Honda Ridgeline 2006 2008 User Manual

Page 1

INTRODUCTION

2006-2008 RIDGELINE - P/NO. 61SJC02

How to Use This Manual

This manual is divided into multiple sections. The first page of each section is marked with a black tab that lines up with its corresponding thumb index tab on this page and the back cover. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Each section includes:

1. A table of contents, or an exploded view index showing:

• Parts disassembly sequence.

• Bolt torques and thread sizes.

• Page references to descriptions in text.

2. Disassembly/assembly procedures and tools.

3. Inspection.

4. Testing/troubleshooting.

5. Repair.

6. Adjustments.

Safety Messages

Your safety, and the safety of others, is very important. To help you make informed decisions, we have provided safety messages, and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgment. You will find important safety information in a variety of forms including:

Safety Labels

• on the vehicle.

Safety Messages

• preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean:

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General Information

Specifications

Maintenance

*Engine Electrical

Engine Mechanical

Engine Cooling

Fuel and Emissions

*Transaxle

*Steering

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions.

Instructions

• how to service this vehicle correctly and safely.

All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, or stored in a retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures, and tables.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.

First Edition 06/2007 2,392 pages

−

HONDA MOTOR CO.,LTD. Service Publication Office

As sections with * include SRS components; special precautions are required when servicing.

Suspension

*Brakes

(Including VSA)

*Body

*Heating, Ventilation,

and Air Conditioning

*Body Electrical

*Audio, Navigation,

and Telematics

*Restraints

Page 2

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for doing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.

If you need to replace any parts, always use the correct parts supplied by a Honda dealer. Never use inferior quality parts.

FOR YOUR CUSTOMER’S SAFETY

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully.

FOR YOUR SAFETY

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (for example, Hot parts wear gloves). If you have not received shop

−

safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to do the procedures described in this manual.

Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully.

Some of the most important general service safety precautions follow this text. However, we cannot warn you of every conceivable hazard that can arise in doing service and repair procedures. Only you can decide whether or not you should do a given task.

IMPORTANT SAFETY PRECAUTIONS

• Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When doing any service task, be especially careful of the following: – Read all of the instructions before you begin, and

make sure you have the tools, the replacement or repair parts, and the skills required to do the tasks safely and completely.

– Protect your eyes by using proper safety glasses,

goggles, or face shields anytime you hammer, drill, grind, or work around pressurized air or liquids and springs or other stored-energy components. If there is any doubt, put on eye protection.

– Use other protective wear when necessary, such as

gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

– Protect yourself and others whenever you have the

vehicle up in the air. Anytime you raise the vehicle, either with a lift or a jack, make sure that it is always securely supported. Use jack stands if needed.

– Protect yourself by wearing an approved welding

helmet, gloves, and safety shoes anytime you are welding. You can receive burns from hot parts; allow the parts to cool before working in that area.

– Protect yourself from paints and harmful chemicals

by wearing an approved respirator, eye protection, and gloves whenever you are painting. Spray paint only in an approved paint booth that is well ventilated.

• Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: – Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you run the engine.

– Burns from hot parts or coolant. Let the engine and

exhaust system cool before working in those areas.

– Injury from moving parts. If the instruction tells you

to run the engine, be sure your hands, fingers, and clothing are out of the way.

• Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. – Use only a nonflammable solvent, not gasoline, to

clean parts. – Never drain or store gasoline in an open container. – Keep all cigarettes, sparks, and flames away from

the battery and all fuel-related parts.

Page 3

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The Ridgeline SRS includes a driver’s airbag in the steering wheel hub, a passenger’s airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof, and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items requires special precautions and tools, and should be done by an authorized Honda dealer.

• To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work should be done by an authorized Honda dealer.

• Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags.

• Do not bump or impact the SRS unit, front impact sensors, or side impact sensors when the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF; otherwise, the system may fail in a collision, or the airbags may deploy.

• SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, in the roof side, and around the floor. Do not use electrical test equipment on these circuits.

Page 4

General Information

Chassis and Paint Codes

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’06 Model . 1-2 ’07 Model . 1-3 ’08 Model . 1-4

Identification Number Locations . 1-5

Danger/Warning/Caution Label Locations . 1-6

Under-hood Emission Control Label . 1-9

Lift and Support Points . 1-10

Towing . 1-11

Parts Marking . 1-12

Precautions for Variable Torque

Management 4WD (VTM-4) System . 1-12

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Page 5

General Information

Chassis and Paint Codes

’06 Model

Vehicle Identification Number Engine Number

2HJ 6 500001YK1 2 * 6 H J35A9 1000001-

cdef gh

a. Manufacturer, Make, and Type of Vehicle

2HJ: Honda of Canada Mfg.,

Honda Canada Inc. Honda Light duty truck

b. Line, Body, and Engine Type

YK1: Ridgeline/J35A9

c. Body Type and Transmission Type

6: 4-door/5-speed Automatic

d. Vehicle Grade (Series)

