tool 07HAZ-SG00500 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6247 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 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 this check procedure or on the tool label. 2. Position the airbag face up, outdoors, on flat ground, at least 30 feet (10 meters) from any obstacles or people. 3. 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. 4. 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. 5. 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Airbag > Page 6248 - 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. Disposal of Damaged Components Disposal of Damaged Components 1. If installed in a vehicle, follow the removal procedure for the driver's airbag, front passenger's airbag, side airbag, and seat belt tensioner. 2. In all cases, make a short circuit by twisting together the two inflator wires. 3. Package the component in exactly the same packaging that the new replacement part came in. 4. Mark the outside of the box "DAMAGED AIRBAG NOT DEPLOYED", "DAMAGED SIDE AIRBAG NOT DEPLOYED" or "DAMAGED SEAT BELT TENSIONER NOT DEPLOYED" so it does not get confused with your parts stock. 5. Contact your Honda District Service Manager for how and where to return it for disposal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Customer Interest for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6257 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Customer Interest for Child Seat: > 05-016 > May > 05 > Restraints - Child Seat Anchor Locating Button Missing > Page 6258 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > 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 6264 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > 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 6265 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations 73. Under Middle of Dash 93. In Front Passenger's Seat (Side Airbag) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6270 Air Bag Control Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6271 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6272 Air Bag Control Module: Service Precautions Be careful not to bump or impact the SRS unit or the side impact sensors whenever the ignition switch is ON (II), or at least for three minutes after the ignition switch is turned OFF. During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. After a collision in which the airbags were deployed, replace the SRS unit. After a collision in which the side airbag was deployed, replace the side impact sensor on the side where the side airbag deployed and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. Do not disassemble the SRS unit or the side impact sensors. Turn the ignition switch OFF, disconnect the battery negative cable and wait at least three minutes before beginning installation or replacement of the SRS unit, and disconnect the connectors from the SRS unit. Be sure the SRS unit and side impact sensors are installed securely with the mounting bolts torqued to 9.8 Nm (1.0 kg.m, 7.2 lb.ft) Do not spill water or oil on the SRS unit or the side impact sensors and keep them away from dust. Store the SRS unit and the side impact sensors in a cool (less than 104°F / 40°C) and dry (less than 80% relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6273 Air Bag Control Module: Description and Operation SRS Unit The SRS is a safety device which, when used in conjunction with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit (including safing sensor and impact sensor), the cable reel, the driver's airbag and front passenger's airbag. Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit respectively will keep voltage at a constant level. For the SRS to operate: 1. The impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the airbag inflators (and seat belt tensioners). 3. The inflators must ignite and deploy the airbags (and activate the tensioners). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6274 Air Bag Control Module: Service and Repair 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 5 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. Remove the right heater unit duct (A). 7. Pull down the carpet on the right side, then remove the Torx bolt (A) and the harness clip (B) from the SRS unit. 8. Pull down the carpet on the left side, then disconnect the connectors. Remove the Torx bolt (A), loosen the Torx bolt (B), then pull out the SRS unit from the right side. 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. Install the right heater unit duct. 3. Reinstall the dashboard center lower cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6275 4. Reconnect the driver's and front passenger's airbag connectors. 5. Reconnect the side airbag connectors. 6. Reconnect both seat belt tensioner connectors and both seat belt buckle tensioner connectors. 7. Reconnect the battery negative cable. 8. Initialize the OPDS unit. 9. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6284 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6285 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6286 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6287 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6288 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6289 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6290 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6291 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6292 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6293 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6294 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6300 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6301 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6302 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6303 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6304 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6305 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6306 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6307 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6308 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6309 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6310 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6317 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6318 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6319 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 6320 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6323 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6324 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6325 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 6326 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6329 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6330 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6331 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 1. Release the hooks, and remove the child seat tether anchor covers from the anchors on the rear of the headliner. The middle cover is different than the side covers. 2. Remove the child seat tether anchors. Do not remove the toothed washers from the tether anchors. The middle anchor is different than the side anchors. 3. Install the anchors in the reverse order of removal. The anchor with the longer spacer goes in the middle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Front Seat Belt Upper Anchor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Retractor Mounting Bolt (6 X 1.0 mm) ............... 9.8 Nm (1.0 kg-m, 7.2 lb-ft) Retractor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Lower Anchor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Rear Seat Belt Upper Anchor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Retractor Mounting Bolt (6 X 1.0 mm) ............... 9.8 Nm (1.0 kg-m, 7.2 lb-ft) Retractor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Lower Anchor Bolt (7/16-20 UNF) ........................32 Nm (3.3 kg-m, 24 lb-ft) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 6339 Seat Belt: Description and Operation SRS Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front Seat Belt: Service and Repair Front Front Seat Belt Front Seat Belt Replacement SRS components are located in this area. Review the SRS component locations and the precautions and procedures before performing repairs or service. NOTE: Check the front seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Front Seat Belt 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 battery cable, and wait at least 3 minutes before beginning work. 3. Slide the front seat forward fully. 4. Pull the lower anchor cover (A) back, and remove the lower anchor bolt (B). 5. Remove the B-pillar lower trim panel. 6. Remove the upper anchor cover (A), and remove the upper anchor bolt (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6342 7. Disconnect the seat belt tensioner connector (A), and detach the harness clip (B) from the retractor (C). Remove the upper retractor mounting bolt (D), and the lower retractor bolt (E), then remove the front seat belt (F) and retractor. 8. Remove the B-pillar upper trim. 9. Remove the shoulder anchor adjuster (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6343 10. Install the seal belt in the reverse order of removal, and note these items: - Apply liquid thread lock to the upper anchor bolt before reinstallation. - Check that the retractor locking mechanism functions. - Assemble the washers, collar, and bushing on the upper and lower anchor bolts as shown. - 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. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Front Seat Belt Buckle 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 battery cable, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. If equipped, remove the center table. 5. Remove the storage box. 6. Remove the center cover, driver's, passenger's. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6344 7. Driver's: If equipped with seat heater, remove the harness band (A), and disconnect the seat sub- harness connector (B). Without seat heater, detach the seat belt switch connector clip (C). Detach the seat belt buckle tensioner clip (D), and harness clip (E). 8. Passenger's: If equipped with side airbag or seat heater, remove the harness band (A), and disconnect the seat sub-harness connector (B). Without side airbag, detach the seat belt switch connector clip (C) from the harness bracket (D). Detach the seat belt buckle tensioner connector clip (E) from the harness bracket. 9. Remove the center anchor bolt (A), and remove the seat belt buckle (B). 10. Detach the harness clip (C), and pull the seat belt switch/tensioner harness (D) out through the space between the seat cushion and the seat linkage (driver's seat), or the hole on the seat track (passenger's seat). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6345 Center Anchor Bolt Construction 11. Install the buckle in the reverse order of removal, and note these items: - Apply liquid thread lock to the center anchor bolt before reinstallation. - Assemble the washers on the center anchor bolt as shown. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6346 Seat Belt: Service and Repair Rear Rear Seat Belt Rear Seat Belt Replacement NOTE: Check the rear seat belts for damage, and replace them if necessary. Be careful not to damage them during removal and installation. Rear Seat Belt 1. Fold the rear seat up. 2. Pull the carpet (A) back as necessary, and remove the lower anchor bolt (B). 3. Remove the rear side trim panel. 4. Remove the upper anchor cap (A), and remove the upper anchor bolt (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6347 5. Remove the retractor mounting self-tapping screw (A), and the retractor bolt (B), then remove the rear seat belt (C) and retractor (D). 6. Install the seat belt in the reverse order of removal, and note these items: - Check that the retractor locking mechanism functions as described. - Assemble the washers, collar, and bushing on the upper anchor bolt as shown. - Before installing the anchor bolt, make sure there are no twists or kinks in the seat belt. Rear Seat Belt Buckle Rear Center Seat Belt Buckle and Left Rear Seat Belt Buckle 1. Fold the rear seat up (one side). 2. Remove the center cover, right rear seat, left rear seat. 3. Remove the center anchor bolt (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6348 4. Pull the rear center seat belt buckle (A) (right rear seat) or left rear seat belt buckle (left rear seat) out. 5. Install the buckle in the reverse order of removal, and note these items: - Make sure there are no twists or kinks in the seat belt buckle. - Assemble the collar and washer on the center anchor bolt as shown. Rear Center Seat Belt Detachable Anchor and Right Rear Seat Belt Buckle 1. Remove the rear seat. 2. Remove the under cover from the rear seat. 3. Remove the center anchor bolts (A) from under the seat cushion. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6349 4. Pull the rear center seat belt detachable anchor (A) and right rear seat belt buckle (B) out. 5. Install the anchor and buckle in the reverse order of removal, and note these items: - Assemble the washers on the center anchor bolt as shown. - Make sure there are no twists or kinks in the anchor, center belt, and seat belt buckle. Rear Center Seat Belt and Rear Buckles Rear Center Seat Belt 1. Remove the cap (A) from the retractor cover (B). 2. Remove the headliner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Front > Page 6350 3. Remove the retractor mounting bolt (A) and retractor bolt (B), then remove the center seat belt (C) and retractor (D). 4. Install the center seat belt and retractor in the reverse order of removal, and check that the retractor locking mechanism functions. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Locations Seat Belt Buckle: Locations Component Location SRS components are located in the parts areas marked with an asterisk (*). Review the SRS component locations, precautions, and procedures before performing repairs or service. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Locations > Page 6354 Seat Belt Buckle: Description and Operation SRS Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 battery cable, and wait at least 3 minutes before beginning work. 3. Remove the front seat. 4. If equipped, remove the center table. 5. Remove the storage box. 6. Remove the center cover, driver's, passenger's. 7. Driver's: If equipped with seat heater, remove the harness band (A), and disconnect the seat sub- harness connector (B). Without seat heater, detach the seat belt switch connector clip (C). Detach the seat belt buckle tensioner clip (D), and harness clip (E). 8. Passenger's: If equipped with side airbag or seat heater, remove the harness band (A), and disconnect the seat sub-harness connector (B). Without side airbag, detach the seat belt switch connector clip (C) from the harness bracket (D). Detach the seat belt buckle tensioner connector clip (E) from the harness bracket. 9. Remove the center anchor bolt (A), and remove the seat belt buckle (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 6357 10. Detach the harness clip (C), and pull the seat belt switch/tensioner harness (D) out through the space between the seat cushion and the seat linkage (driver's seat), or the hole on the seat track (passenger's seat). Center Anchor Bolt Construction 11. Install the buckle in the reverse order of removal, and note these items: - Apply liquid thread lock to the center anchor bolt before reinstallation. - Assemble the washers on the center anchor bolt as shown. - Reconnect the negative cable to the battery. - Enter the anti-theft code for the radio, then enter the customer's radio station presets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 6358 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Rear Center Seat Belt Buckle and Left Rear Seat Belt Buckle 1. Fold the rear seat up (one side). 2. Remove the center cover, right rear seat, left rear seat. 3. Remove the center anchor bolt (A). 4. Pull the rear center seat belt buckle (A) (right rear seat) or left rear seat belt buckle (left rear seat) out. 5. Install the buckle in the reverse order of removal, and note these items: - Make sure there are no twists or kinks in the seat belt buckle. - Assemble the collar and washer on the center anchor bolt as shown. Rear Center Seat Belt Detachable Anchor and Right Rear Seat Belt Buckle 1. Remove the rear seat. 2. Remove the under cover from the rear seat. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckles > Page 6359 3. Remove the center anchor bolts (A) from under the seat cushion. 4. Pull the rear center seat belt detachable anchor (A) and right rear seat belt buckle (B) out. 5. Install the anchor and buckle in the reverse order of removal, and note these items: - Assemble the washers on the center anchor bolt as shown. - Make sure there are no twists or kinks in the anchor, center belt, and seat belt buckle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 90. Under Driver's Seat 91. Under Front Passenger's Seat Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6363 Seat Belt Buckle Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-073 > Dec > 05 > Restraints - Rear Seat Belt Retractor Rattles/Squeaks Seat Belt Retractor: Customer Interest Restraints - Rear Seat Belt Retractor Rattles/Squeaks 05-073 December 16, 2005 Applies To: 2002-04 CR-V - ALL Japan-Produced Vehicles 2005 CR-V - From VIN JHLRD7...5C000001 thru JHLRD7...5C059336 - From VIN JHLRD6...5C000001 thru JHLRD6...5C019332 Rear Seat Belt Retractor Noise SYMPTOM A squeak or rattle is heard from the rear seat belt retractors while driving over bumps or rough roads. PROBABLE CAUSE The seat belt retractor tab is rubbing against the body. CORRECTIVE ACTION Remove any felt from the seat belt retractor tab, then install a floor boot to insulate the retractors from the body. PARTS INFORMATION Floor Boot (two required): P/N 91608-S5A-003, H/C 6634497 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 854078 Flat Rate Time: 0.4 hour Failed Part: Right Rear P/N 04824-SCA-A11ZA H/C 7743685 Left Rear P/N 04828-SCA-A12ZA H/C 7822885 Defect Code: 07404 Symptom Code: 04205 Template ID: 05-073A 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 side trim panel: 2002-04 CR-V: ^ Refer to page 20-66 of the 2002-04 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-073 > Dec > 05 > Restraints - Rear Seat Belt Retractor Rattles/Squeaks > Page 6372 2005 CR-V: ^ Refer to page 20-72 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. 2. Remove the retractor self-tapping screw and the retractor bolt. 3. Using an X-acto knife, carefully remove any felt from the retractor tab. 4. Install the floor boot. 5. Repeat steps 1 thru 4 for the other side. 6. Reinstall the seat belt retractors. Torque the retractor mounting screws to 4 Nm (3 lb-ft) and torque the retractor mounting bolts to 32 Nm (24 lb-ft). 7. Install the rear side trim in the reverse order of removal. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-073 > Dec > 05 > Restraints Rear Seat Belt Retractor Rattles/Squeaks Seat Belt Retractor: All Technical Service Bulletins Restraints - Rear Seat Belt Retractor Rattles/Squeaks 05-073 December 16, 2005 Applies To: 2002-04 CR-V - ALL Japan-Produced Vehicles 2005 CR-V - From VIN JHLRD7...5C000001 thru JHLRD7...5C059336 - From VIN JHLRD6...5C000001 thru JHLRD6...5C019332 Rear Seat Belt Retractor Noise SYMPTOM A squeak or rattle is heard from the rear seat belt retractors while driving over bumps or rough roads. PROBABLE CAUSE The seat belt retractor tab is rubbing against the body. CORRECTIVE ACTION Remove any felt from the seat belt retractor tab, then install a floor boot to insulate the retractors from the body. PARTS INFORMATION Floor Boot (two required): P/N 91608-S5A-003, H/C 6634497 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 854078 Flat Rate Time: 0.4 hour Failed Part: Right Rear P/N 04824-SCA-A11ZA H/C 7743685 Left Rear P/N 04828-SCA-A12ZA H/C 7822885 Defect Code: 07404 Symptom Code: 04205 Template ID: 05-073A 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 side trim panel: 2002-04 CR-V: ^ Refer to page 20-66 of the 2002-04 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-073 > Dec > 05 > Restraints Rear Seat Belt Retractor Rattles/Squeaks > Page 6378 2005 CR-V: ^ Refer to page 20-72 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword TRIM, then select Interior Trim Removal/Installation-Rear Side Area from the list. 2. Remove the retractor self-tapping screw and the retractor bolt. 3. Using an X-acto knife, carefully remove any felt from the retractor tab. 4. Install the floor boot. 5. Repeat steps 1 thru 4 for the other side. 6. Reinstall the seat belt retractors. Torque the retractor mounting screws to 4 Nm (3 lb-ft) and torque the retractor mounting bolts to 32 Nm (24 lb-ft). 7. Install the rear side trim in the reverse order of removal. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Seat Belt Tensioner: Locations 90. Under Driver's Seat 91. Under Front Passenger's Seat 96. Right B Pillar (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6382 Seat Belt Tensioner: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6383 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6384 Seat Belt Tensioner: Description and Operation SRS Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6385 Seat Belt Tensioner: Service and Repair 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. Remove the access panel, then disconnect the front passenger's airbag 4P connector from dashboard wire harness. 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. Seat belt buckle tensioner: 8. Disconnect the seat belt buckle tensioner 4P connectors from the floor wire harness. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 6386 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. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations 96. Left B-Pillar (Right Similar) 130. Behind Right Side of Front Bumper 135. Behind Left Side of Front Bumper Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6391 Impact Sensor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6392 Impact Sensor: Service Precautions SRS Unit, Front Sensors, and Side Impact Sensors - Be careful not to bump or impact the SRS unit, front sensors, or the side impact sensors whenever the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF. - During installation or replacement, be careful not to bump (by impact wrench, hammer, etc.) the area around the SRS unit, front sensors, and the side impact sensor. The airbags could accidentally deploy and cause damage or injury. - After a collision in which any airbags or seat belt tensioners were deployed, replace the SRS unit, front sensors, and other related components. After a collision in which a side airbag was deployed, replace the side impact sensor on the deployed side and the SRS unit. After a collision in which the airbags or the side airbags did not deploy, inspect for any damage or any deformation on the SRS unit, front sensors, and the side impact sensors. If there is any damage, replace the SRS unit and/or the side impact sensors. - Do not disassemble the SRS unit or the side impact sensors. - Turn the ignition switch OFF, disconnect the battery negative cable, and wait at least 3 minutes before beginning installation or replacement of the SRS unit, or disconnecting the connectors from the SRS unit. - Be sure the SRS unit and side impact sensors are installed securely, with the mounting bolts torqued to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) - Do not spill water or oil on the SRS unit or the side impact sensors, and keep them away from dust. - Store the SRS unit and the side impact sensors in a cool (less than 104 °F/40 °C) and dry (less than 80 % relative humidity, no moisture) area. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6393 Impact Sensor: Service and Repair 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 and the B-pillar lower trim panel. 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 (1) to the side impact sensor (B). 2. Reconnect the negative battery 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. Front Sensor Replacement Removal 1. Disconnect the negative battery 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6394 4. Disconnect the engine compartment wire harness 2P connector (1), and remove the two Torx bolts (A) using a Torx T30 bit, then remove the front sensor (B). Installation 1. Install the new front sensor with new Torx bolts (A), then connect the engine compartment wire harness 2P connector (1) to the front sensor (B). 2. Reconnect the negative battery cable. 3. After installing the front 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations 90. Under Driver's Seat 91. Under Front Passenger's Seat Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6398 Seat Belt Buckle Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6407 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6408 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6409 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6410 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6411 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6412 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6413 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6414 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6415 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6416 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6417 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6423 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6424 PARTS INFORMATION TOOL INFORMATION Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6425 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6426 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6427 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6428 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6429 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6430 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6431 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6432 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6433 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6441 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6442 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6443 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6444 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6445 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6455 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6456 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6462 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6463 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 35. In Steering Column Cover 45. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Component Locations > Page 6466 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6467 Alarm Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6468 Alarm Module: Service and Repair Immobilizer Control Unit-Receiver Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 7P connector (A) from the immobilizer control unit-receiver (B). 4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (C). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with a Honda PGM Tester, then check the immobilizer system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6472 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 6477 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 6478 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations 64. Under Middle of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 6482 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6491 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6492 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6498 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6499 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6504 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6505 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6506 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6507 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6508 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6509 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6510 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6511 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6512 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6513 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6514 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6515 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6516 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6517 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6518 (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6519 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6520 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6521 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6522 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6523 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6524 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6525 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6526 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6527 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6528 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6534 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6535 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6536 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6537 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6538 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6539 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6540 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6541 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6542 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6543 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6544 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6545 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6546 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6547 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6548 (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6549 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6550 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6551 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6552 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6553 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6554 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6555 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6556 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6557 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6558 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test Keyless Entry Transmitter: Testing and Inspection Transmitter Test 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 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 with the transmitter. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. If the new transmitter won't lock and unlock the doors, test the keyless unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test > Page 6561 Keyless Entry Transmitter: Testing and Inspection Keyless Receiver Unit Input Test Keyless Receiver Unit Input Test 1. Remove the dashboard pocket. 2. Disconnect the 5P connector (A) from the keyless receiver 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 are OK, go to step 4. 4. Reconnect the connector, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. 5. Disconnect the connector, and make this input test at the connector. - If the test indicates a problem, find and correct the cause, then recheck the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test > Page 6562 - If the input tests proves OK, replace the keyless receiver unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Page 6563 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be programmed into the keyless receiver unit memory. (If a fourth code is stored, the code that was programmed first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the tailgate are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 seconds, push the transmitter lock or unlock button. 3. Within 1 to 4 seconds, turn the ignition switch OFF. 4. Within 1 to 4 seconds, turn the ignition switch ON (II). 5. Within 1 to 4 seconds, push the transmitter lock or unlock button. 6. Within 1 to 4 seconds, turn the ignition switch OFF. 7. Within 4 seconds, turn the ignition switch ON (II). 8. Within 1 to 4 seconds, push the transmitter lock or unlock button. 9. Within 1 to 4 seconds, turn the ignition switch OFF. 10. Within 4 seconds, turn the ignition switch ON (II). 11. Within 1 to 4 seconds, push the transmitter lock or unlock button. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. 13. Within 10 seconds, press the transmitter lock or unlock buttons on the two additional transmitters. 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 remove the key. 15. Confirm proper operation of the transmitters. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations 55. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 6567 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Locations 33. Left Middle of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6577 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6578 - 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6579 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6580 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6581 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6582 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6587 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6588 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6589 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6590 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6591 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6592 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6593 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6594 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6595 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6596 - 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6597 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6598 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6599 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Audio System - CD/DVD Precautions > Page 6600 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6605 1. Print out the appropriate system worksheet from an Interactive Network (iN) workstation. ^ From the iN main menu, click on SERVICE. ^ Click on (ISIS) Service Publications. ^ Click on SEARCH BY PUBLICATION. ^ Click on Job Aids. ^ Click on Audio System Worksheet, Navigation System Worksheet, or Rear Entertainment System Worksheet. 2. Duplicate and confirm the problem using the customer information written on the repair order or have the customer demonstrate the problem, then write down the results on the worksheet. Using the SYMPTOM TROUBLESHOOTING INDEX or the DTC INDEX (if applicable) in the applicable service manual, find the symptom that matches the customers complaint, and follow the diagnostic procedure: ^ Refer to the appropriate section in the service manual, or ^ From the iN main menu: - Click on SERVICE. - Click on ISIS (Service Publications). - Click on SEARCH BY VEHICLE. - Enter the model and the model year. - Enter a keyword: AUDIO, NAVIGATION, or RES, and the DTC (if applicable) - Select the appropriate Service Bulletin, ServiceNews article, or Symptom Troubleshooting from the list. 3. Repair the vehicle according to your diagnosis, then confirm the repair by trying to duplicate the customer's original complaint, or check to see if the DTC returns: ^ If the problem is gone, return the vehicle to the customer. ^ If the problem is still there, go to step 4. 4. Replace the audio/navigation/RES unit with a remanufactured unit: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6606 ^ For warranty repairs, go to the IN-WARRANTY EXCHANGE procedure. ^ For vehicle service contract (VSC) and certified used car (CUC) repairs, call. ^ For goodwill repairs, contact your dealership's District Parts and Service Manager (DPSM). IN-WARRANTY EXCHANGE Service Technician: NOTE: ^ Use the iN to order a remanufactured audio, navigation, or RES unit. Do not call the Remanufactured Parts Dealer Service Group. ^ A Tech Line reference number is not required to submit the order. Check Yes, and enter the Reference Number only when there is a preexisting Tech Line contact. 1. With your completed Audio/Navigation/RES Worksheet, go to an iN workstation. 2. From the iN main menu, click on SERVICE, then click on AUDIO, then select Warranty Audio Order. 3. Select the model, year, and keyword (AUDIO, NAVIGATION, or RES) for the vehicle you are working on, then click on Search. 4. Review all displayed publications for additional repair information. If you cannot repair the problem, go to step 5. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6607 5. Click Warranty Audio Order to view the Warranty Audio Order form. 6. Enter the VIN and the mileage, then click the Submit button to view the Warranty Audio Order form. Use the completed Audio/Navigation/RES Worksheet to help you answer the questions on the Warranty Audio Order form. Questions with a red asterisk (*) are required fields that you must answer to submit the form. Make sure the information is complete (17-digit VIN, etc.). This information is critical to the remanufacturing process. Screen # 2 of the form contains the problem description, condition information, and shared functions. Fill this section out with as much information as possible. Select one part number from the list provided, then click Submit. It is your responsibility to ensure the correct part number is selected based on color and application information. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6608 NOTE: Once you submit your order, you can track it using the Warranty Audio VIN Inquiry screen on the iN. For details, go to WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS in this service bulletin. 7. You will receive a remanufactured audio/navigation/RES unit packed in a reusable shipping box. Save this box and the packing materials. You must return the failed audio/navigation/RES unit core in this box. Otherwise your dealership risks being billed a core loss charge, ranging from $800 to $2,500, depending on the unit. 8. Remove the failed audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or, ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate removal procedure from the list. 9. Install the remanufactured audio/navigation/RES unit: ^ Refer to the appropriate component section of the service manual or ^ Online, enter a keyword: AUDIO, NAVIGATION, or RES. Select the appropriate installation procedure from the list. 10. If the remanufactured unit has a shipping cover and shipping screws, make sure you transfer them to the faulty unit being returned. Also be sure to transfer all of the mounting brackets to the replacement unit. Failure to do this may result in dash squeaks and rattles. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is stuck in the unit, leave it there for these reasons: ^ The manufacturer needs it for diagnosis and testing. ^ Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core. Customer media (CDs, CD magazines, DVDs, DVD-As, cassette tapes, etc.) will be properly removed by the supplier at the point of tear down and inspection of the failed unit, and mailed to your dealer. Make sure the failed audio/navigation/RES unit core is not disassembled! If the core is disassembled, your dealership will be debited a core loss charge ranging from $800 to $2,500, depending on the unit. 11. Put the failed audio/navigation/RES unit core in the same box that the remanufactured unit came in. NOTE: If you do not return the failed audio/navigation/RES unit core in this same box, your warranty claim will be debited and the core will be sent back to your dealership. Parts Manager: 12. The Warranty Audio/Navigation/RES Unit Order form you submitted is kept on the iN for 60 days. Print out a copy to put in the box with your core return: ^ From the iN main menu, click on SERVICE. ^ Click on Transactions. ^ Click on Advanced Search, and enter a date range. ^ Click on Filtered by Service. ^ Under Transaction Description, click on Warranty Audio Order, then go back to the top of the page and click on Search. ^ Scroll down to the appropriate VIN, then select it to view the form. ^ Review the form, then print out a copy by clicking on the printer icon. 13. Print out a copy of the Core Return Update Acknowledgement to put in the box with your core return: ^ From the iN main menu, click on PARTS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6609 ^ Click on Returns and Surplus. ^ Click on Audio Core Return. ^ Select the appropriate VIN to view the Update Core Return information screen. ^ Review the form, then print out a copy by clicking on the printer icon. 14. Place the printed copies of the Warranty Audio/Navigation/RES Unit Order form and the Core Return Update Acknowledgement into the core return box with the failed audio/navigation/RES unit core. NOTE: If you return a failed audio/navigation/RES core without the proper forms, your warranty claim will be debited and the core will be sent back to your dealership. 15. Ship the failed audio/navigation/RES unit core to the appropriate location by using the prepaid shipping label that came with the remanufactured audio/navigation/RES unit. NOTE: If the failed audio/navigation/RES unit core is not received at the specified address within 30 days from the order date of the remanufactured audio/navigation/RES unit, your warranty claim will be debited, and your dealership will be issued a core loss charge ranging between $800 and $2,500. If you know that you cannot return the core within 30 days, call the Remanufactured Parts Dealer Service Group, and ask for an extension. ^ If you call for an extension and the core is not received within 60 days from the order date, you will be debited the full amount of the warranty claim. ^ If you do not call for an extension, and the core is received between 31 and 60 days from the order date of the remanufactured audio/navigation/RES unit, a $250 late core charge will be assessed. WARRANTY AUDIO ORDER PROGRAM FREQUENTLY ASKED QUESTIONS Here is a list of answers to the most frequently asked questions about the warranty audio order program: Question: When do I use the warranty audio order program? Answer: Use the program when you are replacing an audio/navigation/RES unit under warranty (including goodwill) that has an internal failure. NOTE: The customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, etc.) is removed by the supplier at tear down and inspection of the failed unit, and mailed to your dealership. Any failed audio/navigation/RES unit core that is returned disassembled is considered an unusable core, and your dealership will be issued a core loss charge ranging between $800 and $2,500. Remanufactured audio/navigation/RES units are not available for non-warranty repairs. New components should be used to repair new, unsold vehicles. A new component may be used to repair a customer's vehicle only if the remanufactured component is currently unavailable from American Honda. Your DPSM must authorize ordering a new component. Question: How do I order a remanufactured audio/navigation/RES unit? Answer: For a warranty replacement, use the ordering information IN WARRANTY EXCHANGE. For goodwill repair, contact your DPSM. For a non-warranty repair, see OUT-OF-WARRANTY REPAIR. Question: Who do I call for questions on the Warranty Audio Order Program? Answer: For administrative questions, call the Remanufactured Parts Dealer Service Group. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6610 Question: Who do I call if I need help diagnosing the problem or if I have technical questions about the unit? Answer: If you cannot find the answers in the appropriate service manual, service bulletins, or ServiceNews articles on iN, create a Tech Line access code, then call Tech Line: 1. From the iN main menu, select SERVICE. 2. Select Tech Line. A dropdown menu appears, then select Tech Line. The ISIS main screen appears. 3. Select SEARCH BY VEHICLE, and enter any vehicle with any keyword like NAVI, AUDIO, or RES. 4. At the top of the screen you will see this statement: If you cannot resolve the problem with the information below, then click Tech Line. Select Tech Line. 5. The Tech Line access code screen appears. Fill in all the required fields, then select SUBMIT. 6. Have the access number ready when you call Tech Line. Question: Do I need a Tech Line reference number to order a remanufactured audio/navigation/RES unit? Answer: No. Question: What year and model audio/navigation/RES unit can I order through the warranty audio order program? Answer: Most current models are available through the vehicle's standard warranty period. If your application is not available, you will receive a message instructing you to call the Re manufactured Parts Dealer Service Group at 888-997-7278. Question: How can I track my order once I submit it? Answer: To track your order, go the Warranty Audio Order VIN Inquiry screen on the iN. 1. From the iN main menu, click on PARTS. 2. Click on Parts Ordering. 3. Click on Audio VIN Inquiry. 4. Enter a date in the All Orders Accepted Since box, then click on Submit. The AUDIO VIN INQUIRY ACKNOWLEDGEMENT screen appears, listing orders by VIN, ORD REF (Order Reference), STAT (Status), SHIP DATE, SHIPPER, and PART NUMBER. The status of your order is displayed by one of these codes: Codes generated by RPO Tech Line: ^ PEND - Your order is waiting to be processed by RPO Tech Line. ^ HOLD - Your order is waiting for additional dealer diagnosis. ^ ERR - Your order caused an error; call. ^ DENY - RPO Tech Line denied your order; call. ^ APPR - RPO Tech Line approved your order and forwarded it to AHM Parts. Codes generated by AHM Parts Division: ^ BO/TOS - Your order is on back order or is temporarily out of stock. ^ CAN/BOC - Your order has been cancelled contact your assigned parts center. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6611 ^ ALO/BOA - Your order has been allocated, but not released for shipment. ^ REL/BOR - Your order has been picked, packed, and shipped. ^ INV - Your order has been invoiced to your dealer parts account. CORE RETURN INFORMATION Service Technician: 1. If the customer's media (CD, CD magazine, DVD, DVD-A, or cassette tape) is stuck inside the faulty unit, fill out a Customer Media Return Label (reorder number Y0325), and attach it to the unit. The manufacturer will remove the media, and mail it back to your dealership. 2. Use the pre paid shipping label. Each audio supplier provides a prepaid shipping label with the remanufactured audio unit. Return the core using this label to ensure it is received at the appropriate location for credit. Use the pre paid shipping labels to return audio cores to authorized locations only; do not use them for any other purpose. If you need additional prepaid shipping labels, contact Remanufactured Parts Operations. ^ Complete the shipping label with your dealership information. ^ Pack one audio unit per box, and use a separate shipping label for each one. ^ On the line requesting Your Internal Reference Information, enter YOUR DEALER NUMBER and the WARRANTY CLAIM NUMBER. 3. On the repair order, write down the warranty claim number, the original part number, the serial numbers from both the faulty and remanufactured units, and the return tracking number. 4. Ship the faulty unit in the same box the remanufactured unit came in. Make sure you include this required paperwork: ^ A copy of the Core Return Update Acknowledgement from the iN. ^ A copy of the warranty audio order. NOTE: When the Remanufacturing Center gets the faulty unit, your warranty audio order will be updated to indicate that the core was received. If the core is received 31-60 days from the order date, and you have been debited a core loss charge, your dealership will be credited back, less a $250 late fee. OUT-OF-WARRANTY REPAIR (AUDIO, NAVIGATION, AND RES UNITS PRODUCED IN 1998 OR LATER) NOTE: If you are making a repair or exchange because of a service bulletin or service campaign, do not use OUT-OF-WARRANTY procedures. Refer to IN-WARRANTY EXCHANGE for more information. Service Advisor: 1. Give your customer an estimate for repairing the unit (see step 6), plus the labor cost to replace it. For an Alpine unit, your customer has the option of contacting Alpine Electronics directly. Alpine's customer service number is 800-421-2284, Ext. 860304. Service Technician: 2. Remove the failed unit: ^ Refer to the appropriate component section of the service manual or, Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6612 ^ Online, enter keyword AUDIO, NAVI, or RES, and select the appropriate removal procedure from the list. NOTE: If the customer's media (CD, CD magazine, DVD, DVD-A, cassette tape, navigation DVD, etc.) is stuck in the unit, leave it there. The manufacturer will remove and return it. 3. Obtain an Out-of-Warranty/New Replacement component repair form, and complete the Technician section.To obtain the form, do this: ^ On ISIS, click on Technical Library, then click on Job Aids. ^ Select the applicable form from the list, and print it out: - Out-of-Warranty/New Replacement Audio System Component Repair Form - Out-of-Warranty/New Replacement Navigation System Component Repair Form - Out-of-Warranty/New Replacement Rear Entertainment System Component Repair Form Parts Manager: 4. Complete the parts manager's section of the Out-of-Warranty/New Replacement component repair form. Make sure you include your name, department, and dealership phone number on the form. 5. Identify the manufacturer. Units sent to the wrong manufacturer may not be shipped back within the usual 5-7 days. ^ Look for the number code on the face of the unit. ^ If the unit has no number code on its face, check the label on the unit housing, and compare the first two or three letters of the radio reference number (or the audio unit model number) to this list: Alpine - CM, CD, MR, or MF Clarion - PH Fujitsu Ten - CE or SD Panasonic - CQ or CR Pioneer KEH or DEH 6. Contact the manufacturer (see step 9) to request an estimate for the cost of the repair plus shipping. 7. Complete the required paperwork: ^ Paying by check - Make a dealership check out to the manufacturer for the cost of repair and return shipping. Make sure to include the check number on the form. NOTE: For all Panasonic products, make your check out to Komtec Electronics. ^ Paying by credit card (Visa or Mastercard only) - When you use a credit card, fill in all of these fields on the component repair form: - Credit card number - Credit card expiration date Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6613 - The name as it appears on the credit card - Signature (authorized card holder) - Phone number - Authorized charge amount NOTE: If you send in a faulty unit without a check or complete credit card information, the manufacturer may send it back to you unrepaired, or they may repair it and send it back to you C.O.D. ^ Print two copies of the completed Out-of-Warranty/New Replacement component repair form. Keep one copy with the repair order, and include the other copy with the faulty unit when you send it to the manufacturer. 8. Carefully pack the faulty unit and the paperwork in a suitable box, and label the box clearly. You are responsible for lost or damaged units; keep all shipping documents and insurance receipts. 9. Ship the faulty unit to the appropriate manufacturer via UPS. Alpine Electronics of America c/o Standard Radio Engineering Corp. 2012 Abalone Ave., Unit D Torrance, CA 90501 800-421-2284, Ext. 860304 Bose Corporation Automotive Systems Division-Service Framingham, MA 01701-9168 800-231-2673 S3 Clarion Factory Service Center 241 Beaver Rd. Walton, KY 41094 800-347-8667 (You must get authorization from Clarion before shipping units) Fujitsu Ten 19600 5. Vermont Ave. Torrance, CA 90502 800-237-5413 FTH Group Inc. (Kenwood Accessory Parts) 16685 E. Johnson Dr. City of Industry, CA 91745 626-333-2435 (You must get an RMA authorization number from www.fthgroupinc.com; from the home page, select Consumer Products) Komtec Electronics (Panasonic) 6590 Darin Way Cypress, CA 90630 714-903-3300 (Make sure your check is made out to Komtec) * Pioneer Electronics Service, Inc. 1925 E. Dominguez St. Long Beach, CA 90801 800-553-3756* Visteon c/o Model Electronics 615 E. Crescent Ave. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6614 Ramsey, NJ 07446 800-433-9657 (Visteon offers an open line of credit. Call their 800 number to establish an account.) NOTE: ^ The manufacturer will repair the unit and ship it back within 5-7 working days, via UPS ground prepaid or 2nd Day Air (whichever you requested). Do not forget to include the shipping cost in your dealership payment. Units damaged by misuse or mishandling cannot be shipped back within the usual 5-7 days. ^ Each manufacturer's guarantee for the repair differs. To confirm the repair guarantee, contact the manufacturer using the phone number listed above. 10. To check on the status of your repair order, call the manufacturer. If your customer has any further questions or concerns, have them call Automobile Customer Service at 800-999-1009. NOTE: A damaged unit may need extra repair. If so, the manufacturer will call you with an estimate of any added charges. ^ If you accept the estimate, mail a dealership check for the additional amount to the manufacturer, authorize the increased amount to be applied to the credit card payment, or have the manufacturer ship the unit back to you, and you pay the difference upon arrival (C.O.D.). ^ If you reject the estimate, the faulty unit will be returned to you along with a refund. However, you will be charged $30.00 (C.O.D.) for diagnosis, shipping, and handling. The unit will be shipped back to you, via UPS Ground. COMPLETING THE OUT-OF-WARRANTY/NEW REPLACEMENT AUDIO SYSTEM COMPONENT REPAIR FORM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6615 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6616 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio/Navigation/RES - Warr. Exchange/Non-Warr Repair > Page 6617 NOTE: It is very important that you fill out this form fully and accurately. An accurate explanation of the problem and conditions helps the manufacturer to duplicate the problem, speeding the repair, and reducing the number of No Trouble Found" (NTF) units. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams (LX: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations 33. Left Middle of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6626 Speaker: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6627 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6628 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 6629 Speaker: Service and Repair Speaker Replacement Door Speaker: 1. Remove the door panel. 2. Push down on the clip, then pull the top of the speaker (A) straight out just enough to release the upper clip. If you pull the speaker out too far, you will damage the lower clips (C). Then lift the speaker straight up to release the lower clips. 3. Disconnect the 2P connector (B), and remove the speaker. 4. Install the speaker in the reverse order of removal. Tweeter: 1. Remove the tweeter speaker grille (A) and tweeter (B) as an assembly. 2. Disconnect the 2P connector (C) from the tweeter. 3. Remove the tweeter speaker grille from the tweeter. 4. Install the tweeter in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6639 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6640 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6646 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 6647 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 35. In Steering Column Cover 45. Under Left Side of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6650 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6651 Alarm Module: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 6652 Alarm Module: Service and Repair Immobilizer Control Unit-Receiver Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 7P connector (A) from the immobilizer control unit-receiver (B). 4. Remove the two screws and the immobilizer control unit-receiver from the ignition key cylinder (C). 5. Install the immobilizer control unit-receiver in the reverse order of removal. 6. After replacement, rewrite the unit with a Honda PGM Tester, then check the immobilizer system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 6656 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 6657 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6662 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 to transport 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 hooks 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. Never tow the vehicle with wheel lift equipment. 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. This method of towing the CR-V is unacceptable. The only recommended way of towing the CR-V is on a flat-bed truck. Towing the 4WD CR-V with only two wheels on the ground will damage parts of the 4WD system. The 2WD CR-V may also be towed with the front wheels off the ground, or with all four wheels on the ground. If the 2WD CR-V 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, or if the vehicle is towed with all four wheels on the ground, do the following: Manual Transmission - Release the parking brake. - Shift the transmission to Neutral. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Page 6667 Automatic Transmission - Release the parking brake. - Start the engine. - Shift to the D position, then the N position. - Turn off the engine. It is best to tow the vehicle no farther than 50 miles (80 km), and keep the speed below 35 mph (55 km/h). NOTE - Improper towing preparation will damage the transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flat-bed. - Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not designed to support the vehicle's weight. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Trailer Connector: Locations 102. Left Quarter Panel 149. Under Center of Rr. Bumper (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Trailer Connector: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Trailer Connector: Connector Views (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Trailer Connector: Electrical Diagrams Diagram 118-4 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Diagram 118-5 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 Diagram 118-6 (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Trailer Lamps: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 Trailer Lamps: Electrical Diagrams Diagram 118-4 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Diagram 118-5 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Diagram 118-6 (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Trailer Connector: Locations 102. Left Quarter Panel 149. Under Center of Rr. Bumper (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Trailer Connector: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Trailer Connector: Connector Views (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Trailer Connector: Electrical Diagrams Diagram 118-4 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Diagram 118-5 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Diagram 118-6 (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Body Control Systems > System Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Description and Operation > Page 6788 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 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Description and Operation > Page 6792 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. - Apply protective tape around the hinge side edge of the tailgate lower trim to prevent damage to the rear bumper. - Before removing the rear bumper, remove the bolt securing the body side end of the tailgate support strut. After removing the bolt, gently open or close the tailgate to allow maximum clearance between the rear bumper and the tailgate lower trim, and hold the tailgate in this position. 1. Remove the rear bumper as shown. 2. Install the bumper in the reverse order of removal, and note these items: - Make sure the rear bumper engages the hooks of the side spacers and upper brackets on both sides securely. - Replace the clip, if it's damaged. - Push the clip into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 outlet (B). Take care not to scratch the body. 3. Install the air outlet by pushing on the hook portions until the hooks snap into place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the' cowl covers. Take care not to scratch the cowl covers. 3. Detach the clips (D, E) and release the hook (F) by carefully pulling the passenger's cowl cover (G) upward. Pull the cover forward to release the hooks (H), pull the hinge cover (I) out from the front fender (J), and disconnect the windshield washer tube (K), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D, E) by carefully pulling the driver's cowl cover (M) upward, and pull the cover forward to release the hooks (N). Pull the hinge cover (0) out from the front fender (P), and disconnect the windshield washer tube (L) routed from the washer reservoir then remove the cover. Take care not to scratch the body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 6800 5. If necessary, release the clips, then remove the insulators (A, B) from both cowl covers (C, D). 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Make sure the washer tubes are connected securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Outer Handle 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. Release the clip and detach the hook (A), then remove the lock rod protector (B). 4. Disconnect the outer handle rod (A) and cylinder rod(B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6808 5. Release the retainer clip (A) with a hook-shaped tool. Remove the lock cylinder (B). 6. Remove the bolt, then remove the cylinder protector (A). 7. Remove the bolt, then remove the spacer (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 6809 8. While pulling the outer handle (A), remove the handle from the holes in the door panel. Take care not to scratch the door. 9. Install the handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the door locks and opens properly. - When 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 sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Latch Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary - Lock rod protector 2. Raise the glass fully. 3. Pull the glass run channel (A) away as necessary, and remove the bolt, then remove the center lower channel (B) by pulling it downward. 4. Disconnect the outer handle rod and cylinder rod. 5. Remove the latch (A). Take care not to bend the outer handle rod (B), cylinder rod (C), lock rod (D), and inner handle rod (E). The Honda Lock type is shown (the Mitsui type is similar). 1. Release the inner handle rod from the rod holder (F). 2. Disconnect the connectors (G). 3. Remove the screws. 4. Remove the latch through the hole in the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 6813 6. Install the latch in the reverse order of removal, and note these items: - Make sure the actuator connectors are plugged in properly, and each rod is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Panel Removal/Installation Special Tools Required - Trim pad remover. Snap-on A 177A, or equivalent, commercially available. - KTC trim tool set SOJATP2014 NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. Using a trim tool, pry out the upper portion of the cover (A) to release the hooks (B), then remove the cover. 2. Remove the screws. 3. Driver's door: Pull the inner handle (A) rearward and out half-way to release the power door lock switch bracket (B) from the door panel (C). 4. Passenger's door: Pull the inner handle (A) halfway. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6817 5. Driver's door: Disconnect the power door lock switch connector (A). Disconnect the inner handle rod (B), then remove the inner handle (C). 6. Lower the glass fully. 7. Remove the screws from under the armrest. 8. Passenger's door: Remove the switch panel (A). 1. Insert a flat-tip screwdriver wrapped with protective tape through a hole under the armrest, and push up the back of the panel to release the rear hook (B). 2. Pull out along the edge of the panel to release the hooks (C) and clip. 3. Disconnect the power window switch connector (D). 9. Remove the mirror mount cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6818 10. Remove the door panel (A) with as little bending as possible to avoid creasing or breaking it 1. Release the clip (B). 2. Release the clips (C) that hold the door panel with a commercially available trim pad remover (D). 3. Starting at the rear, pull the door panel upward, then release the lock knob (E). 11. Driver's door: Disconnect the power window switch connector (A), power mirror switch connector (B), hatch glass opener switch connector (C), and detach the harness clips (D) from the back of the door panel. 12. Driver's door: Push up the back of the switch panel (A) to release the clip and hooks (B), then remove the panel. 13. Install the panel in the reverse order of removal, and note these items: - Replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6819 - Make sure the connectors are plugged in properly, and the rod is connected properly. - Push the clips into place securely. - Do the power window control unit reset procedure. - Check the window and power door lock operations. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments Front and Rear Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed, but the striker can be adjusted slightly up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel (C) between the body and striker. 2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (D). Do not tap the striker too hard. 4. Loosen the screws, and remove the shop towel. 5. Lightly tighten the screws. 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the front pillar, remove the door checker 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 the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front 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. To prevent scratching the power mirror and door, wrap the power mirror with a shop towel. Disconnecting the power mirror connector is not required. 