USA models 2: RT 4: RTS 5: RTL

RTL with Moonroof and XM radio RTL with Moonroof and XM radio and

Navigation System Canada models 4: LX 5: EXL

EXL SR

EXL with Navigation System

e. Check Digit

f. Model Year

6: ’06

g. Factory Code

H: Alliston, Ontario Factory in Canada

h. Serial Number

500001: USA models 000001: Canada models

a. Engine Type

J35A9: 3.5 L SOHC VTEC Sequential Multiport

Fuel-injected engine

b. Serial Number

Transmission Number

BJFA 8000001-

a. Transmission Type

BJFA: 5-speed Automatic

b. Serial Number

Paint Code

Code Color

NH-578 White NH-689M B-92P Nighthawk Black Pearl B-533M Steel Blue Metallic G-521M Amazon Green Metallic R-519P Redrock Pearl

Billet Silver Metallic

USA

models

Canada models

○ ○○ ○○ ○○ ○○ ○○

1-2

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification.

Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification.

COLOR LABEL

Page 6

’07 Model

Vehicle Identification Number Engine Number

2HJ 6 500001YK1 2 * 7 H J35A9 2000001-

cdef gh

a. Manufacturer, Make, and Type of Vehicle

2HJ: Honda of Canada Mfg.,

Honda Canada Inc. Honda Light duty truck

b. Line, Body, and Engine Type

YK1: Ridgeline/J35A9

c. Body Type and Transmission Type

6: 4-door/5-speed Automatic

d. Vehicle Grade (Series)

USA models 2: RT 3: RTX 4: RTS 5: RTL

RTL with Navigation System Canada models 4: LX 5: EXL

EXL with Moonroof

EXL with Moonroof and Navigation System

e. Check Digit

f. Model Year

7: ’07

g. Factory Code

H: Alliston, Ontario Factory in Canada

h. Serial Number

500001: USA models 000001: Canada models

a. Engine Type

J35A9: 3.5 L SOHC VTEC Sequential Multiport

Fuel-injected engine

b. Serial Number

Transmission Number

BJFA 9000001-

a. Transmission Type

BJFA: 5-speed Automatic

b. Serial Number

Paint Code

Code Color

NH-578 White NH-578X NH-689M NH-705M NH-707 Formal Black II NH-707X B-533M Steel Blue Metallic G-525M R-529P Dark Cherry Pearl

White Billet Silver Metallic Nimbus Gray Metallic

Formal Black II

Dark Silver Sage Metallic

USA

models

Canada models

○ ○ ○○ ○○

○ ○○ ○○ ○○ ○○

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification.

Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification.

COLOR LABEL

1-3

Page 7

General Information

Chassis and Paint Codes (cont’d)

’08 Model

Vehicle Identification Number

2HJ 6 500001YK1 2 * 8 H

a. Manufacturer, Make, and Type of Vehicle

2HJ: Honda of Canada Mfg.,

b. Line, Body, and Engine Type

YK1: Ridgeline/J35A9

c. Body Type and Transmission Type

6: 4-door/5-speed Automatic

d. Vehicle Grade (Series)

USA models 2: RT 3: RTX 4: RTS 5: RTL

Canada models 4: LX 5: EXL

e. Check Digit

f. Model Year

8: ’08

g. Factory Code

H: Alliston, Ontario Factory in Canada

h. Serial Number

500001: USA models 000001: Canada models

cdef gh

Honda Canada Inc. Honda Light duty truck

RTL with Navigation System

EXL with Moonroof EXL with Moonroof and Navigation System

Engine Number

J35A9 4000001-

a. Engine Type

J35A9: 3.5 L SOHC VTEC Sequential Multiport

Fuel-injected engine

b. Serial Number

Transmission Number

BJFA 1000001-

a. Transmission Type

BJFA: 5-speed Automatic

b. Serial Number

Paint Code

Code Color

NH-578 White NH-578X NH-689M NH-705M NH-707 Formal Black II NH-707X B-533M Steel Blue Metallic R-529P Dark Cherry Pearl

White Billet Silver Metallic Nimbus Gray Metallic

Formal Black II

USA

models

Canada models

○ ○ ○○ ○○

○ ○○ ○○ ○○

1-4

Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification.

Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification.

COLOR LABEL

Page 8

Identification Number Locations

Vehicle Identification Number (VIN)

Engine Number

Transmission NumberBar Code

1-5

Page 9

General Information

Danger/Warning/Caution Label Locations

Passenger’s Compartment:

SRS INFORMATION

USA models

SRS WARNING INFORMATION

FRONT PASSENGER MODULE DANGER

FRONT PASSENGER AIRBAG WARNING (CHILD SEAT)

USA models

STEERING COLUMN NOTICE

MONITOR NOTICE

FRONTSEATBELTTENSIONER WARNING

SIDE AIRBAG MODULE DANGER

VTM-4 LOCK INFORMATION

1-6

Page 10

Steering Wheel:

Rear Compartment:

DRIVER MODULE DANGER

CABLE REEL CAUTION

ROOF SIDE MODULE DANGER

(cont’d)

1-7

Page 11

General Information

Danger/Warning/Caution Label Locations (cont’d)

’06 Model:

ENGINE COOLANT INFORMATION

AIR CONDITIONING INFORMATION

’07-08 Models:

ENGINE COOLANT INFORMATION

SRS WARNING

RADIATOR CAP DANGER

SERVICE INFORMATION (Under-hood Emission Control)

BATTERY DANGER

SERVICE INFORMATION (Under-hood Emission Control)

Driver’s Doorjamb:

SIDE AIRBAG INFORMATION

Located on driver’s doorjamb and passenger’s doorjamb (not shown)

Left Bed Side Panel:

TIRE INFORMATION

AIR CONDITIONING INFORMATION

1-8

RADIATOR CAP DANGER

BATTERY DANGER

PORTABLE FUEL TANK WARNING

Page 12

Under-hood Emission Control Label

Emission Group Identification Test Group and Evaporative Family

Example:

’06-07 Models

VEHICLE EMISSION CONTROL INFORMATION

THIS VEHICLE CONFORMSTO U.S. EPA TIER 2 BIN 5REGULATIONS APPLICABLE TO 2006 MODEL YEAR NEWLIGHT-DUTY TRUCKS AND CALIFORNIAREGULATIONS APPLICABLE TO 2006 MODEL YEARNEW LEV II ULEV LIGHT-DUTYTRUCKS.

2WU-TWC, TWC, 2A/F SENSOR, 2HO2S, EGR, SFI

6HNXT03.5AKR 6HNXR0156BBA OBD IICERTIFIED

3.5L

VALVE LASH (IN )

NO OTHER ADJUSTMENTS NEEDED.

LOADED I/M TESTING OF THIS VEHICLE MUST BE CONDUCTED ON A FOUR-WHEEL DRIVE SPEED SYNCHRONIZED DYNAMOMETER. OTHERWISE, A NON-LOADED TEST PROCEDURE MUST BE PERFORMED.

0.22 0.02mm(COLD)

0.30 0.02mm(COLD)

(EX)

HONDA MOTOR CO. , LTD.

EVAP CANISTER

PURGE VALVE

PCV VALVE

EXHAUST EMISSIONS STANDARDS ARB: LEV II ULEV (CERTIFICATION AND IN-USE) EPA: TIER 2 BIN 5 (CERTIFICATION AND IN-USE)

TO EVAP CANIST ER

FRONT

XC•

RJE-A01

’08 Model

VEHICLE EMISSION CONTROL INFORMATION

EPA:U.S. T2B5 LDT3 OBD: CA OBDII FUEL: GASOLINE ARB: LEV II ULEV LDT2 OBD: CA OBD II FUEL: GASOLINE

8HNXT03.5MKR 3.5L8HNXR0163BBA

LOADED I/M TESTINGOF THISVEHICLEMUST BE CONDUCTED ON A FOUR-WHEEL DRIVESPEED SYNCHRONIZED DYNAMOMETER. OTHERWISE, A NON-LOADED TESTPROCEDURE MUSTBE PERFORMED.

THE FACTORY INSTALLED LONG-LIFE COOLAN TM USTBE REP LACEDACC ORDING TO MAINTENANCE MINDER SUB CODE 5, OR AT 10 YEARS WHICHEVER COMES FIRS T. THEREA FTER EV ERY 5 YEAR S. WHEN ADDING OR REPLACING THE COOLANT, ALWAY S USE HondaRE COMMENDED GENUINE LONG-LIF EANTI-F REEZE/COOLANT TYPE 2. THIS COOLANT IS PRE-MIXED WITH 50% DISTILLED WATER. IT DOES NOT REQUIRE ANY ADDITIONAL MIXING . NEVER DILUTE THE COOLANT, OR THE LIFE OF THE ENGINE MAY BE SERIOUSLY SHORTENED. CHECK OR ADDTHE COOLANT AT THE RESERVE TANK, NOT THERADIATOR. FOR FURTHERIN FORMATIONON THE COOLING SYSTEM, READ THEO WNER’SMANU ALOR CHECK WITH YOUR Honda DEALER.

HONDA MOTOR CO. , LTD.