2. Remove the screw (A) from the rear edge of the door. Starting at the rear, pry the door glass outer weatherstrip (B) up to detach the clips (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations Front Door Window Motor: Locations 110. Driver's Door 113. Front Passenger's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Page 6833 Front Door Window Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front 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 move 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 (A) 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 6837 5. Apply multipurpose grease to 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: - Make sure the motor connector is plugged in properly. - 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. - Do the power window control unit reset procedure. - 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Rear Door Outer Handle 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 screws, and release the hooks (A), then remove the rod protector (B). 4. Remove the access cap (A), then disconnect the outer handle rod (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 6843 5. Remove the bolt, then remove the protector (A). 6. Remove the bolt, then remove the spacer (A). 7. While pulling the outer handle (A), remove the handle from the holes in the door. Take care not to scratch the door. 8. Install the handle in the reverse order of removal, and note these items: - Make sure the outer handle rod is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair Rear Door Latch Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary - Rod protector 2. Raise the glass fully. 3. Remove the access cap, then disconnect the outer handle rod. 4. Disconnect the lock rod (A) from the lock crank (B), and release the inner handle rod (C) and lock rod from the rod holder (D). 5. Remove the latch (A). Take care not to bend the inner handle rod (B), lock rod (C), and outer handle rod (D). The Honda Lock type is shown (the Mitsui type is similar). 1. Disconnect the connector (E). 2. Remove the screws. 3. Remove the latch from the hole in the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 6847 6. If necessary, remove the lock crank (A) from the door. 7. Install the latch in the reverse order of removal, and note these items: - Make sure the connector is plugged in properly, and each rod is connected securely. - Make sure the door locks and opens properly. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair Rear Door Panel Removal/Installation Special Tools Required - Trim pad remover. Snap-on A 177A, or equivalent, commercially available. - KTC trim tool set SOJATP2014 NOTE: Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. Lower the glass fully. 2. Remove the inner handle (A). Take care not to scratch the door panel. 1. Using a trim tool, pry out the upper portion of the cover (B) to release the hooks (C, D), then remove the cover. 2. Remove the screws. 3. Pull the inner handle forward and out half-way to release the hook (E). 4. Disconnect the inner handle rod (F). 3. Remove the door quarter inner trim (A). Take care not to scratch the door. 1. Using a trim tool, insert it next to the pin, and detach the pin by prying on the trim while holding the hook area. Take care not to break the hooks (B). 2. Pull the trim forward to release the hooks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 6851 4. Remove the clip from the door quarter inner trim mounting portion. 5. Remove the screws from under the armrest. 6. Remove the switch panel (A). 1. Insert a flat-tip screwdriver wrapped with protective tape through a hole under the armrest, and push up the back of the panel to release the rear hook (B). 2. Pull out along the edge of the panel to release the hooks (C) and clip. 3. Disconnect the power window switch connector (D). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 6852 7. Remove the door panel (A) with as little bending as possible to avoid creasing or breaking it. 1. Release the clips that hold the door panel with a commercially available trim pad remover (B). 2. Starting at the rear, pull the door panel upward, then release the lock knob (C). 8. From the back of the door panel, detach the harness clip (A). 9. Install the panel in the reverse order of removal, and note these items: - Replace any damaged clips. - Make sure the connector is plugged in properly and the rod is connected properly. - Push the clips into place securely. - Check the window operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments Front and Rear Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed, but the striker can be adjusted slightly up or down, and in or out. 1. Loosen the screws (B), then insert a shop towel (C) between the body and striker. 2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (D). Do not tap the striker too hard. 4. Loosen the screws, and remove the shop towel. 5. Lightly tighten the screws. 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Weatherstrip Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Rear Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the center pillar, remove the door checker 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 the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Weatherstrip > Page 6860 Rear Door Weatherstrip: Service and Repair Rear Door Center Pillar Seal Rear Door Center Pillar Seal Replacement NOTE: Take care not to scratch the door. 1. Pull the door center pillar seal (A) away, then remove it. 2. After installing the seal to the upper edge of the door flange, align the seal to the bottom edge of the flange, the push the seal into place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the screw (A) from the front edge of the door. Starting at the front, pry the door glass outer weatherstrip (B) up to detach the clips (C), and release the weatherstrip from the door quarter glass seal (D), then remove it. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Locations 116. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Locations > Page 6868 Rear Door Window Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary - Rod protector 2. Carefully move the glass (A) until you can see the bolts, then remove them. Remove the glass from the regulator (B), and carefully lower the glass. Take care not to drop the glass inside the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 6872 3. Pull the glass run channel (A) away as needed. Pull back the door quarter glass seal (B), then remove the screw (C). Remove the bolts (D, E) securing the center channel (F), then remove the collar (G). 4. Pull the upper portion of the center channel (A) forward to remove it from the door quarter glass seal (B), and pull up the center channel. Take care not to scratch the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 6873 5. Remove the door quarter glass (A) and seal (B) as an assembly from the door. 6. Release the glass (A) from the center channel (B), and carefully remove the glass out through the window slot. Take care not to drop the glass inside the door. 7. Disconnect and detach the connector (A) from the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 6874 8. Remove the bolts (B), and loosen the bolts (C), then remove the regulator (D) through the hole in the door. 9. Apply multipurpose grease to the sliding surfaces of the regulator (A) where shown. 10. Install the glass and regulator in the reverse order of removal, and note these items: - Make sure the motor connector is plugged in properly. - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks. - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6880 *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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6881 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6882 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6883 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6884 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6885 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6886 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6887 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6888 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 before performing repairs or service. NOTE: - Put on gloves to protect your hands. - Take care not to scratch the body and related parts. 1. Remove these items from the left side of the vehicle: - Front door sill trim. - Kick panel. - Rear door sill trim. - B-pillar lower trim. - Rear side trim panel. 2. Pull the carpet back as necessary. 3. Remove the bolts (A), then remove the opener (B). Detach the clips (C) (for some models) by using a clip remover, and remove the fuel fill door opener cable (D) from the clips (E, F). 4. Remove the cushion tape (G). Remove the cable from the clip (H), and detach the clips (C) by using a clip remover. 5. Remove the fuel fill door latch (I) from the body by turning it 90 °, then remove the fuel fill door opener cable from the vehicle. Take care not to kink the cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable > Component Information > Service and Repair > Page 6892 6. Install the opener cable (A) in the reverse order of removal, and note these items: - Replace any damaged clips, and replace the cushion tape. - Align the mark(B) on the cable with the clips and cushion tape. At the bottom of the center pillar, align the front cushion tape (C) with the hole (D) in the body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. Using a clip remover, detach the clips. Release the hooks (A), then remove the hood insulator (B). Take care not to scratch the hood. 2. Install the insulator in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 (A) from the hood latch (B). Take care not to bend the cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 6900 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 . - Make sure the hood opens properly and locks securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations Openers - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations > Page 6904 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 from the left side of the vehicle: - Front inner fender. - Kick panel. 2. Disconnect the hood opener cable (A) from the hood latch (B) and remove the bolts (C), then remove the hood release handle (D). 3. Using a clip remover, detach the clips (E). 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 note these items: - Replace any damaged clips. - Route the cable through the hole (G) in the body. - Make sure the hood opens properly and locks securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 6909 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Liftgate Window Glass Weatherstrip > Component Information > Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Hatch Glass Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the tailgate. 1. Remove the tailgate side trim from both sides. 2. Remove the high mount brake light. 3. Disconnect the rear window defogger connectors, and release the wire harnesses from both sides. 4. Remove the hatch glass support strut brackets from both sides of the tailgate. 5. With an assistant, holding the hatch glass, remove the hatch glass weatherstrip (A) by pulling out on it. 6. Clean the bonding surface around the hatch glass opening flange with alcohol. 7. Apply sealant (Cemedine P/N 08712-0004, or equivalent) (A) in the groove around the hatch glass weatherstrip (B). 8. Locate the painted alignment mark (C) on the hatch glass weatherstrip. Align the painted mark with the alignment tab in the center of the hatch glass opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 9. Check for water leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Component Locations Power Trunk / Liftgate Lock Actuator: Component Locations Openers Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Component Locations > Page 6919 127. Left Side of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Component Locations > Page 6920 126. Middle of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 6921 Power Trunk / Liftgate Lock Actuator: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 6922 Power Trunk / Liftgate Lock Actuator: Service and Repair Hatch Glass Actuator Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate lower trim panel. 2. Disconnect the hatch glass rod (A), hatch glass open rod (B), and actuator connector (C), then detach the connector from the tailgate. 3. Remove the bolts, then remove the hatch glass actuator (A). 4. Install the actuator in the reverse order of removal, and make sure the actuator connector is plugged in properly, and the hatch glass open rod is connected securely. 5. Reconnect the hatch glass rod (A) in the following sequence. 1. Move the lever (B) of the latch (C) into the "lock" position. 2. Move the lever (D) on the actuator into the "set" position as shown by the arrow. 3. While holding the latch lever (B) in the "lock" position, take up the slack in the rod by pulling it toward the actuator as shown. 4. Tighten the fastener (E) on the rod. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 6923 6. Make sure the hatch glass opens properly and locks securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations 108. Driver's Door 125. Middle of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 6927 Power Trunk / Liftgate Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Tailgate Handle Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate stop assembly. 2. Disconnect the cylinder rod (A) and the hatch glass open rod (B) from the tailgate lock cylinder (C). 3. Release the retainer clip (A) with a hook-shaped tool, then remove the lock cylinder (B) from the tailgate handle (C). 4. Remove the bolt securing the cylinder protector (A) and tailgate handle. Release the hook (B), then remove the protector, Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Page 6931 5. Remove the bolt securing the tailgate handle, and remove the spacer (A). 6. Remove the outer handle (A) while pulling it as shown. 7. Install the tailgate handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the tailgate locks and opens properly. - 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair Trim Removal/Installation - Tailgate 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. 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Locations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Hatch Glass Latch Trunk / Liftgate Latch: Service and Repair Hatch Glass Latch Hatch Glass Latch Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate lower trim panel. 2. Disconnect the hatch glass latch switch connector (A), hatch glass latch connector (B), and detach the hatch glass latch connector from the tailgate. 3. Remove the bolts, then pull the hatch glass latch (C) out. 4. Disconnect the hatch glass rod (A), than remove the hatch glass latch (B). Take care not to bend the rod. 5. Install the latch in the reverse order of removal, and note these items: - Make sure each connector is plugged in properly, and the rod is connected properly. - Make sure the hatch glass opens properly and locks securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Hatch Glass Latch > Page 6940 Trunk / Liftgate Latch: Service and Repair Tailgate Latch Tailgate Latch Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate lower trim panel. 2. Remove the tailgate latch (A). 1. Disconnect the tailgate rod (B) and cylinder rod (0. 2. Disconnect the actuator connector (D). 3. Remove the screws securing the latch. 4. Remove the latch through the hole in the tailgate. Take care not to bend the tailgate rod and cylinder rod. 3. Install the latch in the reverse order of removal, and note these items: - Make sure the actuator connector is plugged in properly, and each rod is connected securely. - If the tailgate rod (A) was disconnected at the upper end (the tailgate stop assembly side), reconnect it with its lower end in the bottom hole in the lever (B). - Make sure the tailgate locks and opens properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6945 *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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6946 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6947 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6948 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6949 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6950 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6951 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6952 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 6953 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Glass/Hatch Glass Support Strut Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the tailgate. - Do not damage the rear window defogger grid lines and terminals. 1. Remove the tailgate side trim from both sides. 2. Remove the high mount brake light. 3. Disconnect the rear window defogger connectors (A), and release the wire harnesses (B) and harness holders (C) from both hatch glass support strut brackets (D). On the right side, release the wire harness from the wire harness trim (E). 4. While holding the hatch glass, use a Torx T30 bit to remove the bolts, then remove the hatch glass support strut brackets (A) from both sides. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Page 6957 5. While holding the hatch glass (A), use a Torx T30 bit to remove the bolt, then release the double-sided adhesive tape (B), and remove the hatch glass support strut (C), support strut nut (D), and seal (E) from the hatch glass. 6. With an assistant, holding the hatch glass, remove the nuts from both sides. Unlock the hatch glass latch. 7. Remove the hatch glass (A). Take care not to scratch the tailgate. 8. Install the glass and support struts in the reverse order of removal, and note these items: - Replace the removed support strut mounting bolts with new ones. - Make sure the rear window defogger connectors are plugged in properly. - Adjust the position of the glass. - Check that the hatch glass opens properly and locks securely. 9. Check for water leaks and wind noise. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 6961 Front Door Component Location Index Openers Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Tailgate Weatherstrip Replacement 1. Remove the tailgate weatherstrip (A) by pulling out on it. 2. Clean the bonding surface around the tailgate flange with alcohol. 3. Apply sealant (Cemedine P/N 08712-0004, or equivalent) (B) in the groove around all of the tailgate weatherstrip. 4. Locate the painted alignment mark (C) on the tailgate weatherstrip. Align the painted mark with the alignment tab in the center of the tailgate opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 5. Check for water leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the emblems, take care not to scratch the body. Use dental floss to cut the adhesive safely. 1. To remove the front "H" emblem, remove the front grille. 2. Clean the body surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface. 3. Apply the emblems where shown. For '03-04 models: When installing the LEV emblem on the rear door quarter glass, align the emblem as shown, then press the emblem into place, and remove the application tape. 4. Reinstall the front grille. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the' cowl covers. Take care not to scratch the cowl covers. 3. Detach the clips (D, E) and release the hook (F) by carefully pulling the passenger's cowl cover (G) upward. Pull the cover forward to release the hooks (H), pull the hinge cover (I) out from the front fender (J), and disconnect the windshield washer tube (K), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D, E) by carefully pulling the driver's cowl cover (M) upward, and pull the cover forward to release the hooks (N). Pull the hinge cover (0) out from the front fender (P), and disconnect the windshield washer tube (L) routed from the washer reservoir then remove the cover. Take care not to scratch the body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 6972 5. If necessary, release the clips, then remove the insulators (A, B) from both cowl covers (C, D). 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Make sure the washer tubes are connected securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Side Windshield Trim Replacement Windshield Moulding / Trim: Service and Repair Side Windshield Trim Replacement Side Windshield Trim Replacement 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. 1. Remove the front roof side trim. 2. Remove the nut, and detach the side windshield trim (A) from the retainer (B) by pulling the trim up. Take care not to scratch the body. 3. Install the trim in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Side Windshield Trim Replacement > Page 6977 Windshield Moulding / Trim: Service and Repair Side Windshield Trim Retainer Replacement Side Windshield Trim Retainer Replacement NOTE: - Take care not to scratch the body. - When heating the body with a dryer, be careful not to get it too hot. Heat it gradually to prevent damage to the paint. - Remove the plastic parts, and/or protect them from the heat with aluminum foil. 1. While heating the retainer (A) to 212-248 °F (100 -120 °C) with a dryer, gently pull it away from the body with pliers. 2. With a putty knife, scrape the remaining adhesive tape from the bonding surface while heating it with a dryer. 3. Clean the bonding surface with a sponge dampened in alcohol. Make sure the bonding surface is kept free or water, oil and grease. 4. Peel the adhesive backing away from the double-sided adhesive tape on new retainer. 5. Line up the retainers with the alignment marks (B) on the body, and attach the retainers with the adhesive tape (C). 6. Apply two-part epoxy adhesive (D) around the edge of the retainers as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender Front Fender Liner: Service and Repair Front Inner Fender Front Inner Fender Replacement NOTE: Take care not to scratch the body. 1. Remove the front inner fender (A). 1. On the back of the wheel arch, remove the screws (B). 2. With a Torx T30 bit, remove the bolt (C) securing the front wheel arch protector. 3. From under the front bumper (D), remove the bolt (E) securing the front bumper, splash shield (F), and front inner fender. 4. From the wheel arch, remove the clips (G) securing the front inner fender (and splash shield) on the body. 5. Release the hook (H) of the splash shield, then remove the front inner fender. 2. Install the inner fender in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6983 Front Fender Liner: Service and Repair Front Fender Fairing Front Fender Fairing Replacement 1. Remove the front inner fender as necessary. 2. For the left front fender fairing removal, remove the washer reservoir. 3. Open the front door. From outside the door, remove the upper clip, and from inside the door, remove the lower clip securing the front fender fairing (A) and front fender (B). 4. From the wheel arch, remove the clip (A), and release the clip (B), then remove the front fender fairing (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6984 5. Install the fender fairing in the reverse order of removal, and note these items: - Replace any damaged clips. - Before installing the clips of the door upper and lower portions, install the front fender fairing (A) to the front fender (B) properly as shown. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6985 Front Fender Liner: Service and Repair Front Wheelhouse/Damper Housing Removal Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6986 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse M/T: Leave the transmission mount bracket attached to the front side frame. A/T: When replacing the front wheelhouse, support the wheelhouse and transmission mount bracket as an assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6987 - Check the damper housing position, and check for damage. - If necessary, remove the Wheelhouse upper member, and replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimension. 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. - Weld the damper housing and front side frame. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6988 - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, and damper housing extension lower. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6989 - From the dashboard upper side, plug weld the holes in the damper housing extension upper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Fender > Front Fender Liner > System Information > Service and Repair > Front Inner Fender > Page 6990 - Weld the front wheelhouse, damper housing, and front side frame. - Weld the wheelhouse upper member. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest for Firewall: > 06-037 > Jun > 06 > Body - Water Leaks to The Interior From Behind Dash Firewall: Customer Interest Body - Water Leaks to The Interior From Behind Dash 06-037 June 27, 2006 Applies To: 2002-05 CR-V - All UK-produced vehicles 2006 CR-V 2WD - From VIN SHSRD6...6U400001 thru SHSRD6...6U406731 2006 CR-V 4WD - From VIN SHSRD7.. .6U400001 thru SHSRD7...6U429536 Cowl Water Leak SYMPTOM Water leaks into the vehicle from behind the dashboard. PROBABLE CAUSE During production, part of the passenger's compartment front bulkhead may not have been properly sealed. CORRECTIVE ACTION Seal the outside bulkhead area with sealant. REQUIRED MATERIALS 3M Ultrapro Autobody Sealant (or equivalent): Caulking gun cartridge - 3M P/N 08300 Squeezable tube - 3M P/N 08301 One container repairs one vehicle. WARRANTY CLAIM INFORMATION Operation Number: 8410A4 Flat Rate Time: 1.0 hour Failed Part: 61500-59A-A00ZZ Defect Code: 07408 Symptom Code: 05904 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 cowl cover. ^ Refer to page 20-137 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword COWL, then select Cowl Cover Replacement from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest for Firewall: > 06-037 > Jun > 06 > Body - Water Leaks to The Interior From Behind Dash > Page 6999 2. Seal the entire exterior horizontal seam on the bulkhead. Make sure you apply the sealant above and below the vertical brackets. 3. Reinstall the cowl cover. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Firewall: > 06-037 > Jun > 06 > Body - Water Leaks to The Interior From Behind Dash Firewall: All Technical Service Bulletins Body - Water Leaks to The Interior From Behind Dash 06-037 June 27, 2006 Applies To: 2002-05 CR-V - All UK-produced vehicles 2006 CR-V 2WD - From VIN SHSRD6...6U400001 thru SHSRD6...6U406731 2006 CR-V 4WD - From VIN SHSRD7.. .6U400001 thru SHSRD7...6U429536 Cowl Water Leak SYMPTOM Water leaks into the vehicle from behind the dashboard. PROBABLE CAUSE During production, part of the passenger's compartment front bulkhead may not have been properly sealed. CORRECTIVE ACTION Seal the outside bulkhead area with sealant. REQUIRED MATERIALS 3M Ultrapro Autobody Sealant (or equivalent): Caulking gun cartridge - 3M P/N 08300 Squeezable tube - 3M P/N 08301 One container repairs one vehicle. WARRANTY CLAIM INFORMATION Operation Number: 8410A4 Flat Rate Time: 1.0 hour Failed Part: 61500-59A-A00ZZ Defect Code: 07408 Symptom Code: 05904 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 cowl cover. ^ Refer to page 20-137 of the 2005-06 CR-V Service Manual, or ^ Online, enter keyword COWL, then select Cowl Cover Replacement from the list. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Firewall: > 06-037 > Jun > 06 > Body - Water Leaks to The Interior From Behind Dash > Page 7005 2. Seal the entire exterior horizontal seam on the bulkhead. Make sure you apply the sealant above and below the vertical brackets. 3. Reinstall the cowl cover. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Body/Frame - Universal Subframe Removal Adapter > Page 7014 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Page 7015 Subframe: Service and Repair Subframe Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Page 7016 Subframe Replacement Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 clips, and remove the front grille (A) from the front bumper (B) by pulling it out. Take care not to scratch the front bumper. 3. If necessary, remove the screws (A, B) and clip (C), then remove the grille molding (D), splash shield (E), and front grille absorber (F) from the front grille (G). 4. Install the grille in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Front Seat Armrest Arm Rest: Service and Repair Front Seat Armrest Front Seat Armrest Replacement Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Take care not to tear the seams or damage the seat covers. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. 1. Using a trim tool, remove the cap (A). 2. Remove the nut, the washer (B), and the wave washer (C), then remove the armrest (D). If necessary, remove the bushings (E) from the armrest. 3. Remove the bolts, then remove the armrest bracket (A). 4. Install the armrest in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Front Seat Armrest > Page 7025 Arm Rest: Service and Repair Rear Seat Armrest Rear Seat Armrest Replacement NOTE: Take care not to tear the seams or damage the seat covers. 1. Remove the clip (A) from the right portion of the armrest pivot. 2. Remove the armrest. 1. Slide the armrest (A) toward the right side. 2. Remove the left pivot shaft (B) from the collar (C), and remove the right pivot shaft (D) from the collar (E) by pulling the armrest back. 3. Install the armrest in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Front Seat Armrest > Page 7026 Arm Rest: Service and Repair Rear Seat Armrest Cover Rear Seat Armrest Cover Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. 1. Remove the armrest. 2. Remove the beverage holder (A). 1. Pull up on the rear edge of the holder to release the hooks (B). 2. Release the front hooks (C), then remove the holder. 3. Release the clips (A) from the beverage holder opening, release the rear hook (B), then pull back the edge of the armrest cover (C) all the way around and remove it. 4. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Front Seat Armrest > Page 7027 - Replace any clips you removed with new ones (A). Install them with commercially available upholstery ring pliers (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 - Rear seats, both sides - B-pillar lower trim panel, both sides - Dashboard center lower cover, A/T model, M/T model 2. Remove the carpet (A). 1. Remove the clips (B). 2. Detach the clips (C), then pull back the cargo area floor mat (D). 3. Release the fasteners (E), then pull back the carpet from under the dashboard, 4. Remove both rear seat belts (F) through the slit in the carpet, and release the fasteners (G) for both rear side trim panels. 3. Install the carpet in the reverse order of removal, and note these items: - Take care not to damage, wrinkle or twist the carpet. - Make sure the seat harnesses are routed correctly. - Replace any damaged clips. - Slip both rear seat belts through the slit in the carpet properly. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Console 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Console Lamp: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7071 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7072 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7073 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7074 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7075 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7076 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7077 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7078 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7079 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7086 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7087 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7088 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7089 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7092 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7093 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7094 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7095 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7098 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7099 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7100 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Front Seat Center Table Replacement Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Take care not to scratch the dashboard, tear the seams or damage the seat covers. - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Put on gloves to protect your hands. - A/T models are shown, and M/T models are similar. 1. Set up the table, 2. Remove the screw (A), release the tabs (B), and pull the outer cover (C) back to detach the clips (D) and hooks (E), then remove it. 3. Remove the nuts, then remove the center table (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Page 7104 4. Remove the inner cover (A) and the center table cover (B) from the center table frame (C). 