CONFORMS TO REGULATIONS: 2008MY

2WU-TWC, TWC, 2A/F SENSOR, 2HO2S, EGR, SFI

INFORMATION

•

RJE-A03

’06 Model

THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5 REGULATIONS APPLICABLE TO 2006 MODEL YEAR NEW LIGHT-DUTY TRUCKS AND CALIFORNIA REGULATIONS APPLICABLE TO 2006 MODEL YEAR NEW LEV II ULEV LIGHT-DUTY TRUCKS.

’07 Model

THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5 REGULATIONS APPLICABLE TO 2007 MODEL YEAR NEW LIGHT-DUTY TRUCKS AND CALIFORNIA REGULATIONS APPLICABLE TO 2007 MODEL YEAR NEW LEV II ULEV LIGHT-DUTY TRUCKS.

Test Group:

HNX803.5TMKR

ab cd e

a. Model Year

6: ’06 7: ’07 8: ’08

b. Manufacturer Subcode

HNX: HONDA

c. Family Type

T: LDT

d. Displacement e. Sequence Characters

AKR: ’06 model TKR: ’07 model MKR: ’08 model

Evaporative Family:

HNX80163R BBA

ab cd e

a. Model Year

6: ’06 7: ’07 8: ’08

b. Manufacturer Subcode

HNX: HONDA

c. Family Type

R: EVAP/ORVR

d. Canister Working Capacity Group

0156: ’06 model 0163: ’07-08 models

e. Sequence Characters

BBA: ’06 and ’08 models BBY: ’07 model

1-9

Page 13

General Information

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, causing the vehicle to tip forward on the lift.

Vehicle Lift

1. Position the lift blocks (A) under the vehicle’s front support points (B) and rear support points (C).

Floor Jack

1. When lifting the front of the vehicle, set the parking brake. When lifting the rear of the vehicle, put the shift lever in the P position.

2. Block the wheels that are not being lifted.

3. Position the floor jack under the front jacking bracket (A) or the rear jacking bracket (B). Center the jacking bracket on the jack lift platform (C), and jack up the vehicle high enough to fit the safety stands under it.

2. Raise the lift a few inches, and rock the vehicle gently to be sure it’s firmly supported.

3. Raise the lift to its height, and inspect the vehicle support 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 vehicle lift. Always use safety stands when working on or under any vehicle that is supported only by a jack.

4. Position the safety stands under the support points and adjust them so the vehicle is level.

5. Lower the vehicle onto the stands.

1-10

Page 14

Towing

If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with a rope or chain. It is very dangerous.

Emergency Towing

There are three popular methods of towing a vehicle.

The operator loads the vehicle

Flat-bed Equipment

on the back of a truck.

transporting the vehicle.

To accommodate flat-bed equipment, the vehicle is equipped with a front towing hook (A), front tie down hook slot (B), rear towing hook (C), and rear tie down hook slot (D).

The towing hooks can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots can be used to secure the vehicle to the truck.

Front:

−

This is the only way of

The tow truck uses two

Wheel Lift Equipment

pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain on the ground.

lift equipment.

Sling-type Equipment

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.

the Ridgeline is unacceptable.

The only recommended way of towing the Ridgeline is on a flat-bed truck.

• Towing the Ridgeline with only two wheels on the ground will damage parts of the 4WD system. If the vehicle is damaged, it should be transported on a flatbed truck or trailer.

• 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.

For non-emergency towing information, refer to the owner’s manual.

−

Never tow the vehicle with this wheel

The tow truck uses metal

−

This method of towing

Rear:

Trailer Towing (’07-08 USA RTX model)

This vehicle has a class three trailer hitch (A) as standard equipment. The cover (B), the ball mount (C),

the hitch pin (D), and the hitch pin clip (E) are stored in the in-bed trunk.

1-11

Page 15

General Information

Parts Marking Precautions for Variable Torque

Management 4WD (VTM-4) System

To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. These labels should not be removed. The original engine or transmission VIN plates are not transferable to the replacement engine or transmission.

NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part.

This vehicle is equipped with the Variable Torque Management 4WD (VTM-4) System. The VTM-4 system distributes driving torque between the front and rear wheels when accelerating and when wheel spin occurs.

The VTM-4 system does not have a manual switch to disable the 4WD system. Whenever service work requires spinning the front or rear wheels with the engine, always lift and support the vehicle so all four wheels are off the ground.

1-121-12

Page 16

Specifications

Standards and Service Limits

Engine Electrical . 2-2 Engine Assembly . 2-2 Cylinder Head . 2-3 Engine Block . 2-4 Engine Lubrication . 2-5 Cooling System . 2-5 Fuel and Emissions . 2-5 Automatic Transmission and A/T Differential . 2-6 Rear Differential . 2-15 Steering . 2-15 Suspension . 2-15 Brakes . 2-16 Air Conditioning . 2-16

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Design Specifications

Dimensions . 2-17 Weight . 2-17 Engine . 2-17 Starter . 2-17 Automatic Transmission . 2-18 Steering . 2-18 Suspension . 2-18 Wheel Alignment . 2-18 Brakes . 2-18 Tires . 2-18 Air Conditioning . 2-18 Electrical Ratings . 2-19 Body Specifications . 2-20

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Page 17

Standards and Service Limits

Engine Electrical

Item Measurement Qualification Standard or New Service Limit

Ignition coil Rated voltage 12 V

Firingorder 142536

Spark plug Type NGK: IZFR5K11

Gap 1.0 1.1 mm (0.039 0.043 in.)

Ignition timing At idle

Check the mark Drive belt Tension Auto tensioner Alternator Output At 13.5 V and

Coil (rotor) resistance At 68 °F (20 °C) 2.3 2.7

Slip ring O.D. 14.2 14.4 mm (0.56 0.57 in.) 13.8 mm (0.54 in.)

Brush length 10.5 mm (0.41 in.) 1.5 mm (0.06 in.)

Brush spring tension 2.94 3.53 N (0.30 0.36 kgf, 0.66 0.80 lbf) Starter Output 1.6 kW

Commutator mica depth 0.4 0.6 mm (0.016 0.024 in.) 0.20 mm (0.008 in.)

Commutator runout 0.05 mm (0.002 in.) max. 0.1 mm (0.004 in.)

Commutator O.D. 29.3 29.5 mm (1.154 1.161 in.) 28.8 mm (1.134 in.)

Brush length 7.7 8.0 mm (0.30 0.31 in.) 0.9 mm (0.04 in.)

Brush spring tension (new) 15.9 19.5 N (1.62 1.99 kgf, 3.57 4.39 lbf)

red

In N or P position 10 2 ° BTDC

normal engine temperature

−−−−−

DENSO: SKJ16DR-M11

− − ―――

130 A

−

−−

−− −

−−

−− −

Engine Assembly

Item Measurement Qualification Standard or New Service Limit

Compression Pressure

Check the engine with the starter

cranking

Minimum 930 kPa (9.5 kgf/cm , 135 psi) Maximum variation

200 kPa (2.0 kgf/cm , 28 psi)

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2-2

Page 18

Cylinder Head

Item Measurement Qualification Standard or New Service Limit

Head Warpage 0.05 mm (0.002 in.)

Height 120.95 121.05 mm (4.762 4.766 in.) Camshaft End play 0.05 0.20 mm (0.002 0.008 in.) 0.20 mm (0.008 in.)

Camshaft-to-holder oil clearance 0.050 0.089 mm (0.0020 0.0035 in.) 0.15 mm (0.006 in.)

Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)

Cam lobe height Intake, primary 35.041 mm (1.3796 in.)

Intake, mid 36.445 mm (1.4348 in.) Intake, secondary Exhaust 36.326 mm (1.4302 in.)

Valve Clearance (cold) Intake 0.20 0.24 mm (0.008 0.009 in.)

Exhaust 0.28 0.32 mm (0.011 0.013 in.)

Stem O.D. Intake 5.485 5.495 mm (0.2159 0.2163 in.) 5.455 mm (0.2148 in.)

Exhaust 5.450 5.460 mm (0.2146 0.2150 in.) 5.420 mm (0.2134 in.)

Stem-to-guide clearance Intake 0.020 0.045 mm (0.0008 0.0018 in.) 0.08 mm (0.003 in.)

Exhaust 0.055 0.080 mm (0.0022 0.0031 in.) 0.11 mm (0.004 in.)

Valve seat Width Intake 1.25 1.55 mm (0.049 0.061 in.) 2.00 mm (0.079 in.)

Exhaust 1.25 1.55 mm (0.049 0.061 in.) 2.00 mm (0.079 in.)

Stem installed height Intake 46.75 47.55 mm (1.841 1.872 in.) 47.80 mm (1.882 in.)

Exhaust 46.68 47.48 mm (1.838 1.869 in.) 47.73 mm (1.879 in.)

Valve spring Free length Intake 51.54 mm (2.029 in.)

Exhaust 51.06 mm (2.010 in.)

Valve guide I.D. Intake 5.515 5.530 mm (0.2171 0.2177 in.) 5.55 mm (0.219 in.)

Exhaust 5.515 5.530 mm (0.2171 0.2177 in.) 5.55 mm (0.219 in.)

Installed height Intake 21.20 22.20 mm (0.835 0.874 in.)

Exhaust 20.60 21.60 mm (0.811 0.850 in.)

Rocker arm Arm-to-shaft clearance Intake 0.026 0.067 mm (0.0010 0.0026 in.) 0.067 mm (0.0026 in.)

Exhaust 0.026 0.077 mm (0.0010 0.0030 in.) 0.077 mm (0.0030 in.)

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− − ―――

−−

35.284 mm (1.3891 in.)