5. Install the table in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips, hooks, and tabs into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7110 *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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7111 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7112 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7113 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7114 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7115 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7116 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7117 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7118 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Removal/Installation Special Tools Required KTC trim tool set SOJATP2014 NOTE: - Use the appropriate tool from the KTC trim tool set to avoid damage when prying components. - Take care not to bend and scratch the headliner. - Be careful not to damage the dashboard and other interior trim. 1. Remove these items: - A-pillar trim, both sides - B-pillar upper trim, one side - C-pillar trim, one side - Tailgate weatherstrip, as necessary - D-pillar trim, both sides - Ceiling lights, front and rear 2. From both sides, remove the sunvisor (A) and holder (B). 1. Using a trim tool, pry the cap (C). 2. Pull the clip portions (D) of the cap down. 3. Remove the sunvisor from the body and holder. 4. Using a flat-tip screwdriver, push the hook (E), and turn the holder 90 degree, then pull it out. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7122 3. Remove the roof console (A). 1. Remove the lens (B). 2. Remove the screws. 3. Pull out the roof console, and disconnect the front individual map light connector (C). 4. Remove the caps (A), and remove the screws, then remove the grab handles (B) (driver's and each passenger's). 5. Remove the cap (A) from the center seat belt retractor cover (B). 6. With the help of an assistant, remove the headliner (A). 1. Remove the remaining front door opening trim (B) and rear door opening trim (C) from each roof portion. 2. With moonroof: Remove the roof trim (D). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7123 3. Remove the upper portion of the remaining B-pillar upper trim (E) and C-pillar trim (F). Take care not to damage the trim. 4. Detach the clip (G), and release the fasteners (H) by pulling the rear portion of the headliner down. Take care not to damage the headliner. 5. Lower the headliner, and remove it from the remaining trim, and disconnect the moonroof connector (I) (with moonroof). Take care not to damage the interior wire harness (J). 7. With the help of an assistant, remove the cushion tape, then remove the interior wire harness (A) from the headliner (B). Take care not to damage the headliner and interior wire harness. 8. Remove the headliner through the tailgate opening. Take care not to damage the headliner. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7124 9. Remove the anchor cover bracket (A), then remove the anchor cover (B) from the headliner. 10. Remove the speed nuts (A), and remove the cushion tape (B), then remove the retractor cover bracket (C) and retractor cover (D) from the headliner. 11. Using a clip remover, detach the clips (A, B), then remove the front roof side pad (C) and rear roof side pad (D). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7125 12. Install the headliner in the reverse order of removed, and note these items: - When reinstalling the headliner through the tailgate opening, be careful not to fold or bend it. Also, be careful not to scratch the body. - Replace any damaged clips, and replace the cushion tape. - Check that both sides of the headliner are securely attached to the trim. - Push the clips into place securely. - With moonroof: When reinstalling the roof trim (A), install the joint (B) as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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: 2. Install the trim 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 front seat belt anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal / Installation - Door Area Trim Panel: Service and Repair Trim Removal / Installation - Door Area Trim Removal/Installation - Door Area Special Tools Required KTC trim tool set SOJATP2014 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: 2. Install the trim 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 front seat belt anchor bolts before installation. - Before installing the anchor bolts, make sure there are no twists or kinks in the seat belt. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal / Installation - Door Area > Page 7133 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. Remove these items, then remove the trim in the sequence shown: - Rear door sill trim - Cargo area floor mat, cargo floor lid, cargo storage bin, tie-down hooks, rear trim panel - Accessory power socket (from the left rear side trim panel) 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Make sure there are no pinches in the seat belt. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal / Installation - Door Area > Page 7134 Trim Panel: Service and Repair Trim Removal / Installation - Rear Side Pillar Area Trim Removal/Installation - Rear Side Pillar 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. Remove the upper portion of the rear side trim panel as necessary . 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - When installing the rear side trim panel, make sure there are no pinches in the seat belt. - Apply liquid thread lock to the rear seat belt anchor bolt before installation. - Before installing the anchor bolt, make sure there are no twists or kinks in the seat belt. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Trim Removal / Installation - Door Area > Page 7135 Trim Panel: Service and Repair Trim Removal / Installation - Cargo Area Trim Removal/Installation - Cargo 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. 2. Install the trim in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7142 *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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7143 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7144 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7145 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7146 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7147 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7148 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7149 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7150 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 7159 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 7160 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations 64. Under Middle of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 7164 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7173 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7174 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7180 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7181 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7186 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7187 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7188 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7189 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7190 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7191 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7192 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7193 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7194 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7195 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7196 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7197 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7198 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7199 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7200 (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7201 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7202 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7203 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7204 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7205 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7206 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7207 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7208 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7209 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7210 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7216 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7217 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7218 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7219 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7220 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7221 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7222 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7223 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7224 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7225 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7226 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7227 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7228 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7229 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7230 (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7231 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7232 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7233 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7234 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7235 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7236 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7237 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7238 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7239 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7240 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test Keyless Entry Transmitter: Testing and Inspection Transmitter Test 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 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 with the transmitter. - If the doors lock and unlock, the transmitter is OK. - If the doors don't lock and unlock, replace the transmitter. If the new transmitter won't lock and unlock the doors, test the keyless unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test > Page 7243 Keyless Entry Transmitter: Testing and Inspection Keyless Receiver Unit Input Test Keyless Receiver Unit Input Test 1. Remove the dashboard pocket. 2. Disconnect the 5P connector (A) from the keyless receiver 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 are OK, go to step 4. 4. Reconnect the connector, and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. 5. Disconnect the connector, and make this input test at the connector. - If the test indicates a problem, find and correct the cause, then recheck the system. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Transmitter Test > Page 7244 - If the input tests proves OK, replace the keyless receiver unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Page 7245 Keyless Entry Transmitter: Service and Repair Transmitter Programming Storing transmitter codes: The codes of up to three transmitters can be programmed into the keyless receiver unit memory. (If a fourth code is stored, the code that was programmed first will be erased.) NOTE: It is important to maintain the time limits between the steps. Make sure the doors and the tailgate are closed. 1. Turn the ignition switch ON (II). 2. Within 1 to 4 seconds, push the transmitter lock or unlock button. 3. Within 1 to 4 seconds, turn the ignition switch OFF. 4. Within 1 to 4 seconds, turn the ignition switch ON (II). 5. Within 1 to 4 seconds, push the transmitter lock or unlock button. 6. Within 1 to 4 seconds, turn the ignition switch OFF. 7. Within 4 seconds, turn the ignition switch ON (II). 8. Within 1 to 4 seconds, push the transmitter lock or unlock button. 9. Within 1 to 4 seconds, turn the ignition switch OFF. 10. Within 4 seconds, turn the ignition switch ON (II). 11. Within 1 to 4 seconds, push the transmitter lock or unlock button. 12. Confirm you can hear the sound of the door lock actuators. Within 1 to 4 seconds, push the transmitter lock or unlock button again. 13. Within 10 seconds, press the transmitter lock or unlock buttons on the two additional transmitters. 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 remove the key. 15. Confirm proper operation of the transmitters. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Power Door Lock Actuator: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 7250 109. Driver's Door 112. Front Passenger's Door 115. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 7251 Power Door Lock Actuator: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection > Door Power Door Lock Actuator: Testing and Inspection Door 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 work as specified, replace it. Passenger's door: 1. Remove the passenger's door panel. 2. Disconnect the 2P connector from the actuator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection > Door > Page 7254 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 work as specified, replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection > Door > Page 7255 Power Door Lock Actuator: Testing and Inspection Tailgate Tailgate Lock Actuator Test 1. Remove the tailgate lower trim 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 actuator apply battery voltage only momentarily. 4. If the actuator does not operate as specified, replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Testing and Inspection > Door > Page 7256 Power Door Lock Actuator: Testing and Inspection Hatch Glass Opener Hatch Glass Opener Actuator Test 1. Remove the tailgate lower trim panel. 2. Disconnect the 2P connector from the actuator. 3. Connect power to the No.1 terminal and ground to the No.2 terminals momentarily. The actuator should operate. 4. If the actuator does not operate as specified, replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7260 107. Driver's Door 109. Driver's Door 111. Front Passenger's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7261 Power Door Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch Power Door Lock Switch: Testing and Inspection Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7264 Power Door Lock Switch: Testing and Inspection Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7265 Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Identify the type of door lock actuator. 3. Disconnect the 3P connector from the actuator. 4. Check for continuity between the No.1 [No. 2] and No.3 [No. 1] 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. [] : Mitsui Type 5. Check for continuity between the No.1 [No. 2] and No.2 [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. [] : Mitsui Type 6. If the continuity is not as specified, replace the driver's door lock actuator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7266 Power Door Lock Switch: Testing and Inspection Door Lock Switch Door Lock Switch Test 1. Remove the door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the No.1 and No.2 terminals: - There should be continuity when the door lock switch is in the LOCKED position. - There should be no continuity when the door lock 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 switch is in the UNLOCKED position. - There should be no continuity when the door lock switch is in the LOCKED position. 5. If the continuity is not as specified, replace the door lock switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch Power Door Lock Switch: Service and Repair Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch > Page 7269 Power Door Lock Switch: Service and Repair Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7274 *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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7275 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7276 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7277 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7278 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7279 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7280 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7281 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7282 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations Mirrors Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations > Page 7287 Power Mirror Motor: Testing and Inspection Power Mirror Actuator Test 1. Remove the door panel. 2. Disconnect the 3P [or 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. 6. If the continuity is not as specified, replace the mirror actuator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations > Page 7288 Power Mirror Motor: Service and Repair Power Mirror Actuator Replacement 1. Remove the mirror holder, and disconnect the mirror defogger connectors. With defogger 2. Remove the power mirror. 3. Disconnect the 3P (USA) or 6P (Canada) connector from the mirror. 4. Remove the screw from the harness clip (A). 5. Cut the wire harness with cutter, and remove the gasket (A). 6. Remove the three screws. and separate the mirror housing (A) from the bracket (B). 7. Remove the four screws, and the actuator (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Locations > Page 7289 8. Route the wire harness (A) of the new actuator through the hole in the bracket (B) and gasket (C). 9. Install the actuator, bracket, harness clip, and gasket in the reverse order of removal. 10. Insert the new actuator terminals into the connector in the original arrangement as shown. 11. Apply tape to seal the intersection of the wire harness and the gasket. 12. Reassemble in the reverse order of disassembly. Be careful not to break the mirror when reinstalling it to the actuator. 13. Reinstall the mirror assembly to the door. 14. Operate the power mirror to ensure smooth operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7293 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7294 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7295 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7296 Power Mirror Switch: Service and Repair Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7302 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7303 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7304 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7305 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7306 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7307 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Industrial Fallout Paint Damage > Page 7308 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Page 7309 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Chart Paint Specifications Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Chart Paint Specifications > Page 7312 Paint: Application and ID Paint Code and Color Label Location Paint Code Vehicle Identification Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 finishes give the CR-V a deep gloss and stunning finish.This 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 or wash thoroughly with water.If paint gets in your eyes, flush with water and get prompt medical attention. - Paint is flammable.Store it in a safe place, and keep it away from sparks, flames, or cigarettes. Basic Rules for Repairing a Paint Finish To repair paint damage, always use the 2-part acylic urethane paints designated; polish and bake each of the three coats, as in production, to maintain the original film thickness, and to assure the same quality as the original finish. Outline of Factory Painting Process: Features in Each Work Process 1. Pretreatment and Electrodeposition In the pretreatment process, the entire body is degreased, cleaned, and coated with zinc phosphate by dipping. After the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (Cationic Electrodeposition). This produces a thorough corrosion inhibiting coating on the inner surface and corners of the body, pillars, sills, and panel joints.Chipping primer is then applied to the most susceptible areas. 2. Intermediate coat The intermediate coat is applied to the prepared surface for further protection against damage. 3. Top Coat Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness, and weather resistance. Sectional View of Paint Coats: Refinishing Processes Refinishing Processes Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7315 Paint damage can appear in any form. Before making a repair, check the damaged area carefully, and determine the best procedure for repairing the damage. The following shows you refinishing methods for various types of paint damage or defects. Preprocessing of Painting Preprocessing of Painting 1. Featheredging NOTE: The paint film damaged area should be sanded flat and smooth. - If this is not done correctly the end results will not be acceptable. Damage to metal surface: - Sand the damaged area flat and smooth. Use the disc sander and #6O~#8O disc paper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7316 Use the double action sander and #6O~#8O disc paper. - Sand the area larger than the damaged area. Use the double action sander and #1BO~#24O 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 #18O~#24O~#32O 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7317 - 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 other industrial dryer at 122 degrees F (60 degrees C) - 140 degrees F (60 degrees C). NOTE: Follow the body filler manufacturer's instructions for drying time. 2. Polishing The body filler is dry when a white mark appears when the surface is scratched with your finger nail. -1. Throughly sand the body filler surface. Use the double action sander and #8O~#12O disc paper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7318 -2. Sand the surface evenly, particularly the area that was filled. Use the flexible block and #12O~#18O sandpaper. -3. Featheredge the paint coat. Sand the body filler surface until the proper dimension are met. Use the double action sander and #24O~#32O #400 disc papers. 3. Air blowing / degreasing Also clean and degrease the surfaces where masking tape will be attached. Use the alcohol, wax and grease remover. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7319 - 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 other industrial dryer. NOTE: Follow the primer surfacer manufacturer's instruction for drying time. 4. Polishing Check that the primer surfacer has dried thoroughly, then sand the primer surfacer. Use the double action sander and #32O~#4OO~#6OO disc papers. 5. Air blowing / degreasing Also clean and degrease the surfaces where masking tape will be attached. Use alcohol, and wax and grease remover. 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 other industrial dryer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7320 NOTE: Follow the top coat manufacturer's instruction for drying time. 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 #2000 sandpaper and compound. 5. Air blowing/degreasing Use alcohol, and wax and grease remover. Also clean and degrease surfaces where the masking tape will be attached. Top Coating Top Coating 1. Masking Mask the area surrounding the damage to protect it from the top coat overspray. Use masking tape and paper. 2. Spraying top coat enamel / clear coat Spray 2 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 manufacturer's instructions. Drying After spraying the top coat enamel, allow it to air dry, then force dry it with infrared lamps or other industrial dryer. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7321 NOTE: Follow the top coat manufacturer's instructions for drying time. Spraying clear coat Spray the top coat clear evenly over the surface of the top coat enamel. Do not try to cover the surface with one heavy coat. Drying After spraying the clear coat, allow it to dry for 10 minutes, then force dry it with infrared lamps or other industrial dryer. NOTE: Follow the top coat 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 #1 2OO~#2OOO 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7322 -4. After buffing, remove the masking paper and tape, and thoroughly wash the entire vehicle. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7323 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7324 Paint: Service and Repair Plastic Parts Paint Features of Plastic Material Features of Plastic Material Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7325 - 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. Use of the Repair Material (Reference) 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7326 1. Filler 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7327 Drying Time: NOTE: Use a spray gun to apply the paint. Do not use a brush. Force dry the intermediate coat and top coat. NOTE: Mix only an amount that can be used before it hardens. Refinishing Processes Refinishing Processes Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7328 - The following shows refinishing methods to various types of paint damage or defects. - Be careful not to deform and 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 #24O~#4OO~#6OO sandpaper. Hole / Deep Gouge: Cut out and make any torn or burred area flat. Use a knife, flexible block, and #180~#240 sandpapers. 2. Air blowing/degreasing Clean the damaged area throughly. Use alcohol, and wax and grease remover. Undercoating Undercoating 1. Spraying primer Primer is used to till cavities in the putty and primer surfacer. - Spray primer on the exposed area. - Spray the 2 to 3 coats of primer on 2 to 3 coats over the area you applied putty. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7329 - 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. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7330 3. Sanding Sand the surface evenly, particularly at the area where the PP material and putty meet. Use a flexible block and #240~#400~#600 sandpaper. 4. Air blowing / degreasing Use alcohol, a tack cloth, and wax and grease remover. 5. Spraying primer surfacer NOTE: Spray the bumper primer on the area where the PP material was exposed and around the putty. - Spray the primer surface wider then the putty and painted surfaces of bumper primer. - Spray 2 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. 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7331 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 Check the top coat enamel has dried thoroughly, then sand the top coat enamel. Use a flexible block and #600~#800~#1000 sandpapers. NOTE: Be careful not to sand down to the primer surfacer. When the painting repair is almost complete, polish the top coat. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7332 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. 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. Use a buffing sponge, and buffing wool and compounds. Finish up with buffing: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7333 -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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7334 Paint: Service and Repair Soft Chipping Guard Primer Coat General The removal of paint and undercoating by stone chips immediately exposes metal to the atmosphere, causing it to oxidize.The thickness of this oxidation increases if the process continues unchecked.The soft chipping guard primer protects against damage due to the impact of such objects. - The soft chipping guard primer coat is applied over the E-D. (Electrostatically Deposited) primer. It is followed by guide coating and top coating. - The soft chipping guard primer produces a smooth surface when dry.It should be sprayed so the thickness of the protective film is 20 microns. Basic Rules for Repairing a Soft Chipping Guard Primer Coat: - Soft chipping guard primer coat is then applied to the most susceptible area. - Spray the primer surface (2-part urethane primer surfacer) on the soft chipping guard primer coating areas when you replaced parts using soft chipping guard primer coat. WARNING: Wear goggles or safety glasses to prevent eye injury. - Ventilate when spraying undercoat. 1. Sanding the replacement part. Use a double action sander and #400 disc sandpaper. NOTE: Do not oversand the edges or corners of the part. - Do not expose base metal. 2. Air blowing/degreasing Use alcohol, and wax and grease remover. 3. Masking Use masking tape and paper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Body Paint > Page 7335 4. Spraying primer surfacer - Spray about 4 to 5 coats to get 20 microns of thickness. One coat deposits about 5 to 7 microns. - Do not try to cover the surface with one heavy coat. Apply several thin coats is recommended. - Use a 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. 5. Drying After spraying primer surfacer, allow 7 to 10 minutes of drying time, then force dry it with infrared lamps or an industrial dryer. 6. Polishing Check the primer surfacer has dried thoroughly, then sand the primer surfacer. Use a double action sander and #400~#600 disc sandpaper. 7. Intermediate coating and top coating. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Control Unit Input Test NOTE: For the hatch glass unlock button test, refer to the rear window wiper control unit input test. 1. Before testing, troubleshoot the multiplex control system. See: Powertrain Management/Computers and Control Systems/Information Bus 2. Remove the driver's 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. Reconnect all Connections to the under-dash fuse/relay box, and make these input tests at the appropriate connectors on the under-dash fuse/relay box. - If any test indicates a problem, find and Correct the cause, then recheck the system. - If all the input tests prove OK, go to step 6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 7340 6. Disconnect the connectors. and make these input tests at the connectors. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the multiplex control unit must be faulty, replace the under-dash fuse/relay box assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 7341 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay (Canada: EX-L) And A/F Sensor Relay ('02) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Page 7345 Seat Heater Relay: Testing and Inspection Seat Heaters Relay Test 1. Remove the front seat. 2. Disconnect the 6P connector from the seat heater relay (A). 3. Check for continuity between the No.6 and No.5 terminals, and No.6 and No.4 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. 4. Check for continuity between the No.1 and No.6 terminals, and No.3 and No.4 terminals when power and ground are connected to the No.6 and No.5 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. Seat Heater Main Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations 41. Under left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 7349 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 7350 Sunroof / Moonroof Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Moonroof Open Relay Moonroof Close Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Page 7356 6. Remove the sunshade (A). 7. Remove the front sunshade base sliders (A) and rear sunshade base sliders (B) from both guide rail portions of the frame. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Drain channel - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. From both sides of the frame (A), remove the screws (B, C), then remove the slide stops (D) and cable tube rear brackets (E), and remove the cable tube side bracket mounting bolts (F) and the cable tube mounting screws (G). 4. From the driver's side, detach the moonroof connector (H) from the frame. 5. Remove the cable tube side brackets (I) and cable tubes (J) from both sides of the frame. 6. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter. 7. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair > Page 7360 8. Remove the drain channel sliders (A) from the glass brackets (B) on both sides. 9. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Limit Switch: Component Locations Moonroof Component Location Index 121. Middle of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations > Page 7365 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7366 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7367 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test: 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, adjust the limit switch, and recheck. 7. If the continuity is still not as specified, replace the moonroof motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7368 Sunroof / Moonroof Limit Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Component Locations 121. Middle of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Component Locations > Page 7373 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 7374 Sunroof / Moonroof Motor: Diagrams (USA: EX; Canada: EX-L) (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Motor Sunroof / Moonroof Motor: Testing and Inspection Motor Motor Test 1. Remove the headliner. 2. Disconnect the 6P connector from the moonroof motor. Motor Test: 3. Check the motor by connecting power and ground according to the table. 4. If the motor does not run or fails to run smoothly, replace it. NOTE: See the closing force check for the motor clutch test. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Motor > Page 7377 Sunroof / Moonroof Motor: Testing and Inspection Closing Force and Opening Drag Closing Force and Opening Drag Check 1. Remove the headliner. 