− − ―――

−−

− − ―――

−−

――― ――― ―――

―――

――― ―――

2-3

Page 19

Standards and Service Limits

Engine Block

Item Measurement Qualification Standard or New Service Limit

Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)

Bore diameter 89.000 89.015 mm (3.5039 3.5045 in.) 89.065 mm (3.5065 in.)

Bore taper 0.05 mm (0.002 in.)

Reboring limit 0.25 mm (0.01 in.) Piston Skirt O.D. at 16.0 mm (0.63 in.) from

bottom of skirt

Clearance in cylinder 0.015 0.040 mm (0.0006 0.0016 in.) 0.08 mm (0.003 in.)

Ring groove width Top 1.240 1.250 mm (0.0488 0.0492 in.) 1.27 mm (0.050 in.)

Second 1.220 1.230 mm (0.0480 0.0484 in.) 1.25 mm (0.049 in.) Oil 2.805 2.825 mm (0.1104 0.1112 in.) 2.85 mm (0.112 in.)

Piston ring Ring-to-groove clearance Top 0.055 0.080 mm (0.0022 0.0031 in.) 0.15 mm (0.006 in.)

Second 0.030 0.055 mm (0.0012 0.0022 in.) 0.13 mm (0.005 in.)

Ring end gap Top 0.20 0.35 mm (0.008 0.014 in.) 0.60 mm (0.024 in.)

Second 0.40 0.55 mm (0.016 0.022 in.) 0.70 mm (0.028 in.) Oil 0.20 0.70 mm (0.008 0.028 in.) 0.80 mm (0.031 in.)

Piston pin O.D. 21.962 21.965 mm (0.8646 0.8648 in.) 21.954 mm (0.8643 in.)

Pin-to-piston clearance 0.0050 to 0.0010 mm

Connecting rod Pin-to-rod clearance 0.005 0.014 mm (0.0002 0.0006 in.) 0.019 mm (0.0007 in.)

Small-end bore diameter 21.970 21.976 mm (0.8650 0.8652 in.)

Large-end bore diameter 58.0 mm (2.28 in.)

End play installed on crankshaft 0.15 0.35 mm (0.006 0.014 in.) 0.45 mm (0.018 in.) Crankshaft Main journal diameter 71.976 72.000 mm (2.8337 2.8346 in.)

Rod journal diameter 54.976 55.000 mm (2.1644 2.1654 in.)

Rod/main journal taper 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.)

Rod/main journal out-of-round 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.)

End play 0.10 0.35 mm (0.004 0.014 in.) 0.45 mm (0.018 in.)

Runout 0.025 mm (0.0010 in.) max. 0.03 mm (0.0012 in.) Crankshaft bearing

Main bearing-to-journal oil clearance 0.020 0.044 mm (0.0008 0.0017 in.) 0.050 mm (0.0020 in.)

Rod bearing clearance 0.020 0.044 mm (0.0008 0.0017 in.) 0.050 mm (0.0020 in.)

−− ――― ―――

88.975 88.985 mm (3.5029 3.5033 in.) 88.965 mm (3.5026 in.)

−−

−＋

( 0.00020 to 0.00004 in.)

−＋

−−

− − ―――

−−

− − ―――

−−

0.004 mm (0.0002 in.)

―――

2-4

Page 20

Engine Lubrication

Item Measurement Qualification Standard or New Service Limit

Engine oil Capacity Engine overhaul 5.0 L (5.3 US qt)

Oil change, including filter Oil change, without filter

Oil pump Inner-to-outer rotor clearance 0.04 0.16 mm (0.002 0.006 in.) 0.20 mm (0.008 in.)

Pump housing-to-outer rotor clearance 0.10 0.19 mm (0.004 0.007 in.) 0.20 mm (0.008 in.) Pump housing-to-outer rotor axial clearance Oil pressure with oil temperature at 176 °F (80 °C)

At idle 70 kPa (0.7 kgf/cm , 10 psi) At 3,000 rpm 490 kPa (5.0 kgf/cm , 71 psi)

4.3L(4.5USqt)

4.0L(4.2USqt)

−−

0.02 0.07 mm (0.001 0.003 in.) 0.12 mm (0.005 in.)

−−

Cooling System

Item Measurement Qualification Standard or New

Radiator Coolant capacities (including engine,

heater, hoses, and reservoir) Use Honda Long Life Antifreeze/

Coolant Type 2 Coolant reservoir Coolant capacity 0.6 L (0.16 US gal) Radiator cap Opening pressure 93 123 kPa (0.95 1.25 kgf/cm , 14 18 psi) Thermostat Opening temperature Begins to open 169 176 °F (76 80 °C)

Valve lift at fully open 10.0 mm (0.39 in.) min.

Engine overhaul 8.1 L (2.14 US gal) Coolant change 6.2 L (1.64 US gal)

−− −

−−

Fully open 194 °F (90 °C)

Fuel and Emissions

Item Measurement Qualification Standard or New

Fuel pressure regulator Fuel tank Capacity 83.3 L (22.01 US gal) Engine idle Idle speed without load In N or P position 730 50 rpm

Pressure with fuel pressure gauge

connected

Idle speed with high electrical load

(A/C switch ON, temperature set to

Max Cool, blower fan on High, and

headlights on high beam)

390 440 kPa (4.0 4.5 kgf/cm , 57 64 psi)

−− −

In N or P position 730 50 rpm

2-5

Page 21

Standards and Service Limits

Automatic Transmission and A/T Differential

Item Measurement Qualification Standard or New Service Limit

Automatic transmission

Capacity

Use Honda ATF-Z1 fluid ATF pressure Line pressure At 2,000 rpm

5th clutch pressure At 2,000 rpm

4th clutch pressure At 2,000 rpm

3rd clutch pressure At 2,000 rpm

2nd clutch pressure At 2,000 rpm

1st clutch pressure At 2,000 rpm

1st-hold clutch pressure At 2,000 rpm

Torque converter Stall speed

Check with vehicle on level ground Clutch Clutch end-plate-to-top-disc clearance 1st 1.15 1.35 mm

Clutch return spring free length 1st 68.3 mm (2.69 in.) 66.3 mm (2.61 in.)

Clutch disc thickness 1.94 mm (0.076 in.)

Clutch plate thickness 1st 1.6 mm (0.063 in.) When discolored

1st clutch end plate thickness Mark 1 3.1 mm (0.122 in.) When discolored

1st-hold clutch plate B thickness 5.0 mm (0.197 in.) When discolored

Fluid change 3.1 L (3.3 US qt) Overhaul 8.1 L (8.6 US qt) (2006 models)

8.0 L (8.4 US qt) (2007 models)

in N or P position

in D position

in 2 position

in 1 position

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

950 1,010 kPa

−

(9.7 10.3 kgf/cm , 140 146 psi)

−−

800 880 kPa

−

(8.2 9.0 kgf/cm , 120 130 psi)

−−

2 2

1,950 rpm 1,800 2,100 rpm

900 kPa (9.2 kgf/cm , 130 psi) 890 kPa (9.1 kgf/cm , 130 psi) 890 kPa (9.1 kgf/cm , 130 psi) 890 kPa (9.1 kgf/cm , 130 psi) 890 kPa (9.1 kgf/cm , 130 psi) 890 kPa (9.1 kgf/cm , 130 psi) 760 kPa (7.7 kgf/cm , 110 psi)

−

――― −

(0.045 0.053 in.)

2nd 1.05 1.25 mm

――― −

(0.041 0.049 in.)

3rd 0.8 1.0 mm

――― −

(0.031 0.039 in.)

4th, 5th 0.75 0.95 mm

――― −

(0.030 0.037 in.)

1st-hold 0.6 1.0 mm

――― −

(0.024 0.039 in.)

2nd 48.3 mm (1.90 in.) 46.3 mm (1.82 in.) 3rd 52.0 mm (2.05 in.) 50.0 mm (1.97 in.) 4th 37.4 mm (1.47 in.) 35.4 mm (1.39 in.) 5th 50.0 mm (1.97 in.) 48.0 mm (1.89 in.)

―――

2nd 1.8 mm (0.071 in.) When discolored 3rd 2.0 mm (0.079 in.) When discolored 4th, 5th 1.6 mm (0.063 in.) When discolored 1st-hold 1.8 mm (0.071 in.) When discolored

Mark 2 3.2 mm (0.126 in.) When discolored Mark 3 3.3 mm (0.130 in.) When discolored Mark 4 3.4 mm (0.134 in.) When discolored Mark 5 3.5 mm (0.138 in.) When discolored Mark 6 3.6 mm (0.142 in.) When discolored Mark 7 3.7 mm (0.146 in.) When discolored Mark 8 3.8 mm (0.150 in.) When discolored Mark 9 3.9 mm (0.154 in.) When discolored

−

2-6

Page 22

Item Measurement Qualification Standard or New Service Limit

Clutch (cont’d) 2nd, 3rd, 4th, 5th clutch end plate

thickness

Stator shaft I.D. at needle bearing contact area Torque converter

I.D. at mainshaft sealing ring contact

area ATF pump Gear-to-body thrust clearance 0.03 0.06 mm (0.001 0.002 in.) 0.07 mm (0.003 in.)

Gear-to-body clearance Drive gear 0.210 0.265 mm (0.008 0.010 in.)