2. Closing force check: - With a shop towel (A) on the leading edge of the glass (B), attach a spring scale (C) as shown. - Have an assistant hold the switch to close the glass while you measure the force required to stop it. - Read the force as soon as the glass stops moving, then immediately release the switch and spring scale. 3. If the force is not within specification, remove the moonroof motor, then check: - The gear portion and the inner cable for breakage and damage. If the gear portion is broken, replace the motor. If the inner cable is damaged, remove the frame, and replace the cable assembly. - The moonroof motor. If the motor fails to run or doesn't turn smoothly, replace it. - The opening drag. Go to step 4. 4. Opening drag check: Protect the leading edge of the glass with a shop towel (A). Measure the effort required to open the glass using a spring scale (B) as shown. 5. If the load is over 40 N (4 kgf, 9 lbf), check: - The side clearance and glass height adjustment. - For broken or damaged sliding parts. If any sliding parts are damaged, replace them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Page 7378 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations 41. Under left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 7382 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 7383 Sunroof / Moonroof Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Moonroof Open Relay Moonroof Close Relay Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 7388 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7389 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7390 Sunroof / Moonroof Switch: Testing and Inspection Moonroof Switch Test 1. Remove the dashboard lower cover. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the bulb (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7391 Sunroof / Moonroof Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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 (F). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moon roof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 7396 Sunroof / Moonroof Drain: Service and Repair Drain Channel Slider and Cable Assembly Drain Channel Slider and Cable Assembly Replacement 1. Remove the frame. 2. Remove these parts from the frame: - Drain channel - Sunshade - Moonroof motor 3. Put on gloves to protect your hands. From both sides of the frame (A), remove the screws (B, C), then remove the slide stops {D) and cable tube rear brackets (E), and remove the cable tube side bracket mounting bolts (F) and the cable tube mounting screws (G). 4. From the driver's side, detach the moonroof connector (H) from the frame. 5. Remove the cable tube side brackets (I) and cable tubes (J) from both sides of the frame. 6. Pivot the glass bracket (A) down by sliding the link lifter (B) back, then slide both glass brackets back with the link lifter. 7. Slide the cable assembly (A) and both glass brackets (B) back, then remove them from the frame (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 7397 8. Remove the drain channel sliders (A) from the glass brackets (B) on both sides. 9. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 7398 Sunroof / Moonroof Drain: Service and Repair Frame and Drain Tube Frame and Drain Tube Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Headliner - Moonroof glass 2. Disconnect the moonroof connector (A) and drain tubes (B). 3. With an assistant holding the frame (C), remove the bolts (D) and ground bolt (E), starting at the rear, and release the rear hooks (F) by moving the frame forward, then remove the frame. 4. With the help of an assistant, carefully remove the frame through the tailgate opening. Take care not to scratch the interior trim and body, or tear the seat covers. 5. To remove a front drain valve (A) from the body, remove the kick panel, left or right. Tie a string to the top of the drain tube, then pull the front drain tube (B) down out of the front pillar. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Drain Channel > Page 7399 6. To remove a rear drain valve (A) from the cargo area, remove these parts: - Rear side trim panel. - C-pillar trim. Using a clip remover, detach the clips (B), then remove the rear drain tube (C). 7. 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 connector is 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. 8. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 NOTE: Put on gloves to protect your hands. 1. Remove these items: - Headliner - Moonroof glass 2. Disconnect the moonroof connector (A) and drain tubes (B). 3. With an assistant holding the frame (C), remove the bolts (D) and ground bolt (E), starting at the rear, and release the rear hooks (F) by moving the frame forward, then remove the frame. 4. With the help of an assistant, carefully remove the frame through the tailgate opening. Take care not to scratch the interior trim and body, or tear the seat covers. 5. To remove a front drain valve (A) from the body, remove the kick panel, left or right. Tie a string to the top of the drain tube, then pull the front drain tube (B) down out of the front pillar. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 7403 6. To remove a rear drain valve (A) from the cargo area, remove these parts: - Rear side trim panel. - C-pillar trim. Using a clip remover, detach the clips (B), then remove the rear drain tube (C). 7. 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 connector is 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. 8. Check for water leaks. Let the water run freely from a hose without a nozzle. Do not use a high-pressure spray. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7413 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7414 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7420 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 7421 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (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 before performing repairs or service. NOTE: - Take care not to tear the seams or damage the seat covers. - On the passenger's seat with side airbag, do not touch the OPDS sensor in the seat-back pad, and keep it away from oil. Oil can corrode the sensor causing it to fail. - Put on gloves to protect your hands. Seat-back Cover 1. Remove the front seat. 2. Remove the armrest. 3. With side airbag: From under the seat cushion, detach the side airbag connector clip (A), and from under the passenger's seat cushion, remove the harness bands (B), and disconnect the seat subharness connectors (C). Detach these clips. Release the hook springs (D), pull the seat cushion cover (E) back, then remove the harness band (F). 4. Fold the seat-back forward. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7428 5. With side airbag: Release the hooks (A), and unzip the seat-back cover (B). 6. Turn over the seat-back cover (A), release the inside springs (B) and hooks (C). Pull the side airbag harness and the seat subharness (passenger's seat) out through a holes (D) in the seat-back cover. 7. With side airbag: Remove the side airbag, and release the hooks (A) from the airbag module holder (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7429 8. Pull out the headrest guides (A) while pinching the end of the guides, and remove them. 9. Pull back the seat-back cover all the way around, then remove it. 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 clips, hooks, and inside springs. - Make sure the side airbag harness and seat subharness (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: - Center table - Recline cover, driver's seat, passenger's seat - Center cover, driver's seat , passenger's seat 3. From under the seat cushion, detach the side airbag connector clip, and from under the passenger's seat, disconnect the seat subharness connectors, and detach these clips. Release the hook springs from the seat cushion frame spring, then pull the cover back, and remove the harness bands. 4. If equipped, disconnect the seat cushion heater connector. 5. Release the hooks (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7430 6. From under the seat cushion, release the seat cushion cover (A) from the seat cushion frame spring (B), and release the hooks (C). 7. Remove the seat cushion cover (A) with the seat cushion pad from the seat cushion frame. 8. 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). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7431 9. 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 seat subharness (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7432 Seat Cover: Service and Repair Left Rear Seat Cover Left Rear Seat Cover Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. Seat-back Cover 1. Remove the left rear seat. 2. Remove the screws (A, B), then remove the recline cover (C). 3. Remove the bolt (A) and screws (B), then remove the center cover (C). 4. Remove the bolts securing the seat-back (A) and seat cushion (B), pull the center pivot (C) out from the pivot bracket, then separate them. If Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7433 necessary, remove the bushing (D). 5. Release the bottom hook (A), unzip the seat-back cover (B), then fold back the cover. Loosen the seat-back strap (C) with the adjuster (D), and separate it into two pieces. Pull the strap secured to the seat-back frame inside the seat-back cover through the slot (E). 6. Pull out the headrest guides (A) while pinching the end of the guides, and remove them. 7. Remove the latch cover. 8. Pull back the edge of the seat-back cover all the way around, and release the clips (A), then remove the seat-back cover (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7434 9. Install the seat-back 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 hook and clips. - Replace any clips (A) you removed with new ones using commercially available upholstery ring pliers (B). Seat Cushion Cover 1. Remove the left rear seat. 2. Remove the seat-back. 3. To allow the seat cushion to slide, use a screwdriver to move the latch. 4. Slide both seat tracks back fully. NOTE: While sliding the outer seat track, keep the outer mounting bracket raised securely so it does not spring back. 5. Remove the outer seat track cover. 6. Remove the screws (A) and release the clips (B), then remove the inner seat track end cover B (C) and inner seat track end cover A (D). 7. Remove both dampers and both damper cover. 8. Slide both seat tracks forward fully. NOTE: While sliding the outer seat track, keep the outer mounting bracket raised securely so it does not spring back. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7435 9. Pull back the rear edge of the seat cushion cover (A) to release it from the hooks (B), and remove the screws. 10. While pushing the slide lever (A) down, remove the bottom cover (B) by pulling it to release the hooks (C). Pass the strap (D) through the slot, and pass both side cables (E) through the side slits in the cover. Take care not to kink the cables. 11. Release all of the hook strips (A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7436 12. Remove the seat cushion cover (A) with the seat cushion pad from the seat cushion frame (B). Pass the seat belt buckle (C) through the hole in the seat cushion cover. 13. Pull back the edge of the seat-back cover all the way around, and release the clips (A), then remove the seat cushion. 14. 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 hook and clips. - Replace any clips (A) you removed with new ones using commercially available upholstery ring pliers (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7437 Seat Cover: Service and Repair Right Rear Seat Cover Right Rear Seat Cover Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. Seat-back Cover 1. Remove the right rear seat. 2. Remove the armrest. 3. Release the bottom hook (A), unzip the seat-back cover (B), then fold back the cover. From between the left recline adjuster and the pad, remove a piece of cloth (C). 4. Loosen the seat-back strap (D) with the adjuster (E), and separate it into two pieces. Pull the strap secured on the seat-back frame inside the seat-back cover through the slot (F). 5. Release the hook strips (A) from the edge of the armrest back cover (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7438 6. From the front of the seat-back, remove the armrest collars (A) and armrest back cover (B). 7. Release the clips (A) and hook strips (B) from the back of the seat-back. 8. Pull out the headrest guides (A) and center headrest guides (B) while pinching the end of the guides, and remove them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7439 9. Pull back the edge of the seat-back cover all the way around, and release the clips (A), then remove the seat-back cover (B). 10. Install the seat-back 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 hook and clips. - Replace any clips (A) you removed with new ones using commercially available upholstery ring pliers (B). Seat Cushion Cover 1. Remove the right rear seat. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7440 2. Remove the screws (A, B), then remove the recline cover (C) and the center cover (D). 3. Remove the bolts securing the seat-back (A) and seat cushion (B), then separate them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7441 4. To allow the seat cushion to slide, use a screwdriver to close the latch. 5. Slide both seat tracks (A) back fully. 1. Raise both mounting brackets (B), and place shop towels (C) between the brackets and the bottom cover (D). 2. Push the slide lever (E) down. 3. Slide both seat tracks back fully, taking care not to let the mounting brackets scratch the bottom cover. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7442 6. Remove the screws, then remove the latch cover (A), outer seat track cover B (B), and outer seat track cover A (C). The left seat track is shown, the right seat track is similar. 7. Remove the screws (A, B), then remove both dampers (C) and both damper covers (D). 8. Slide both seat tracks (A) forward fully. 1. Raise both mounting brackets (B), and hold them. 2. Push the slide lever (C) down. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7443 3. While holding both mounting brackets, slide both seat tracks forward fully. NOTE: While sliding both seat tracks, keep both mounting brackets raised securely so they do not spring back. 9. Pull back the rear edge of the seat cushion cover (A) to release it from the hooks (B), and remove the screws. 10. While pushing the slide lever (A) down, remove the under cover (B) by pulling it to release the hooks (C). Pass the strap (D) through its slot, and pass both side cables (E) through the side slots in the cover. Take care not to kink the cables. 11. Release all of the hook strips (A). 12. Remove the rear seat belt buckle and center seat belt detachable anchor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7444 13. Remove the seat cushion cover (A) with the seat cushion pad from the seat cushion frame (B). Pass the center seat belt buckle (C) through a hole in the seat cushion cover. 14. Pull back the edge of the seat cushion coverall the way around, and release the clips (A), then remove the seat cushion cover (B). 15. 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 hook and clips. - Replace any clips (A) you removed with new ones using commercially available upholstery ring pliers (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7445 Seat Cover: Service and Repair Rear Seat Armrest Cover Rear Seat Armrest Cover Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. 1. Remove the armrest. 2. Remove the beverage holder (A). 1. Pull up on the rear edge of the holder to release the hooks (B). 2. Release the front hooks (C), then remove the holder. 3. Release the clips (A) from the beverage holder opening, release the rear hook (B), then pull back the edge of the armrest cover (C) all the way around and remove it. 4. 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Cover > Page 7446 - Replace any clips you removed with new ones (A). Install them with commercially available upholstery ring pliers (B). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Seat Heater: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 Seat Heater: Connector Views (Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 (Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 Seat Heater: Electrical Diagrams Diagram 147 (Canada: EX-L) 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7484 Seat Heater: Testing and Inspection Seat Heater Test 1. Remove the front seat. 2. Disconnect the seat heater harness 2P connector (A) from the seat sub-harness and the 6P connector (B) from the seat heater relay (C). 3. Check for continuity between the Al and B3 terminals, and A2 and B6 terminals. There should be continuity. If there is no continuity, replace the seat cushion. 4. Check for continuity between the B1 and B4 terminals, and B1 and B5 terminals. There should be continuity. If there is no continuity, replace the seat cushion. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay (Canada: EX-L) And A/F Sensor Relay ('02) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Page 7488 Seat Heater Relay: Testing and Inspection Seat Heaters Relay Test 1. Remove the front seat. 2. Disconnect the 6P connector from the seat heater relay (A). 3. Check for continuity between the No.6 and No.5 terminals, and No.6 and No.4 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. 4. Check for continuity between the No.1 and No.6 terminals, and No.3 and No.4 terminals when power and ground are connected to the No.6 and No.5 terminals. There should be continuity. If there is no continuity, replace the seat heater relay. Seat Heater Main Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams (Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7492 Seat Heater Switch: Testing and Inspection Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 7493 Seat Heater Switch: Service and Repair Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair Rear Seat-back Latch Lever Replacement NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. - The right rear seat is shown, and the left rear seat is symmetrical. 1. Remove the latch cover (A). 1. Pull up the rear edge of the latch lever cover to release the clips. 2. Release the cover from the pivot pins (B) of the latch lever (C) while pulling the latch lever. 2. Release the bottom hook, unzip the seat-back cover, then fold back the cover, right rear seat, left rear seat. 3. Disconnect the lock knob rod (A) from the outer recline adjuster (B). 4. Release the pivot pin (A) of the latch lever (B) from the seat-back frame (C), then remove the latch lever by pulling it up. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 7497 5. Install the lever in the reverse order of removal, and note these items: - Make sure the lock knob rod (A) is passed through the holes (B) in the seat-back frame (C) correctly when reinstalling the latch lever. - To prevent wrinkles, make sure the material is stretched evenly over the pad before securing the clips. - Replace any damaged clips with new ones. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Seats > Seat Latch Cable > Component Information > Service and Repair Seat Latch Cable: Service and Repair Right Rear Seat-back Lock Control Cable NOTE: - Take care not to tear the seams or damage the seat covers. - Put on gloves to protect your hands. 1. Remove the armrest. 2. Release the bottom hook, unzip the seat-back cover, then fold back the cover. 3. Release the hook strips from the edge of the armrest back cover. 4. Remove the armrest back cover. 5. Release the hook strips at the armrest portions from the back of the seat-back. 6. Pull the bottom of the seat-back pad (A) away from the seat-back frame (B). 7. Disconnect the seat-back lock control cable (A) from the inner recline adjuster (B) and the outer recline adjuster (C). Release the clamps (D), then remove the cable. 8. Install the cable in the reverse order of removal, and note these items: - After reconnecting the cable, adjust its tension with its adjusting nuts (D). - Replace any clamps you removed with new ones. - To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hooks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations 8. Front of Engine Compartment (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7506 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7510 107. Driver's Door 109. Driver's Door 111. Front Passenger's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 7511 Power Door Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch Power Door Lock Switch: Testing and Inspection Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7514 Power Door Lock Switch: Testing and Inspection Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7515 Power Door Lock Switch: Testing and Inspection Door Lock Knob Switch Door Lock Knob Switch Test 1. Remove the driver's door panel. 2. Identify the type of door lock actuator. 3. Disconnect the 3P connector from the actuator. 4. Check for continuity between the No.1 [No. 2] and No.3 [No. 1] 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. [] : Mitsui Type 5. Check for continuity between the No.1 [No. 2] and No.2 [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. [] : Mitsui Type 6. If the continuity is not as specified, replace the driver's door lock actuator. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Tailgate Switch > Page 7516 Power Door Lock Switch: Testing and Inspection Door Lock Switch Door Lock Switch Test 1. Remove the door panel. 2. Remove the two mounting screws and the door lock switch. 3. Check for continuity between the No.1 and No.2 terminals: - There should be continuity when the door lock switch is in the LOCKED position. - There should be no continuity when the door lock 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 switch is in the UNLOCKED position. - There should be no continuity when the door lock switch is in the LOCKED position. 5. If the continuity is not as specified, replace the door lock switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch Power Door Lock Switch: Service and Repair Tailgate Switch Tailgate Switch Test/Replacement 1. Open the tailgate. 2. Remove the mounting screw from the tailgate switch. 3. Disconnect the connector (A) from the tailgate switch (B). 4. Check for continuity between the tailgate switch positive terminal (C) and body (D). - There should be continuity with the switch is released (tailgate open position). - There should be no continuity with the switch is pushed (tailgate closed position). 5. If the continuity is not as specified, replace the tailgate switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Tailgate Switch > Page 7519 Power Door Lock Switch: Service and Repair Hatch Glass Opener Switch Hatch Glass Opener Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 2P connector from the opener switch. 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity when the opener switch is pushed. - There should be no continuity when the opener switch is released. 4. If the continuity is not as specified, replace the opener switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7523 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7524 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7525 Power Mirror Switch: Testing and Inspection Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7526 Power Mirror Switch: Service and Repair Power Mirror Switch Test/Replacement 1. Remove the driver's door panel. 2. Disconnect the 13P connector (A) from the power mirror switch (B). Mirror/Defogger Switch(Canada) 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 switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations 108. Driver's Door 125. Middle of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 7530 Power Trunk / Liftgate Lock Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams (Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7534 Seat Heater Switch: Testing and Inspection Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 7535 Seat Heater Switch: Service and Repair Seat Heaters Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Disconnect the 10P connector (A) from the seat heater switch (B), and remove the seat heater switch. 3. Check for continuity in each switch position according to the table. 4. If the continuity is not as specified, replace the bulbs (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations Sunroof / Moonroof Limit Switch: Component Locations Moonroof Component Location Index 121. Middle of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Component Locations > Page 7540 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7541 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7542 Sunroof / Moonroof Limit Switch: Testing and Inspection Limit Switch Test: 5. Check for continuity between the terminals in each switch position according to the table. 6. If the continuity is not as specified, adjust the limit switch, and recheck. 7. If the continuity is still not as specified, replace the moonroof motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Locations > Page 7543 Sunroof / Moonroof Limit Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moonroof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Component Locations > Page 7548 120. Left Side of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7549 (USA: EX; Canada: EX-L) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7550 Sunroof / Moonroof Switch: Testing and Inspection Moonroof Switch Test 1. Remove the dashboard lower cover. 2. Disconnect the 6P connector (A) from the moonroof switch (B), and remove the moonroof switch. 3. Check for continuity between the terminals in each switch position according to the table. 4. If the continuity is not as specified, replace the bulb (C) or the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7551 Sunroof / Moonroof Switch: Adjustments Position Switch Adjustment 1. Remove the headliner. 2. With the moonroof wrench, close the glass (A) fully: - Make sure both link lifters (B) are parallel, and in the position shown. - Check the glass fit to the roof panel and the glass height. 3. With an open-end wrench, loosen the position switch mounting bolts (C). 4. Adjust the position switch (D): - Move the switch plate (E) a little at a time, then secure it in 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 (F). 5. Check the operation of the glass (from the tilt-up position to fully closed position, from the fully open position to the fully closed position) by operating the moon roof switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7555 Front Door Component Location Index Openers Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair Splash Guard: Service and Repair Fuel Pipe Protector Replacement 1. Remove the clips, then remove the fuel pipe protector (A). Take care not to scratch the body. 2. Install the protector in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair Removal Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 7562 - Cut and remove the wheelhouse upper member, and replace the front wheelhouse. - When removing the front wheelhouse M/T: Leave the transmission mount bracket attached to the front side frame. A/T: When replacing the front wheelhouse, support the wheelhouse and transmission mount bracket as an assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 7563 - Check the damper housing position, and check for damage. - If necessary, remove the Wheelhouse upper member, and replace the front damper extension, damper housing, and damper housing extension as an assembly. Installation 1. Set the new damper housing assembly, front wheelhouse, and front bulkhead into position, and measure the front compartment diagonally. Check the body dimension. 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. - Weld the damper housing and front side frame. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 7564 - Weld the front damper extension and dashboard upper side member. - From the passenger's compartment side, plug weld the holes in the dashboard lower, and damper housing extension lower. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 7565 - From the dashboard upper side, plug weld the holes in the damper housing extension upper. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair > Page 7566 - Weld the front wheelhouse, damper housing, and front side frame. - Weld the wheelhouse upper member. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Latch Tailgate Latch: Service and Repair Latch Tailgate Latch Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate lower trim panel. 2. Remove the tailgate latch (A). -1 Disconnect the tailgate rod (B) and cylinder rod (C). -2 Disconnect the actuator connector (D). -3 Remove the screws securing the latch. -4 Remove the latch through the hole in the tailgate. Take care not to bend the tailgate rod and cylinder rod. 3. Install the latch in the reverse order of removal, and note these items: - Make sure the actuator connector is plugged in properly, and each rod is connected securely. - If the tailgate rod (A) was disconnected at the upper end (the tailgate stop assembly side), reconnect it with its lower end on the bottom of a hole in the lever (B). - Make sure the tailgate locks and opens properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Latch > Page 7572 Tailgate Latch: Service and Repair Stop Assembly Tailgate Stop Assembly Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate lower trim panel. 2. Disconnect the tailgate rod (A) at the lower end from the tailgate latch. 3. Remove the bolt, then remove the tailgate stop assembly (A). 4. If necessary, disconnect the tailgate rod (B) from the tailgate stop assembly. 5. Install the stop assembly in the reverse order of removal and note these items: - Make sure the tailgate rod is connected securely. If you removed the tailgate rod from the tailgate stop assembly, adjust the rod when reinstalling it. - Make sure the tailgate opens properly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7577 *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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7578 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7579 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7580 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7581 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7582 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7583 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7584 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Technical Service Bulletins > Ignition/Locks - Cutting Sidewinder-Type Keys > Page 7585 ^ 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair Tailgate Handle Replacement NOTE: - Take care not to scratch the tailgate. - Put on gloves to protect your hands. 1. Remove the tailgate stop assembly. 2. Disconnect the cylinder rod (A) and the hatch glass open rod (B) from the tailgate lock cylinder (C). 3. Release the retainer clip (A} with a hooked shaped tool, then remove the lock cylinder (B) from the tailgate handle (C). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 7589 4. Remove the bolt securing the cylinder protector (A) and tailgate handle. Release the hook (B), then remove the protector. 5. Remove the bolt securing the tailgate handle, and remove the spacer (A). 6. Remove the outer handle (A) while pulling it as shown. 7. Install the tailgate handle in the reverse order of removal, and note these items: - Make sure each rod is connected securely. - Make sure the tailgate locks and opens properly. - 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair Tailgate Shock / Support: Service and Repair Tailgate Support Strut Replacement NOTE: - Have an assistant help you when removing and installing the support strut. - Take care not to scratch the body and tailgate. 1. Remove the bolt securing the body side end of the tailgate support strut, then release it from the bracket. 2. Remove the bolts, then remove the support strut (A). 3. Install the support strut in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. Using a clip remover, detach the clips (A), then remove the hood rear seal (B), and detach the clips (C) from the' cowl covers. Take care not to scratch the cowl covers. 3. Detach the clips (D, E) and release the hook (F) by carefully pulling the passenger's cowl cover (G) upward. Pull the cover forward to release the hooks (H), pull the hinge cover (I) out from the front fender (J), and disconnect the windshield washer tube (K), then remove the cover. Take care not to scratch the body. 4. Detach the clips (D, E) by carefully pulling the driver's cowl cover (M) upward, and pull the cover forward to release the hooks (N). Pull the hinge cover (0) out from the front fender (P), and disconnect the windshield washer tube (L) routed from the washer reservoir then remove the cover. Take care not to scratch the body. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 7598 5. If necessary, release the clips, then remove the insulators (A, B) from both cowl covers (C, D). 6. Install the covers in the reverse order of removal, and note these items: - Replace any damaged clips. - Push the clips into place securely. - Make sure the washer tubes are connected securely. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Front Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the front pillar, remove the door checker 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 the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front 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. To prevent scratching the power mirror and door, wrap the power mirror with a shop towel. Disconnecting the power mirror connector is not required. 2. Remove the screw (A) from the rear edge of the door. Starting at the rear, pry the door glass outer weatherstrip (B) up to detach the clips (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Liftgate Window Glass Weatherstrip > Component Information > Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Hatch Glass Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the tailgate. 1. Remove the tailgate side trim from both sides. 2. Remove the high mount brake light. 3. Disconnect the rear window defogger connectors, and release the wire harnesses from both sides. 4. Remove the hatch glass support strut brackets from both sides of the tailgate. 5. With an assistant, holding the hatch glass, remove the hatch glass weatherstrip (A) by pulling out on it. 6. Clean the bonding surface around the hatch glass opening flange with alcohol. 7. Apply sealant (Cemedine P/N 08712-0004, or equivalent) (A) in the groove around the hatch glass weatherstrip (B). 8. Locate the painted alignment mark (C) on the hatch glass weatherstrip. Align the painted mark with the alignment tab in the center of the hatch glass opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 9. Check for water leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Weatherstrip Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Rear Door Weatherstrip Replacement NOTE: - Take care not to scratch the door. - Use a clip remover to remove the clips. 1. At the center pillar, remove the door checker 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 the door checker mounting bolt before installation. - Check for water leaks. - Test-drive and check for wind noise. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Weatherstrip > Page 7613 Rear Door Weatherstrip: Service and Repair Rear Door Center Pillar Seal Rear Door Center Pillar Seal Replacement NOTE: Take care not to scratch the door. 1. Pull the door center pillar seal (A) away, then remove it. 2. After installing the seal to the upper edge of the door flange, align the seal to the bottom edge of the flange, the push the seal into place. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the screw (A) from the front edge of the door. Starting at the front, pry the door glass outer weatherstrip (B) up to detach the clips (C), and release the weatherstrip from the door quarter glass seal (D), then remove it. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Tailgate Weatherstrip Replacement 1. Remove the tailgate weatherstrip (A) by pulling out on it. 2. Clean the bonding surface around the tailgate flange with alcohol. 3. Apply sealant (Cemedine P/N 08712-0004, or equivalent) (B) in the groove around all of the tailgate weatherstrip. 4. Locate the painted alignment mark (C) on the tailgate weatherstrip. Align the painted mark with the alignment tab in the center of the tailgate opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 5. Check for water leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 7624 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations 1. Right Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 7628 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 31. Left Side of Dash 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7632 Cruise Control Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations 44. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 7637 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations 31. Left Side of Dash 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7642 Cruise Control Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7648 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7649 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Indicator Does Not Come on Brake Warning Indicator: Testing and Inspection Brake System Indicator Does Not Come on Brake system indicator does not come on 1. Disconnect the negative cable from the battery. 2. Disconnect the multiplex control unit 13P connector and the ABS control unit 47P connector. 3. Check for continuity between the ABS control unit 47P connector terminal No. 13 and body ground. Is there continuity? YES - Repair short to body ground in the wire between the multiplex control unit and the ABS control units. NO - Go to multiplex control system troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection > Brake System Indicator Does Not Come on > Page 7680 Brake Warning Indicator: Testing and Inspection Brake System Indicator Does Not GO Off Brake system indicator does not go off 1. Start the engine. 2. Release the parking brake. Does the brake system indicator go off? YES - The system is OK at this time. NO - Go to step 3. 3. Check the brake fluid level. Is there level OK? YES - Go to step 4. NO - Refill the brake fluid, and rechecks 4. Check the ABS indicator. Does the ABS indicator stay on? YES - Read the ABS DTC, and do the applicable troubleshooting for the DTC. NO - Go to step 5. 5. Turn the ignition switch OFF. 6. Disconnect the negative cable from the battery. 7. Disconnect the ABS control unit 47P connector. 8. Reconnect the battery cable. 9. Connect the ABS control unit 47P connector terminal No. 13 and body ground with a jumper wire. 10. Start the engine. 11. Check the brake system indicator. Does the brake system indicator go off? YES - Replace the ABS modulator-control unit. NO - Go to step 12. 12. Turn the ignition switch OFF. 13. Connect the multiplex control unit 13P connector terminal No. 1 and body ground with a jumper wire. 14. Start the engine. 15. Check the brake system indicator. Does the brake system indicator go off? YES - Repair open in the wire between the multiplex control unit and the ABS control unit. NO - Go to multiplex control system troubleshooting. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations 66. Under Middle of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 Cigarette Lighter: Electrical Diagrams Diagram 155 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location photographs (references to PHOTOS) referred to within these diagrams can be found at Locations by Photo Number. See: Locations/Component Locations/Locations By Photo Number Connector Views: Connector terminal views (references to VIEWS) referred to within these diagrams can be found at Connector Views by View Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7723 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7724 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7725 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7726 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7729 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7730 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7731 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7732 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7735 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7736 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7737 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Dimmer Switch: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Dimmer Switch: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 7776 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7780 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from the 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 correctly, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 OK, go to step 8. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fusel relay box for at least 30 seconds, then reinstall it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7781 9. Install a 2 Ohm resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicate "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom 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 locknut (A), and remove the fuel tank unit from the fuel tank. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7782 15. Measure resistance between the No.1 and No.2 terminals with the float at E(EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting. Otherwise, it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7783 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 7784 8. Remove the locknut (A) and the fuel tank unit. 9. 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). Be sure to check these items: - When connecting the wire harness, make sure the connection is secure and the connectors (K) are firmly locked into 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 it excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Locations SRS Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions Air Bag(s) Arming and Disarming: Service Precautions General Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7791 Air Bag(s) Arming and Disarming: Service Precautions Precautions For Electrical Inspections Precautions For Electrical Inspections When using electrical test equipment, insert the probe of the tester into the wire side of the connector. Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector. Use a U-shaped probe. Do not insert the probe forcibly. Use specified service connectors in troubleshooting. Using improper tools could cause an error in inspection due to poor metal-to-metal contact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7792 Air Bag(s) Arming and Disarming: Service Precautions Wiring Precautions Wiring Precautions SRS wiring can be identified by special yellow outer covering (except the SRS indicator light circuit). Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage in SRS wiring, replace the harness. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7793 Air Bag(s) Arming and Disarming: Service Precautions Airbag Handling and Storage Airbag Handling and Storage Do not disassemble an airbag. It has no serviceable parts. Once an airbag has been deployed, it cannot be repaired or reused. For temporary storage of the airbag during service, please observe the following precautions. - Store the removed airbag with the pad surface up. Never put anything on the removed airbag. - Keep free from any oil, grease, detergent, or water to prevent damage to the airbag assembly. - Store the removed airbag on a secure, flat surface away from any high heat source (exceeding 200 °F/93 °C). - Never perform electrical inspections to the airbags, such as measuring resistance. - Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > General Precautions > Page 7794 - Refer to the scrapping procedures for disposal of the damaged airbag. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags Air Bag(s) Arming and Disarming: Description and Operation Seats With Side Airbags Seats with Side Airbags Seats with side airbags have a "SIDE AIRBAG" label on the seat-back. Because the component parts (seat-back cover, cushion, etc.) of seats with and without airbags are different, make sure you install only the correct replacement parts. - When cleaning, do not saturate the seat with liquid, and do not spray steam on the seat. - Do not repair a torn or frayed seat-back cover. Replace the seat-back cover. - After a collision in which the side airbag was deployed, replace the side airbag with new parts. If the seat-back cushion is split, it must be replaced. If the seat-back frame is deformed, it must be replaced. - Never put after market accessories on the seat (covers, pads, seat heaters, lights, etc.). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7797 Air Bag(s) Arming and Disarming: Description and Operation SRS Components System Description SRS Airbags The SRS is a safety device which, when used with the seat belt, is designed to help protect the driver and front passenger in a frontal impact exceeding a certain set limit. The system consists of the SRS unit, including safing sensor and impact sensor (A), the cable reel (B), the driver's airbag (C), the front passenger's airbag (D), side airbags (E), seat belt tensioners (I), seat belt buckle tensioners (J), and front impact sensors (K). Side Airbags The side airbags (E) are in each front seat-back. They help protect the upper torso of the driver or front seal passenger during a moderate to severe side impact. Side impact sensors (F) in each door sill and in the SRS unit detect such an impact and instantly inflate the driver's or the passenger's side airbag. Only one side airbag will deploy during a side impact. If the impact is on the passenger's side, the passenger's side airbag will deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckle tensioners are linked with the SRS airbags to further increase the effectiveness of the seat belt. In a front-end collision, the tensioners instantly retract the belt and buckle firmly to secure the occupants in their seats. OPDS The side airbag system also includes an Occupant Position Detection System (OPDS). This system consists of sensors (G) and a OPDS unit (H) in the front passenger's seat-back. The OPDS unit sends occupant height and position data to the SRS unit. If the OPDS unit determines that the front passenger is of small stature (for example, a child) and the front passenger is leaning into the side airbag deployment path, the SRS unit will automatically disable the airbag. The SRS unit will also disable the airbag when the OPDS detects certain objects on the seat. When the side airbag is disabled, the Side Airbag Cutoff indicator on the instrument panel alerts the driver that the passenger's side airbag will not deploy in a side impact. When the object is removed, or the passenger sits upright, the Side Airbag Cutoff indicator will go off after a few seconds, alerting the driver that the side airbag will deploy in a side impact. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7798 Air Bag(s) Arming and Disarming: Description and Operation SRS Operation SRS Operation The main circuit in the SRS unit senses and judges the force of impact and, if necessary, ignites the inflator charges. If battery voltage is too low or power is disconnected due to the impact, the voltage regulator and the back-up power circuit, respectively, will keep voltage at a constant level. For the SRS to operate: Seat Bell Tensioners and Seat Belt Buckle Tensioners 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and send them to the tensioners. 3. The inflators must ignite and deploy the tensioners. Driver's and Front Passenger's Airbag(s) 1. A front impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals, and depending on the severity of the collision and whether the seat belt buckle switch is ON or OFF, it sends the appropriate signals to the airbag inflator(s). 3. The inflators that received signals must ignite and deploy the airbags. Side Airbag(s) 1. A side impact sensor must activate, and send electric signals to the microprocessor. 2. The microprocessor must compute the signals and send them to the side airbag inflator(s). However, the microprocessor cuts off the signals to the front passenger's side airbag if the OPDS unit determines that the front passenger 5 head is in the deployment path of the side airbag. 3. The inflator that received the signal must ignite and deploy the side airbag. Self-diagnosis System A self-diagnosis circuit is built into the SRS unit; when the ignition switch is turned ON (II), the SRS indicator comes on and goes off after about 6 seconds if the system is operating normally If the indicator does not come on, or does not go off after 6 seconds, or if it comes on while driving, it indicates an abnormality in the system. The system must be inspected and repaired as soon as possible. For better serviceability, the SRS unit memory stores a DTC that relates to the cause of the malfunction, and the unit is connected to the data link circuit. This information can be read with the Honda PGM Tester when it is connected to the data link connector (DLC). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7799 Air Bag(s) Arming and Disarming: Description and Operation Definitions Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant's head and torso. Asynchronous Performed in a nonperiodic fashion, (i.e., no defined time or interval). (B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key "ON" and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the "AIR BAG" warning lamp to flash seven times and then go "OFF" whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. "CONTINUOUS MONITORING" Tests performed by the SDM on the SRS every 100 milliseconds while "Ignition 1" voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly "DLC" a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate. Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly "Code", a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the "Initiator Assembly Resistance Test". Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM "Ignition 1" inputs, with ignition switch "ON", is within the normal operating voltage range for at least ten seconds before turning ignition switch "OFF". Ignition 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Description and Operation > Seats With Side Airbags > Page 7800 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. "Initiator Assembly Resistance Test" Tests performed once each ignition cycle when no malfunctions are detected during "Turn-ON" or "Continuous Monitoring." This test checks for the correct SDM configuration for the vehicle, shorts to "Ignition 1 in the deployment loops, high resistance or opens in the "Driver Side High", "Driver Side Low", "Passenger Side High" and "Passenger Side Low" circuits and measures the resistance of the inflator assembly consisting of: 1. Initiators. 2. SRS coil assembly (driver side only). 3. Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM "Ignition 1" terminals and "Ground" terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the "Initiator Assembly Resistance Test". Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from on-board computers via the data link connector. SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current-carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. "Turn-ON" Test which the SDM performs on the SRS once during each ignition cycle immediately after "Ignition 1" voltage is applied to the SDM and before "Continuous Monitoring". Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 the airbag system service. Observe the instructions described or the airbags could accidentally deploy and cause damage or injuries. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work. NOTE: The contents in the memory is not erased even if the ignition switch is turned OFF or the battery cables are disconnected from the battery. Use the replacement parts which are manufactured to the same standards as the original parts and quality. Do not install used SRS parts from another vehicle. Use only new parts when making SRS repairs. Carefully inspect any SRS part before you install it. Do not install any part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation. Before removing any of the SRS parts (including the disconnection of the connectors), always disconnect the SRS connector. Use only a digital multimeter to check the system. If it is not a Honda multimeter, make sure its output is 10 mA (0.01 A) or less when switched to the lowest value in the ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio code before disconnecting the battery cable. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7803 Air Bag(s) Arming and Disarming: Service and Repair Connector Disconnection / Connection Disconnecting the Airbag Connectors, Side Airbag Connectors, and Seat Belt Tensioner Connectors Before removing a front airbag, side airbag, or other SRS related devices (the SRS unit, the cable reel, the side impact sensors, the seat belt buckle tensioners, and the seat belt tensioner connector), disconnecting connectors from related devices, or removing the dashboard or the steering column, disconnect the airbag connectors or the side airbag connectors to prevent accidental deployment. Turn the ignition switch OFF, disconnect the negative cable from the battery, and wait at least 3 minutes before beginning the following procedures. - Before disconnecting SRS unit connector A(1) from the SRS unit, disconnect the driver's airbag 4P connector (3), the front passenger's airbag 4P connector (4), the driver's seat belt tensioner 2P connector (6), and the front passenger's seat belt tensioner 2P connector (7). - Before disconnecting SRS unit connector B(8) from the SRS unit, disconnect both side airbag 2P connectors (11, 12), and both seat belt buckle tensioner 4P connectors (9, 10). - Before disconnecting the cable reel 4P connector (2), disconnect the driver's airbag 4P connector (3). - Before disconnecting the floor wire harness 4P connector (5), disconnect both seat belt tensioner 2P connectors (6, 7). 1. Disconnect the battery negative cable, and wait at least 3 minutes. Driver's Airbag Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7804 2. Remove the access panel (A) from the steering wheel, then disconnect the driver's airbag 4P connector (1) from the cable reel. Front Passenger's Airbag 3. Remove the access panel (A), then disconnect the front passenger's airbag 4P connector (1) from dashboard wire harness B. Side Airbag 4. Disconnect both side airbag 2P connectors (1) from the floor wire harness. Seat Belt Tensioner Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 7805 5. Disconnect both seat belt tensioner 2P connectors (1) from the floor wire harness. Seat Belt Buckle Tensioner 6. Disconnect both seat belt buckle tensioner 4P connectors (1) SRS Unit 7. Disconnect SRS unit connectors A(1), SRS unit connectors B(2) and/or SRS unit connectors C(3) from the SRS unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 fusel 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 1. Turn off the engine. 2. Press and hold the Select/Reset button in the instrument panel, then turn the ignition switch ON (Position II). 3. Hold the button for at least 10 seconds, until the indicator resets. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/PCM has been reset, these codes are reset. In some states, part of the emissions testing is to make sure these codes are set to complete. If all of them are not set to complete the vehicle may fail the test, or the test cannot be finished. To check if the readiness codes are set to complete, turn the ignition switch ON (II), but do not start the engine. The MIL will come on for 15-20 seconds. If it then goes off, the readiness codes are complete. If it blinks five times, one or more readiness codes are not complete. To set each code, drive the vehicle or run the engine as described in the procedures to set them. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7823 Malfunction Indicator Lamp: Testing and Inspection MIL Circuit Troubleshooting 1. Connect a scan tool or the HDS to the data link connector (DLC). 2. Turn the ignition switch ON (II), and read the scan tool or the HDS. Does the scan tool or the HDS communicate with the ECM/PCM? YES - Go to step 3. NO - Go to "DLC Circuit Troubleshooting". 3. Check the scan tool or the HDS for DTCs. Are any DTCs indicated? YES - Go to the indicated DTCs Troubleshooting. 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 comes on and stays on, go to step 74. But if the MIL sometimes works normally, first check for these problems. An intermittent short in the wire between the ECM/PCM (E29) and the data link connector (DLC) - An intermittent short in the wire between the ECM/PCM (E31) and the gauge assembly. - The readiness codes are not set. (This is indicated if the MIL blinks five times after you turn the ignition switch ON (II) and wait about 20 seconds.) 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 (50A) fuse in the under-hood fuse/relay box. - A loose No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. - A loose No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. - A poor connection at ECM/PCM terminal E31. - An intermittent open in the GRN/WHT wire between the ECM/PCM (E31) and the gauge assembly. - An intermittent short in the wire between the ECM/PCM (A21) and the manifold absolute pressure (MAP) sensor, intake manifold runner control (IMRC) valve position sensor, or countershaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (A20) and the throttle position (TP) sensor, or mainshaft speed sensor (A/T). - An intermittent short in the wire between the ECM/PCM (E5) and the fuel tank pressure (FTP) sensor. 6. Check the low oil pressure light (with the ignition switch ON). Is the low oil pressure light on? YES - Go to step 9. NO - Go to step 7. 7. Inspect the No.10 METER (7.5A) fuse in the under dash fuse/relay box. Is the fuse OK? YES - Go to step 8. 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. 8. Inspect the No.20 IG (50A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Repair open in the wire between the No.20 IG (50A) fuse and the gauge assembly. If the wires are OK, test the ignition switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7824 NO - Repair short in the wire between No.20 IG (50A) fuse and the under-dash fuse/relay box. All replace the No.20 IG (50A) fuse. 9. Try to start the engine. Does the engine start? YES - Go to step 10. NO - Go to step 13. 10. Turn the ignition switch OFF. 11. Connect ECM/PCM connector terminal E31 to body ground with a jumper wire. 12. Turn the ignition switch ON (II). Is the MIL on? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Check for an open in the wire between the ECM/PCM (E31) and the gauge assembly. Also check for a blown MIL bulb. If the wires and the bulb are OK, replace the gauge assembly. 13. Turn the ignition switch OFF. 14. Inspect the No.6 ECU (ECM/PCM) (15A) fuse in the under-hood fuse/relay box. Is the fuse OK? YES - Go to step 22. NO - Go to step 15. 15. Remove the blown No.6 ECU (ECM/PCM) (15A) fuse in the under-dash fuse/relay box. 16. Remove the glove box. 17. Remove PGM-FI main relay 1(A). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7825 18. Check for continuity between body ground and PGM-FI main relay 1 4P connector terminals No.2 and No.4 individually. Is there continuity? YES - Repair short in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 19. 19. Disconnect each of the components or connectors below, one at a time, and check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Each injector 2P connector - Idle air control (IAC) valve 3P connector - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) 3P connector - Crankshaft position (CKP) sensor 3P connector Did the continuity go away when one of the components or connectors was disconnected? YES - Replace the component that made the short to body ground go away when disconnected. If the item is the ECM/PCM, update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. NO - Go to step 20. 20. Disconnect the connectors of all these components. - PGM-FI main relay 2 - ECM/PCM connector A (31 P) - Injectors - Idle air control (IAC) valve - Camshaft position (CMP) sensor (Top dead center (TDC) sensor) - Crankshaft position (CKP) sensor Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7826 21. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and body ground. Is there continuity? YES - Repair short in the wire between PGM-FI main relay 1 and each item. Also replace the No.6 ECU (ECM/PCM) (15A) fuse NO - Replace PGM-FI main relay 1. Also replace the No.6 ECU (ECM/PCM) (15A) fuse. 22. Inspect the No.17 FUEL PUMP (15A) fuse in the under-dash fuse/relay box. Is the fuse OK? YES - Go to step 34. NO - Go to step 23. 23. Remove the blown No.17 FUEL PUMP (15A) fuse. 24. Disconnect ECM/PCM connector E (31 P). 25. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Go to step 26. NO - Replace the No.17 FUEL PUMP (15A) fuse, and update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 26. Make sure the SRS has no DTC. If there is any DTC, troubleshoot them first. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7827 27. Remove PGM-FI main relay 2 (A). 28. Disconnect the SRS unit connectors. 29. Check for continuity between ECM/PCM connector terminal E9 and body ground. Is there continuity? YES - Repair short in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9), or between the No.17 FUEL PUMP (15A) fuse and PGM-FI main relay 2. Also replace the No.17 FUEL PUMP (15A) fuse. NO - Go to step 30. 30. Fold the rear seats forward, and pull back the carpet to expose the access panel. 31. Remove the access panel from the floor. 32. Disconnect the fuel pump 5P connector. 33. 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 34. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7828 34. Reinstall PGM-FI main relay 2 (A). 35. 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. 36. Disconnect ECM/PCM connector E (31P). 37. Turn the ignition switch ON (II). 38. Measure voltage between ECM/PCM connector terminal E9 and body ground. Is there battery voltage? YES - Go to step 39. NO - Repair open in the wire between the No.17 FUEL PUMP (15A) fuse and the ECM/PCM (E9). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7829 39. Measure voltage between ECM/PCM connector terminal E7 and body ground. Is there battery voltage? YES - Go to step 44. NO - Go to step 40. 40. Turn the ignition switch OFF. 41. Remove PGM-FI main relay 1(A). 42. Measure voltage between PGM-FI main relay 1 4P connector terminal No.4 and body ground. Is there battery voltage? YES - Go to step 43. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7830 43. Check for continuity between PGM-FI main relay 14P connector terminal No.3 and ECM/PCM connector terminal E7. Is there continuity? YES - Test PGM-FI main relay 1. If the relay is OK, update the ECM/PCM if it does not have the latest software, or substitute a known good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Repair open in the wire between PGM-FI main relay 1 and the ECM/PCM (E7). 44. Reconnect ECM/PCM connector E(31P). 45. Turn the ignition switch ON (II). 46. Measure voltage between body ground and ECM/PCM connector terminals A2 and A3 individually. Is there battery voltage? YES - Go to step 53. NO - Go to step 47. 47. Turn the ignition switch OFF. 48. Remove PGM-FI main relay 1(A). 49. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7831 50. Measure voltage between PGM-FI main relay 1 4P connector terminal No.2 and body ground. Is there battery voltage? YES - Go to step 51. NO - Repair open in the wire between the No.6 ECU (ECM/PCM) (15A) fuse and PGM-FI main relay 1. 51. Turn the ignition switch OFF. 52. Check for continuity between PGM-FI main relay 1 4P connector terminal No.1 and ECM/PCM connector terminal 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/PCM (A2, A3). 53. Measure voltage between body ground and ECM/PCM connector terminals A4, A5, A23, and A24 individually. Is there more than 0.2 V? YES - Repair open in the wire(s) that had more than 0.2 V between G101 and the ECM/PCM (A4, A5, A23, A24). NO - Go to step 54. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7832 54. Measure voltage between body ground and ECM/PCM connector terminal A21. Is there about 5 V? YES - Go to step 61. NO - Go to step 55. 55. Turn the ignition switch OFF. 56. Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A21 with the ignition switch ON (II). Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. NO - Go to step 57. 57. Turn the ignition switch OFF. 58. Disconnect the 3P connector from these sensors. - Manifold absolute pressure (MAP) sensor - Intake manifold runner control (IMRC) valve position sensor - Output shaft (countershaft) speed sensor (A/T) 59. Disconnect ECM/PCM connector A (31 P). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7833 60. Check for continuity between ECM/PCM connector terminal A21 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A21) and the MAP sensor, the IMRC valve position sensor, or the output shaft (countershaft) speed sensor(A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 61. Measure voltage between body ground and ECM/PCM connector terminal A20. Is there about 5 V? YES - Go to step 68. NO - Go to step 62. 62. Turn the ignition switch OFF. 63. Disconnect the 3P connector from each of the following sensors, one at a time, and measure voltage between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II). Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) Is there about 5 V? YES - Replace the sensor that restored 5 V when disconnected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7834 NO - Go to step 64. 64. Turn the ignition switch OFF. 65. Disconnect the 3P connector from these sensors: - Throttle position (TP) sensor - Input shaft (mainshaft) speed sensor (A/T) 66. Disconnect ECM/PCM connector A (31 P). 67. Check for continuity between ECM/PCM connector terminal A20 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (A20) and the TP sensor or input shaft (mainshaft) speed sensor (A/T). NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 68. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. NO - Go to step 69. 69. Turn the ignition switch OFF. 70. Disconnect the fuel tank pressure (FTP) sensor 3P connector. 71. Turn the ignition switch ON (II). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7835 72. Measure voltage between body ground and ECM/PCM connector terminal E5. Is there about 5 V? YES - Replace the FTP sensor. NO - Go to step 73. 73. Turn the ignition switch OFF. 74. Disconnect ECM/PCM connector E(31 P). 75. Check for continuity between ECM/PCM connector terminal E5 and body ground. Is there continuity? YES - Repair short in the wire between the ECM/PCM (E5) and the FTP sensor. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 76. Turn the ignition switch OFF. 77. Turn the ignition switch ON (II). 78. Measure voltage between ECM/PCM connector terminal E29 and body ground. Is there about 5 V (or battery voltage)? YES - Go to step 82. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7836 NO - Go to step 79. 79. Turn the ignition switch OFF. 80. Disconnect ECM/PCM connector E(31 P). 81. Check for continuity between ECM/PCM connector terminal E29 and body ground. Is there continuity? YES - Repair short in the wire between the DLC and the ECM/PCM (E29), the SRS unit, or the ABS modulator-control unit. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. 82. Turn the ignition switch OFF. 83. Disconnect ECM/PCM connector E(31P). 84. Turn the ignition switch ON (II). Is the MIL on? YES - Repair short in the wire between the gauge assembly and the ECM/PCM (E31). If the wires are OK, replace the gauge assembly. NO - Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM/PCM, then recheck. If the symptom/indication goes away with a known-good ECM/PCM, replace the original ECM/PCM. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Recalls for Odometer: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Recalls for Odometer: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension > Page 7845 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 06-085 > May > 08 > Campaign - Vehicle Warranty Mileage Extension > Page 7851 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations 142. Right Side of Engine Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 7855 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 Oil Pressure Warning Lamp/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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Lights-on, Key-in, And Seat Belt Reminders, Key Light Timer, And Low Oil Pressure Indicator Image 73-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Testing and Inspection Outside Temperature Display: Testing and Inspection Outside Air Temperature Sensor Test/Replacement 1. Lift the tab (A) to release the lock, and remove the outside air temperature sensor (B) from the back of the front bumper. Disconnect the 2P connector (C) from the outside air temperature sensor. 2. Dip the sensor in ice water, and measure the resistance. Then pour warm water on the sensor, and check for a change in resistance. 3. Compare the resistance reading between the No.1 and No.2 terminals of the outside air temperature sensor with the specifications shown in the graph; the resistance should be within the specifications. 4. If the resistance is out of specification, replace the outside air temperature sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7897 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7898 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Dimmer Switch: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 Dimmer Switch: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 7938 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Supply System - Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7942 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Sending Unit Test Special Tools Required Fuel sender wrench 07XAA-001010A NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram. 1. Check the No.10 METER (7.5A) fuse in the under-dash fuse/relay box before testing. 2. Do the gauge drive circuit check. - If the fuel gauge needle sweeps from the 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 correctly, replace the gauge assembly and retest. 3. Turn the ignition switch OFF. 4. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 OK, go to step 8. - If the voltage is not as specified, check for: a short in the YEL/BLK wire to ground. - an open in the YEL/BLK or BLK wire. - poor ground (G551). 8. Turn the ignition switch OFF. Remove the No.9 BACK UP (10A) fuse from the under-hood fusel relay box for at least 30 seconds, then reinstall it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7943 9. Install a 2 Ohm resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II). 10. Check that the pointer of the fuel gauge indicates "F". - If the pointer of the fuel gauge does not indicate "F", replace the gauge. - If the gauge is OK, inspect the fuel gauge sending unit. NOTE: The pointer of the fuel gauge returns to the bottom 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 locknut (A), and remove the fuel tank unit from the fuel tank. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7944 15. Measure resistance between the No.1 and No.2 terminals with the float at E(EMPTY), 1/2 (HALF FULL), and F (FULL) positions. If you do not get the shown readings, replace the fuel gauge sending unit. NOTE: Remove the No.9 BACK UP (10A) fuse from the under-hood fuse/relay box for at least 10 seconds after completing troubleshooting. Otherwise, it may take up to 20 minutes for the fuel gauge to indicate the correct fuel level. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7945 Fuel Gauge Sender: Service and Repair Fuel Pump/Fuel Gauge Sending Unit Replacement Special Tools Required Fuel sender wrench 07XAA-001010A 1. Relieve the fuel pressure. 2. Remove the fuel fill cap. 3. Fold the rear seats forward, and pull back the carpet to expose the access panel. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 7946 8. Remove the locknut (A) and the fuel tank unit. 9. 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). Be sure to check these items: - When connecting the wire harness, make sure the connection is secure and the connectors (K) are firmly locked into 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 it excessively. - When installing the fuel tank unit, align the marks (L) on the fuel tank (M) and the fuel tank unit (N). Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations 50. Under Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7955 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7956 Parking Brake Warning Switch: Testing and Inspection Parking Brake Switch Test 1. Remove the driver's dash board under panel. 2. Disconnect the connector from the parking brake switch (A). 3. Check for continuity between the switch terminal (B) and body ground. - With the parking brake lever pulled (C), there should be continuity. - With the parking brake lever released (D), there should be no continuity. NOTE: If both the ABS indicator and the brake system indicator come on at the same time, troubleshoot the ABS. - If the parking brake switch and brake fluid level switches are OK, but the brake system indicator does not work, check the ABS. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Tachometer Connector > Component Information > Locations 27. Left Side of Engine Compartment Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Tachometer Connector > Component Information > Locations > Page 7961 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation How the Circuit Works Coolant Temperature Gauge The coolant temperature gauge is controlled by the CPU built-in the gauge assembly. The CPU receives coolant temperature information from the ECM/PCM via the multiplex control unit. The ECM/PCM receives coolant temperature information from the ECT sensor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 7965 Temperature Gauge: Testing and Inspection Coolant Temperature Gauge 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 and stay on? YES - Troubleshoot the cause of the ECM/PCM DTC, and recheck. NO - Go to step 2. 2. Check for a multiplex control unit DTC. Is a DTC indicated? YES - Troubleshooting the cause of the multiplex control unit DTC, and recheck. NO - Go to step 3. 3. Do the communication line check with the self- diagnosis procedure. Is the word "Error" indicated on the odo/trip display? YES - The gauge cannot receive the signal from the multiplex control unit and the ECM/PCM. Check for an open in the GRY/RED wire (gauge connector terminal A1). NO - Go to step 4. 4. Do the gauge drive circuit check with the self- diagnosis procedure. Does the temperature gauge needle sweep from the minimum position to the maximum, then return to the minimum position? YES - Go to step 5. NO - Replace the gauge assembly. 5. Substitute a known-good ECM/PCM, and recheck. Did the symptom/indication go away? YES - Replace the ECM/PCM. NO - Substitute a known-good gauge assembly. If the symptom/indication goes away, replace the gauge assembly. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 7971 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 7975 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 Brake Lamp: Electrical Diagrams Diagram 110-7 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 8014 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Remove the driver's dashboard lower cover. 2. Disconnect the 4P connector (A) from the brake pedal position switch (B). 3. 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. 4. Check for continuity between No.3 and No.4 terminals (with cruise control). - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 5. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Locations > Page 8019 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations 123. Top of Hatch Glass Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Page 8023 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > High Mount Brake Light Replacement Center Mounted Brake Lamp: Service and Repair High Mount Brake Light Replacement High Mount Brake Light Replacement 1. Push in on the clips, and remove the cover (A) from the housing (B). 2. Disconnect the 2P connector (C). 3. Remove the mounting nuts and the housing. 4. Install the high mount brake light in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > High Mount Brake Light Replacement > Page 8026 Center Mounted Brake Lamp: Service and Repair High Mount Brake Light Bracket/Wire Harness Trim High Mount Brake Light Bracket/Wire Harness Trim Replacement NOTE: - Put on gloves to protect your hands. - Place the hatch glass on a padded surface to prevent damage. - Do not damage the rear window defogger grid lines and terminals. 1. Remove the hatch glass. 2. Cut the adhesive portions of the high-mount brake light brackets (A) and wire harness trim (B) with a utility knife, then remove them. Take care not to scratch the hatch glass. 3. Use a putty knife to scrape off all of the old adhesive and adhesive tape from the hatch glass. Clean the inside face of the hatch glass with isopropyl alcohol where new brackets and trim are to be installed. Make sure the bonding surface is kept free of water, oil, and grease. 4. Apply primer (YOKOHAMA RUBBER MS-90, or equivalent) to the inside face of the hatch glass (A): - Be sure the primer lines up with the alignment marks (B). - Be careful not to touch the hatch glass where primer will be applied. 5. Apply primer (SAKAI CHEMISTRY SL-8861, or equivalent) to the back of the high-mount brake light brackets (C). 6. Attach the brackets to the hatch glass with urethane adhesive, and attach the trim (D) to the hatch glass with the adhesive tape (E). Be sure the brackets and trim line up with the alignment marks. 7. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from the hatch glass, use a soft shop towel dampened with alcohol. 8. Let the adhesive dry for at least 1 hour. 9. Reinstall the hatch glass. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations 68. Under Middle of Dash (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Locations > Page 8031 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Console 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 Console Lamp: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp: Customer Interest Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 8075 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 8081 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Page 8082 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Page 8083 Glove Box Lamp: Testing and Inspection Glove Box Light Test/Replacement 1. Open the glove box. 2. Disconnect the 2P connector from the glove box light (A). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the switch released. - There should be no continuity with the switch pushed. 4. If the continuity is not as specified, check the bulb (B). If the bulb is OK, replace the light. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Page 8084 Glove Box Lamp: Service and Repair Glove Box Light Test/Replacement 1. Open the glove box. 2. Disconnect the 2P connector from the glove box light (A). 3. Check for continuity between the No.1 and No.2 terminals. - There should be continuity with the switch released. - There should be no continuity with the switch pushed. 4. If the continuity is not as specified, check the bulb (B). If the bulb is OK, replace the light. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: Customer Interest Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 8093 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting Glove Box Lamp Stays ON Glove Box Lamp Switch: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting Glove Box Lamp Stays ON > Page 8099 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 8104 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test (Canada) 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 8105 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 Dimmer Switch: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 Dimmer Switch: Electrical Diagrams Interior Lights - Dash And Console Lights Image 114 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 Interior Lights - Dash And Console Lights Image 114-1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Locations Dome Lamp: Locations 78. Under Right Side of Dash 118. Middle of Roof 119. Rear of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Dome Lamp: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 8181 Dome Lamp: Testing and Inspection 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 (D). If the bulb is OK, replace the light. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 8185 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations 39. Left Kick Panel (USA: P/N 08V31-S9A-11O Honda Acc.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8190 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 8194 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Testing and Inspection Hazard Flasher Relay: Testing and Inspection Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. 6. Install the switch in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations 59. Center of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 8202 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Bulb Replacement Headlight 1. Disconnect the 3P connector (A) from the headlight. 2. Remove the rubber cover (B). 3. Pull the retaining spring (C) away from the bulb (D), then remove the bulb. 4. Install a new bulb in the reverse order of removal. Make sure the notches in the bulb align with the tabs in the headlight. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams > Page 8213 Low Beam Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Low Beam Cut Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 8218 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8233 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8234 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8235 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8236 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8237 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8238 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8248 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8249 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8250 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8251 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Interior Lighting Module: Electrical Diagrams Diagram 115-0 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 8254 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 5. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 8255 6. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the underdash 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations > Page 8259 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Locations > Page 8260 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations 129. Left Side of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8267 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8268 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8269 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8270 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8271 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8274 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8275 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8276 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8277 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8278 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8279 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8280 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8285 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8286 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8287 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8296 License Plate Lamp: Electrical Diagrams Diagram 110-8 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8297 Diagram 110-9 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8298 License Plate Lamp: Service and Repair License Plate Light Replacement 1. Remove the license plate light (A) from the rear bumper. 2. Disconnect the 2P connector (B) from the light. 3. Take the lens (C) off, then remove the bulb (D). 4. Install the light in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams 127. Spotlights Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 8302 Map Light: Testing and Inspection Spotlight 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 2P 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 (D). If the bulb is OK, replace the light. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 8303 Map Light: Service and Repair Spotlight 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 2P 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 (D). If the bulb is OK, replace the light. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair Bulb Replacement Front Turn Signal/Side Marker Light: Parking Light: 1. Remove the inner fender 2. Disconnect the connectors (A) from the lights. 3. Turn the bulb sockets (B) 450 counterclockwise to remove them from the headlight housing. 4. Install the new bulb(s) in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations 30. Behind Left Headlight (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8313 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8314 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8315 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8316 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8317 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8318 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8319 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8320 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8321 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 Parking 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8327 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8330 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 Parking Lamp: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Parking Lamp: Electrical Diagrams Diagram 110-8 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8344 Diagram 110-9 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations 151. Behind Glove Box (03-04) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 8349 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 8353 Daytime Running Lamp Control Unit: Testing and Inspection Daytime Running Lights Control Unit Input Test (Canada) 1. Remove the driver's dashboard lower cover. 2. Disconnect the 14P connector (A) from the daytime running lights control unit (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, go to step 4. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Page 8354 4. Make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the control unit must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations 39. Left Kick Panel (USA: P/N 08V31-S9A-11O Honda Acc.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8361 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Hazard Warning Switch Test 1. Remove the center panel. 2. Disconnect the 10P connector (A) from the hazard warning switch (B). 3. Push out the hazard warning switch from behind the center panel (C). 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, replace the illumination bulb (D) or the switch. 6. Install the switch in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 Interior Lighting Module: Electrical Diagrams Diagram 115-0 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 8403 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 5. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 8404 6. Reconnect the connectors to the under-dash fuse/relay box, and make sure these input tests at the appropriate connectors on the underdash 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Diagrams > Page 8408 Low Beam Relay: Testing and Inspection 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.4 terminals. - There should be no continuity between the No.1 and No.4 terminals when power is disconnected. Moonroof Open Relay/Moonroof Close Relay/Low Beam Cut Relay (Canada) Low Beam Cut Relay (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations 20. Transmission Housing (M/T) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8416 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation Brake Pedal Position Switch The brake pedal position switch signals the ECM/PCM when the brake pedal is pressed. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 8420 Brake Light Switch: Testing and Inspection Brake Pedal Position Switch Test 1. Remove the driver's dashboard lower cover. 2. Disconnect the 4P connector (A) from the brake pedal position switch (B). 3. 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. 4. Check for continuity between No.3 and No.4 terminals (with cruise control). - There should be continuity when the brake pedal is pressed. - There should be no continuity when the brake pedal is released. 5. If necessary, adjust or replace the switch, or adjust the pedal height. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations 102. Left Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 8424 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations 34. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8428 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8429 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8430 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations 97. Left B-pillar 98. Left C-pillar (Right Similar) 99. Right B-pillar Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 8434 Door Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations 31. Left Side of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 8438 (USA: Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: Customer Interest Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 8447 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON Glove Box Lamp Switch: All Technical Service Bulletins Lighting - Glove Box Lamp Stays ON 04-064 November 9, 2004 Applies To: 2002-04 CR-V - ALL Glove Box Light Stays On SYMPTOM The glove box light stays on when the lid is closed. This is noticeable when the headlights are on and the inside of the vehicle is dark. PROBABLE CAUSE The glove box switch plunger is too short. CORRECTIVE ACTION Install a cap on the glove box switch plunger. PARTS INFORMATION PVC Plug Cap: P/N 34254-SP0-308, H/C 4419834 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 715010 Flat Rate Time: 0.2 hour Failed Part: P/N 34254-SV4-003 H/C 4318861 Defect Code: 06601 Symptom Code: 03228 Template ID: 04-064A 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. Open the glove box lid, and press the cap onto the switch plunger. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glove Box Lamp Switch: > 04-064 > Nov > 04 > Lighting - Glove Box Lamp Stays ON > Page 8453 2. Turn on the headlights, and confirm that the glove box light is off when the glove box lid is closed. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations 59. Center of Dash Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 8457 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations 32. Inside of Steering Wheel (Airbag Inflator Rem.) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 8461 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Locations 117. Front of Roof Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions Spot Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Number. See: Diagrams/Connector Views/Connector Views By View Number Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Trailer Lamps: 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Trailer Lamps: Electrical Diagrams Diagram 118-4 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Diagram 118-5 (Honda Accessory) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Diagram 118-6 (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations 34. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8543 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8544 Combination Switch: Testing and Inspection Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8545 Combination Switch: Service and Repair Combination Light Switch Test/Replacement 1. Remove the dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 16P connector (A) from the combination light switch (B). 4. Remove the two screws, then slide out the combination light switch. Light Switch/Turn Signal 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Circuit Schematics Circuit Schematics 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 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 shares that wiring. To quickly check shared wiring, check the operation of a component it serves. If that component works, you know the shared wiring is OK. Connectors All in-line and junction connectors are numbered (C725, C416, etc.). Component connectors are not numbered but are identified either by the name of the component if the component only has one connector, or by a capital letter (A, B, C, etc.) if the component has more than one connector. Below most connector numbers and component names are PHOTO and VIEW numbers. The PHOTO number refers to a photo in the back of the book that shows the connector's location on the car. The VIEW number refers to an illustration in the back of the book that shows the connector terminals, wire colors, connector cavity numbers, and other details. The connector cavity numbering sequence begins at the top left corner of the connector as seen from either of the viewpoints. 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 Power Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8551 Power Distribution Schematics Power Distribution schematics show how power is supplied from the positive battery terminal to various circuits in the car. Refer to the Power Distribution section to get a more detailed picture of how power is supplied to the circuit you're working on. Individual circuit schematics begin with a fuse. So if Power Distribution shows that an inoperative circuit and another circuit share a fuse, check a component in the other circuit. If it works, you know the fuse is good and power is available to the inoperative circuit. Ground Distribution Schematics Ground Distribution Schematics Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 Ground Distribution Schematics This sample Ground Distribution schematic shows all of the components that share the same ground point. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 Components Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 Connectors - "C" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 Diodes Fuses Ground - "G" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Shielding Splices Switches Terminals - "T" Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Wire Color Abbreviations Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Wires How to Identify Connector Terminals How to Identify Connector Terminals Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Connector terminals are numbered according to the cavities they're in. The cavities are numbered starting from the upper left, looking at the male terminals from the terminal side or looking at the female terminals from the wire side. Both views are in the same direction so the numbers are the same. All actual cavities are numbered, even if they have no wire terminals in them. NOTE: Data Link Connector (DLC) terminals are numbered according to SAE standard J1962, not the Honda standard. The numbers of the four end terminals are molded into the corners of the connector face. The connector cavity number is listed next to each terminal on the circuit schematic. The cavity / terminal shown is #6. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 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. Testing For A Short With A Self-Powered Test Light or DVOM Testing for a Short with a Self-Powered Test Light or DVOM 1. Remove the blown fuse and disconnect the battery and load. 2. Connect one lead of a self-powered test light or digital volt/ohmmeter (DVOM) (switched to the lowest "OHMS" range) to the fuse terminal on the load side. 3. Connect the other lead to a known good ground. 4. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 5. If the self-powered test light goes on or the DVOM displays a low reading or no reading (zero), there is a short to ground in the wiring near that point. Testing for a Short with a Test Light or DVOM Testing for a Short with a Test Light or DVOM Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 1. Remove the blown fuse and disconnect the load. 2. Connect a test light or digital volt/ohmmeter (DVOM), switched to the appropriate DC volts range, across the fuse terminals to make sure voltage is present. You might have to turn the ignition switch to ON; check the schematic to see. 3. Beginning near the fuse box, wiggle the harness. Continue this at convenient points about six inches apart while watching the test light or DVOM. 4. Where the test light goes off, or the DVOM voltage drops to zero, there is a short to ground in the wiring near that point. NOTE: Always use a DVOM on high impedance circuits. A test light may not glow (even with battery voltage present). Testing For A Short With A Short Circuit Locator (Short Finder) Testing for a Short with a Short Circuit Locator (Short Finder) 1. Remove the blown fuse. Leave the battery connected. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 2. Connect the short finder across the battery terminals and the load (component) side of the fuse terminal. 3. Close all switches in the circuit you're testing. 4. Turn on the short finder. This creates a pulsing magnetic field around the wiring between the fuse box and the short. 5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will read current pulses through sheet metal and body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter past the point of the short, the needle will stop moving. Check the wiring and connectors in this area to locate the cause of the short. Testing For Continuity 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 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 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 Voltage Drop 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 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. How to Replace Connector Terminals 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: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 1. Release the secondary lock. 2. Remove the terminal 3. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the secondary lock from the male terminal half. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 2. Remove the secondary lock from the female terminal half. 3. Remove the terminal (same procedure for male and female). 4. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the secondary lock. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 1. Remove the secondary locks. 2. Remove the terminal from the female halt. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE B: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE C: 1. Remove the terminal. 2. Go to HOW TO INSTALL NEW TERMINALS. EXAMPLE D: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 Vanity Lamp: Electrical Diagrams Diagram 114-0 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Condenser > Component Information > Locations 106. Right Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Condenser > Component Information > Locations > Page 8586 68. Noise Condenser Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Under-Hood Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Window Control Module: Component Tests and General Diagnostics Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Loss of battery power - Loss of power from the No.6 (7.5A) and/or the No.23 (20A) fuses in the under-dash fuse/relay box. - Open circuit caused by disconnecting the 20P connector from the power window master switch - Removal of the regulator, glass, or glass run channel 1. Make sure the glass is installed properly. 2. Close the driver's door. 3. Turn the ignition switch OFF. 4. Remove the No.23 (20A) fuse in the under-dash fuse/relay box. 5. Turn the ignition switch ON (II). 6. After 1 second, turn the ignition switch OFF. 7. After 5 seconds, install the No.23 (20A) fuse to the under-dash fuse/relay box. 8. Make sure the driver's window does not work in AUTO with the ignition switch ON (II). 9. Start the engine. 10. Move the driver's window all the way down using the manual DOWN function of the driver's power window switch. 11. Move the driver's window all the way up using the manual UP function of the driver's power window switch, and hold it for 1 second after the window reaches the closed position. 12. If the window does not work in AUTO, repeat steps 2 through 12. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8598 Power Window Control Module: Programming and Relearning Power Window Control Unit Reset Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5A) and/or the No. 23 (20A) fuses from 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 by holding the driver's switch firmly down; when the window reaches the bottom, hold the driver's window switch firmly down for 2 seconds. 3. Move the driver's window all the way up by holding the driver's switch firmly up; when the window reaches the top, hold the driver's window switch firmly up for 2 seconds. 4. If the window does not work in AUTO, turn the ignition switch OFF and repeat Step 1 through 3. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8606 Rear Door Component Location Index 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8607 111. Front Passenger's Door 114. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8608 Power Window Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8609 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8612 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8613 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 switch panel from the door panel. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8614 4. Reconnect the 20P 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, go to step 5. 5. Disconnect the 20P connector from the switch 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 the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8615 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8616 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Test/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8619 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8620 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8621 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Window Control Module: Component Tests and General Diagnostics Resetting the Power Window Control Unit Resetting the power window control unit is required after performing the following procedures: - Loss of battery power - Loss of power from the No.6 (7.5A) and/or the No.23 (20A) fuses in the under-dash fuse/relay box. - Open circuit caused by disconnecting the 20P connector from the power window master switch - Removal of the regulator, glass, or glass run channel 1. Make sure the glass is installed properly. 2. Close the driver's door. 3. Turn the ignition switch OFF. 4. Remove the No.23 (20A) fuse in the under-dash fuse/relay box. 5. Turn the ignition switch ON (II). 6. After 1 second, turn the ignition switch OFF. 7. After 5 seconds, install the No.23 (20A) fuse to the under-dash fuse/relay box. 8. Make sure the driver's window does not work in AUTO with the ignition switch ON (II). 9. Start the engine. 10. Move the driver's window all the way down using the manual DOWN function of the driver's power window switch. 11. Move the driver's window all the way up using the manual UP function of the driver's power window switch, and hold it for 1 second after the window reaches the closed position. 12. If the window does not work in AUTO, repeat steps 2 through 12. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8627 Power Window Control Module: Programming and Relearning Power Window Control Unit Reset Resetting the power window control unit is required after performing the following procedures: - Disconnecting the battery - Removing the No. 6 (7.5A) and/or the No. 23 (20A) fuses from 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 by holding the driver's switch firmly down; when the window reaches the bottom, hold the driver's window switch firmly down for 2 seconds. 3. Move the driver's window all the way up by holding the driver's switch firmly up; when the window reaches the top, hold the driver's window switch firmly up for 2 seconds. 4. If the window does not work in AUTO, turn the ignition switch OFF and repeat Step 1 through 3. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations Front Door Window Motor: Locations 110. Driver's Door 113. Front Passenger's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Page 8632 Front Door Window Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Locations 116. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Locations > Page 8636 Rear Door Window Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Under-Dash Fuse/Relay Box Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Front Door Component Location Index Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8643 Rear Door Component Location Index 107. Driver's Door Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8644 111. Front Passenger's Door 114. Left Rear Door (Right Similar) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8645 Power Window Switch: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8646 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 8649 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 8650 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 switch panel from the door panel. 2. Disconnect the 20P connector (A) from the master switch (B). 3. Inspect the connector and socket terminals to be sure they are all making good contact. - If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. - If the terminals look OK, make the following input tests at the connector. If a test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, the power window master switch must be faulty; replace it. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 8651 4. Reconnect the 20P 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, go to step 5. 5. Disconnect the 20P connector from the switch 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 the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 8652 Power Window Switch: Testing and Inspection Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Switch Test/Replacement > Page 8653 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Test/Replacement 1. Remove the switch panel. 2. Disconnect the 20P connector from the power window master switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 8656 Front Passenger's/Left Rear/Right Rear Switch 3. Check for continuity between the terminals in each switch position according to the tables. Driver's Switch: The driver's switch is combined with the control unit so you cannot isolate the switch to test it. Instead, run the master switch input test procedures. If the tests are normal, the driver's switch must be faulty. 4. If the continuity is not as specified, remove the three screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 8657 Power Window Switch: Service and Repair Passenger's Window Switch Test/Replacement Passenger's Window Switch Test/Replacement 1. Remove the switch panel from the door panel. 2. Disconnect the 5P connector (A) from the power window switch (B). 3. Remove the two screws and the passenger's power window switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Master Switch Replacement > Page 8658 4. Check for continuity between the terminals in each switch position according to the table. 5. If the continuity is not as specified, remove the two screws and replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front 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. To prevent scratching the power mirror and door, wrap the power mirror with a shop towel. Disconnecting the power mirror connector is not required. 2. Remove the screw (A) from the rear edge of the door. Starting at the rear, pry the door glass outer weatherstrip (B) up to detach the clips (C), then remove the weatherstrip. 3. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Liftgate Window Glass Weatherstrip > Component Information > Service and Repair Liftgate Window Glass Weatherstrip: Service and Repair Hatch Glass Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the tailgate. 1. Remove the tailgate side trim from both sides. 2. Remove the high mount brake light. 3. Disconnect the rear window defogger connectors, and release the wire harnesses from both sides. 4. Remove the hatch glass support strut brackets from both sides of the tailgate. 5. With an assistant, holding the hatch glass, remove the hatch glass weatherstrip (A) by pulling out on it. 6. Clean the bonding surface around the hatch glass opening flange with alcohol. 7. Apply sealant (Cemedine P/N 08712-0004, or equivalent) (A) in the groove around the hatch glass weatherstrip (B). 8. Locate the painted alignment mark (C) on the hatch glass weatherstrip. Align the painted mark with the alignment tab in the center of the hatch glass opening, and install the weatherstrip. Make sure it's seated completely and facing in the direction shown. Make sure there are no wrinkles in the weatherstrip. 9. Check for water leaks. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair Quarter Glass Replacement NOTE: - Put on gloves to protect your hands. - Use seat covers to avoid damaging any surface. 1. Remove these items - C-pillar trim - D-pillar trim 2. From inside the vehicle, use a utility knife (A) to cut through the adhesive (B) all the way around: - If the quarter glass (C)will be reinstalled, take care not to damage the molding (D). - If the molding is damaged, replace the quarter glass, molding and clips (E) as an assembly. - If any of the clips are broken, the quarter glass can be reinstalled using butyl tape. - Apply protective tape along the edge of the entire quarter glass opening flange. 3. Carefully remove the quarter glass. Check the molding for damage, and replace the quarter glass if necessary. 4. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire quarter glass opening flange: Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. - Remove the clips and fastener from the body. 5. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface. 6. If the old quarter glass will be reinstalled, use a putty knife to scrape off all of the old adhesive, any broken clips, and the fastener from the glass. Clean the inside face and the edge of the glass with alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil, and grease. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8671 7. If the old quarter glass will be reinstalled (and either clip is broken off the molding), apply a light coat of primer (C-100, or equivalent), then apply butyl tape (A) to the molding (B) as shown. Attach the fastener (C) to the inside face of the quarter glass (D) with adhesive tape (3M 4213, or equivalent): Be sure the fastener lines up with the alignment marks (E). - Be careful not to touch the quarter glass where adhesive will be applied. - Do not peel the separator off the butyl tape. 8. If a new quarter glass will be installed, attach the fastener (A) to the body with adhesive tape (3M 4213, or equivalent). Be sure the fastener lines up with the body contour. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8672 9. If the old quarter glass will be reinstalled (and either clip is broken off the molding), seal the body holes with pieces of urethane tape (A). Then set the quarter glass upright in the opening, and make alignment marks (B) across the quarter glass and body with a grease pencil at the three points shown. Be careful not to touch the quarter glass where adhesive will be applied. 10. Remove the quarter glass. 11. With a sponge, apply a light coat of glass primer to the inside face of the quarter glass (A) as shown, then lightly wipe it off with gauze or cheesecloth: Do not apply body primer to the quarter glass, and do not get the 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. 12. With a sponge, apply a light coat of body primer to any exposed paint around the windshield opening flange. Let the body primer dry for at least 10 minutes; Do not apply body primer to the remaining original adhesive, and be careful not to mix up glass and body primer sponges. - Never touch the primed surfaces with your hands. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8673 13. Before filling a cartridge with adhesive, cut a "V" in the end of the nozzle (A) as shown. 14. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive (A) around the edge of the quarter glass (B) as shown: After applying the adhesive, peel the separator off the butyl tape (C). - Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 15. Use suction cups (A) to hold the quarter glass (B) over the opening, align the clips or the alignment marks (C) made in step 9, and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry. 16. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the quarter glass, wipe with a soft shop towel dampened with alcohol. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8674 17. Let the adhesive dry for at least 1 hour, then spray water over the quarter glass and check for leaks. Mark the leaking areas and let the quarter glass dry then seal with sealant. Let the vehicle stand for at least 4 hours after quarter glass installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 18. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Outer Weatherstrip Replacement NOTE: - Put on gloves to protect your hands. - Take care not to scratch the door. 1. Remove the screw (A) from the front edge of the door. Starting at the front, pry the door glass outer weatherstrip (B) up to detach the clips (C), and release the weatherstrip from the door quarter glass seal (D), then remove it. 2. Install the weatherstrip in the reverse order of removal, and replace any damaged clips. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Front 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 move 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 (A) 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. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 8683 5. Apply multipurpose grease to 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: - Make sure the motor connector is plugged in properly. - 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. - Do the power window control unit reset procedure. - 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Rear Door Glass and Regulator Replacement NOTE: Put on gloves to protect your hands. 1. Remove these items: - Door panel - Plastic cover, as necessary - Rod protector 2. Carefully move the glass (A) until you can see the bolts, then remove them. Remove the glass from the regulator (B), and carefully lower the glass. Take care not to drop the glass inside the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 8687 3. Pull the glass run channel (A) away as needed. Pull back the door quarter glass seal (B), then remove the screw (C). Remove the bolts (D, E) securing the center channel (F), then remove the collar (G). 4. Pull the upper portion of the center channel (A) forward to remove it from the door quarter glass seal (B), and pull up the center channel. Take care not to scratch the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 8688 5. Remove the door quarter glass (A) and seal (B) as an assembly from the door. 6. Release the glass (A) from the center channel (B), and carefully remove the glass out through the window slot. Take care not to drop the glass inside the door. 7. Disconnect and detach the connector (A) from the door. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 8689 8. Remove the bolts (B), and loosen the bolts (C), then remove the regulator (D) through the hole in the door. 9. Apply multipurpose grease to the sliding surfaces of the regulator (A) where shown. 10. Install the glass and regulator in the reverse order of removal, and note these items: - Make sure the motor connector is plugged in properly. - Roll the glass up and down to see if it moves freely without binding. - Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary. - Check for water leaks. - Test-drive and check for wind noise and rattles. - When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel Window Track: Customer Interest Body - Door Glass Comes Out of Run Channel 03-025 December 17, 2004 Applies To: Front Door Glass Comes Out of the Run Channel (Supersedes 03-025, dated September 30, 2003) Updated information is shown with black bars and asterisks. SYMPTOM *The rear edge of the front door glass comes out of the run channel and, on 2004 models, the driver's door glass may reverse direction and open fully while the customer is trying to close it.* PROBABLE CAUSE The door glass and the run channel are not aligned. CORRECTIVE ACTION Align the door glass with the run channel. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 826300 (driver's side) 827300 (passenger's side) Flat Rate Time: 1.0 hour (per side) Failed Part: P/N 73300-SCA-A0 H/C 7106222 Defect Code: 03214 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 door panel and trim: ^ Refer to page 20-7 in the 2002-04 CR-V Service Manual or to page 20-4 in the 2002-03 Civic Si Service Manual. ^ Enter keyword DOOR PAN, and select Front Door Panel Removal Installation from the list. 2. Use a utility knife to cut the adhesive, then pull back the plastic cover: ^ Refer to page 20-3 in the 2002-04 CR-V Service Manual or to page 20-2 in the 2002-03 Civic Si Service Manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel > Page 8698 ^ Enter keyword DOOR PAN, and select from the list either Doors Component Location Index Front Door, for CR-V, or Doors Component Location Index (3-door) for Civic Si. 3. Connect the power window switch, and move the window until you can access the glass mounting bolts. Loosen the bolts, but do not remove them. 4. Loosen but do not remove the four regulator mounting bolts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel > Page 8699 5. Remove the glass run channel, and check for damage in the areas shown. If any damage is found, replace the run channel. Otherwise, reinstall the original part. 6. Torque the regulator bolts to 8 Nm (6 lb-ft) in the order shown. 7. Push the glass against the run channel so that the back edge of the glass is parallel with the run channel. Torque the glass mounting bolts to 9.8 Nm (7.2 lb-ft).* 8. Move the door glass up and down, making sure it operates smoothly and contacts the run channel evenly. 9. Reinstall all removed parts. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel Window Track: All Technical Service Bulletins Body - Door Glass Comes Out of Run Channel 03-025 December 17, 2004 Applies To: Front Door Glass Comes Out of the Run Channel (Supersedes 03-025, dated September 30, 2003) Updated information is shown with black bars and asterisks. SYMPTOM *The rear edge of the front door glass comes out of the run channel and, on 2004 models, the driver's door glass may reverse direction and open fully while the customer is trying to close it.* PROBABLE CAUSE The door glass and the run channel are not aligned. CORRECTIVE ACTION Align the door glass with the run channel. WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 826300 (driver's side) 827300 (passenger's side) Flat Rate Time: 1.0 hour (per side) Failed Part: P/N 73300-SCA-A0 H/C 7106222 Defect Code: 03214 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 door panel and trim: ^ Refer to page 20-7 in the 2002-04 CR-V Service Manual or to page 20-4 in the 2002-03 Civic Si Service Manual. ^ Enter keyword DOOR PAN, and select Front Door Panel Removal Installation from the list. 2. Use a utility knife to cut the adhesive, then pull back the plastic cover: ^ Refer to page 20-3 in the 2002-04 CR-V Service Manual or to page 20-2 in the 2002-03 Civic Si Service Manual. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel > Page 8705 ^ Enter keyword DOOR PAN, and select from the list either Doors Component Location Index Front Door, for CR-V, or Doors Component Location Index (3-door) for Civic Si. 3. Connect the power window switch, and move the window until you can access the glass mounting bolts. Loosen the bolts, but do not remove them. 4. Loosen but do not remove the four regulator mounting bolts. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-025 > Dec > 04 > Body - Door Glass Comes Out of Run Channel > Page 8706 5. Remove the glass run channel, and check for damage in the areas shown. If any damage is found, replace the run channel. Otherwise, reinstall the original part. 6. Torque the regulator bolts to 8 Nm (6 lb-ft) in the order shown. 7. Push the glass against the run channel so that the back edge of the glass is parallel with the run channel. Torque the glass mounting bolts to 9.8 Nm (7.2 lb-ft).* 8. Move the door glass up and down, making sure it operates smoothly and contacts the run channel evenly. 9. Reinstall all removed parts. Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 8712 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 8713 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 8719 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 05-058 > Oct > 05 > A/T Controls - MIL ON/DTC's P0706 or P1706 > Page 8720 Disclaimer Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Side Windshield Trim Replacement Windshield Moulding / Trim: Service and Repair Side Windshield Trim Replacement Side Windshield Trim Replacement 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. 1. Remove the front roof side trim. 2. Remove the nut, and detach the side windshield trim (A) from the retainer (B) by pulling the trim up. Take care not to scratch the body. 3. Install the trim in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Side Windshield Trim Replacement > Page 8726 Windshield Moulding / Trim: Service and Repair Side Windshield Trim Retainer Replacement Side Windshield Trim Retainer Replacement NOTE: - Take care not to scratch the body. - When heating the body with a dryer, be careful not to get it too hot. Heat it gradually to prevent damage to the paint. - Remove the plastic parts, and/or protect them from the heat with aluminum foil. 1. While heating the retainer (A) to 212-248 °F (100 -120 °C) with a dryer, gently pull it away from the body with pliers. 2. With a putty knife, scrape the remaining adhesive tape from the bonding surface while heating it with a dryer. 3. Clean the bonding surface with a sponge dampened in alcohol. Make sure the bonding surface is kept free or water, oil and grease. 4. Peel the adhesive backing away from the double-sided adhesive tape on new retainer. 5. Line up the retainers with the alignment marks (B) on the body, and attach the retainers with the adhesive tape (C). 6. Apply two-part epoxy adhesive (D) around the edge of the retainers as shown. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations 103. Right Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 8735 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (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 8738 Wiper Control Module: Testing and Inspection Rear Wiper Control Unit Input Rear Wiper Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 12P 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. Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 8739 Part 2 4. Reconnect the connector and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. 5. Disconnect the connector, and make these input tests at the connector. - If all the input tests prove OK, the control unit must be faulty; replace the rear wiper control unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 8744 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test (Canada) 1. Remove the left inner fender. 2. Disconnect the 2P connector (A) from the washer fluid level switch (B). 3. Check for continuity between the No.1 and No.2 terminals in each float position (C). - There should be continuity when the float is down. - There should be no continuity when the float is up. 4. If the continuity is not as specified, replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8748 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8749 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8750 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8754 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8755 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8756 Wiper Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams (Canada) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 8760 Washer Fluid Level Switch: Testing and Inspection Washer Fluid Level Switch Test (Canada) 1. Remove the left inner fender. 2. Disconnect the 2P connector (A) from the washer fluid level switch (B). 3. Check for continuity between the No.1 and No.2 terminals in each float position (C). - There should be continuity when the float is down. - There should be no continuity when the float is up. 4. If the continuity is not as specified, replace the switch. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Washer Tubes Replacement 1. Remove the left inner fender. Part 1 2. Remove the windshield washer nozzles and clips, then remove the tubes. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 8767 Part 2 3. Install in the reverse order of removal. Take care not to pinch the washer tubes. Check the windshield washer operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations 137. Behind Left Side of Inner Fender (Japan or U.K. built) Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 8771 Windshield Washer Motor: Diagrams Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 8772 Windshield Washer Motor: Testing and Inspection Washer Motor Test 1. Remove the left inner fender. 2. Disconnect the 2P connectors (A) from the washer motors. 3. Test the motor by connecting battery power to the No.1 terminal and ground the No. 2 terminal of the washer motor. The motor should run. - If the motor does not run or fails to run smoothly, replace it. - If the motor runs smoothly, but little or no washer fluid is pumped, check for a disconnected or blocked washer hose, or a clogged pump outlet in the motor. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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. Open the hood. 2. Remove the bolt, then separate and remove the filler neck (A) from the washer reservoir (B). 3. Remove the left inner fender. 4. Disconnect the 2P connectors (A) and washer tubes (B). 5. Remove the bolt and washer reservoir (C). 6. Install the reservoir in the reverse order of removal. Check the the washer motor operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8779 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8780 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8781 Windshield Washer Switch: Service and Repair Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Rear Window Wiper Protection Tape Wiper Arm: Service and Repair Rear Window Wiper Protection Tape Rear Window Wiper Protection Tape Replacement 1. Slowly peel up the old rear window wiper protection tape. 2. Clean the tailgate bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease, and water from getting on the surface. 3. Peel the adhesive backing from the new rear window wiper protection tape. 4. Align the notch (A) of the application tape (B) with the edge of the tailgate (C) and align the top edge of the application tape with the edge of the tailgate, then press the rear window wiper protection tape (D) into place. 5. Remove the application tape. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Rear Window Wiper Protection Tape > Page 8786 Wiper Arm: Service and Repair Rear Window Wiper Lifter Replacement Rear Window Wiper Lifter Replacement 1. Remove the tailgate lower trim panel. 2. Remove the nut from inside the tailgate, then remove the rear window wiper lifter (A) and the seal (B). 3. Install the lifter in the reverse order of removal. Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Windshield Wipers - Blade Care & Replacement > Page 8791 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations 103. Right Quarter Panel Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 8795 Honda Cr-v 4wd Workshop Manual (L4-2.4L (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 dashboard lower cover. 3. Disconnect the under-dash fuse/relay box connectors B, F, G, J, X and Y. 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 Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 8798 Wiper Control Module: Testing and Inspection Rear Wiper Control Unit Input Rear Wiper Control Unit Input Test 1. Remove the right rear side trim panel. 2. Disconnect the 12P 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. Part 1 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and Inspection > Control Unit Input Test > Page 8799 Part 2 4. Reconnect the connector and make these input tests at the connector. - If any test indicates a problem, find and correct the cause, then recheck the system. - If all the input tests prove OK, go to step 5. 5. Disconnect the connector, and make these input tests at the connector. - If all the input tests prove OK, the control unit must be faulty; replace the rear wiper control unit. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations 22. Under Left Side Of cowl cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations > Page 8804 125. Middle of Tailgate Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Wiper Motor: Connector Views Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8807 Wiper Motor: Testing and Inspection Wiper Motor Test Windshield: 1. Remove the wiper arms, hood seals, and cowl covers. 2. Disconnect the 5P connector (A) from the wiper motor (B). 3. Test the motor by connecting battery power to the No.5 terminal and ground the No.1 terminal of the wiper motor 5P connector. The motor should run. If the motor does not run or fails to run smoothly, replace the motor. 4. Connect an analog voltmeter between the No.3 (+) and No.4 (-) terminals, and run the motor at low or high speed. The voltmeter should indicate 12 V and 4 V or less alternately. Rear Window: 1. Open the tailgate, and remove the tailgate lower trim panel. 2. Disconnect the 4P connector (A) from the wiper motor (B). 3. Test the motor by connecting battery power to the No.1 terminal and ground the No.3 terminal of the wiper motor. The motor should run. If the motor does not run or fails to run smoothly, replace the motor. 4. Connect an ohmmeter between No.3 and No.6 terminal and between No.3 terminal and No.4 terminal. There should be continuity when the wiper is in the park position. 5. Connect an ohmmeter between No.3 terminal and No.6 terminal. There should be no continuity when the wiper is in the stand-by position. 6. Connect an ohmmeter between No.3 terminal and No.4 terminal. There should be continuity when the wiper is in the stand-by position. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8808 Wiper Motor: Service and Repair Wiper Motor Replacement Windshield Wiper Motor: 1. Open the hood. Remove the nuts (A) and the windshield wiper arms (B). 2. Remove the hood seals (C) and cowl covers (D). 3. Disconnect the 5P connector (A) from the wiper motor (B). 4. Remove the four bolts and wiper linkage assembly (C). 5. Remove the three mounting bolts and nut from the wiper linkage (A) to remove the wiper motor (B). 6. Install in the reverse order of removal, and note these items: - Grease 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. Rear Window Wiper Motor: Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 8809 1. Remove the mounting nut (A) and the wiper arm (B). 2. Disconnect the 6P connector (A) from the wiper motor (B). 3. Remove the three bolts and the wiper motor. 4. Install in the reverse order of removal. Check the wiper motor operation. Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations 35. In Steering Column Cover Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8813 Honda Cr-v 4wd Workshop Manual (L4-2.4L (2004)) Honda Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8814 Wiper Switch: Testing and Inspection Wiper/Washer Switch Test/Replacement 1. Remove the driver's dashboard lower cover. 2. Remove the steering column covers. 3. Disconnect the 14P connector (A) from the wiper/washer switch (B) 4. Remove the two screws, then pull out the wiper/washer switch. Windshield/Rear Window 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.