Driven gear I.D. 14.016 14.034 mm (0.5518 0.5525 in.) When worn or

Driven gear shaft O.D. 13.980 13.990 mm (0.5504 0.5508 in.) When worn or

Reverse shift fork Park gear and pawl Regulator valve body

Main valve body Third shaft sealing ring contact I.D. 35.000 35.025 mm (1.3780 1.3789 in.) 35.05 mm (1.3799 in.) ATF guide collar Secondary shaft sealing ring contact

Mainshaft Diameter at stator shaft needle bearing

Fork finger thickness 5.90 6.00 mm (0.220 0.236 in.) 5.4 mm (0.213 in.)

――― ―――

Shift fork shaft bore I.D. 14.000 14.010 mm (0.5512 0.5516 in.)

Shift fork shaft/servo valve bore I.D. 37.000 37.039 mm (1.4567 1.4582 in.) 37.045 mm (1.4585 in.)

Mainshaft sealing ring contact I.D. 31.000 31.025 mm (1.220 1.221 in.) 31.05 mm (1.222 in.)

I.D.

contact area

5th gear collar diameter at needle

bearing contact area

5th gear collar length 48.7 48.8 mm (1.917 1.921 in.)

5th gear collar flange thickness 5.15 5.30 mm (0.203 0.209 in.) When worn or

5th gear I.D. 46.000 46.016 mm (1.8110 1.8116 in.) When worn or

5th gear axial clearance 0.10 0.22 mm (0.004 0.009 in.)

Sealing ring thickness 1.90 1.96 mm (0.074 0.077 in.) 1.85 mm (0.073 in.)

Sealing ring groove width 2.025 2.060 mm (0.080 0.081 in.) 2.08 mm (0.082 in.)

Mark 1 2.1 mm (0.083 in.) When discolored Mark 2 2.2 mm (0.087 in.) When discolored Mark 3 2.3 mm (0.091 in.) When discolored Mark 4 2.4 mm (0.094 in.) When discolored Mark 5 2.5 mm (0.098 in.) When discolored Mark 6 2.6 mm (0.102 in.) When discolored Mark 7 2.7 mm (0.106 in.) When discolored Mark 8 2.8 mm (0.110 in.) When discolored Mark 9 2.9 mm (0.114 in.) When discolored

27.000 27.021 mm (1.063 1.064 in.) When worn or

−−

side ATF pump side 31.000 31.025 mm (1.220 1.221 in.)

Driven gear 0.070 0.125 mm (0.003 0.005 in.)

− − ―――

31.000 31.025 mm (1.220 1.221 in.) 31.05 mm (1.222 in.)

−−

− − ―――

−−

− − ―――

−−

29.000 29.021 mm (1.1417 1.1426 in.) 29.05 mm (1.1437 in.)

−−

22.984 23.000 mm (0.9049 0.9055 in.) When worn or

−−

39.975 39.991 mm (1.5738 1.5744 in.) When worn or

−−

− − ―――

−−

− − ―――

−−

damaged

When wornor damaged

damaged

(cont’d)

2-7

Page 23

Standards and Service Limits

Automatic Transmission and A/T Differential (cont’d)

Item Measurement Qualification Standard or New Service Limit

Countershaft Diameter at bearing contact area Torque converter

housing bearing

5th gear 34.975 34.991 mm (1.3770 1.3776 in.) When worn or damaged Diameter of 2nd gear at needle bearing contact area Reverse gear collar O.D. 39.979 40.000 mm (1.5740 1.5748 in.) When worn or damaged Reverse selector hub O.D. 55.885 55.900 mm (2.200 2.201 in.) When worn or damaged Cotter thickness 4th gear 1.99 2.02 mm (0.078 0.080 in.)

2nd gear 7.74 7.52 mm (0.295 0.296 in.) I.D. of gears 5th gear 41.000 41.016 mm (1.6142 1.6148 in.) When worn or damaged

Idler gear 70.000 70.019 mm (2.7559 2.7567 in.) When worn or damaged

Reverse gear 46.000 46.016 mm (1.8110 1.8116 in.) When worn or damaged Axial clearance of gears 2nd gear 0.005 0.040 mm (0.0002 0.0016 in.)

5th gear 0.12 0.27 mm (0.0047 0.0106 in.)

Idler gear 0.005 0.040 mm (0.0002 0.0016 in.)

Reverse gear 0.10 0.25 mm (0.0039 0.0098 in.) 61 mm washer thickness A 1.525 mm (0.0600 in.) When worn or damaged

B 1.505 mm (0.0593 in.) When worn or damaged

C 1.485 mm (0.0585 in.) When worn or damaged

D 1.465 mm (0.0577 in.) When worn or damaged

E 1.445 mm (0.0569 in.) When worn or damaged

F 1.425 mm (0.0561 in.) When worn or damaged

G 1.405 mm (0.0553 in.) When worn or damaged

50.8 mm washer thickness A 1.91 mm (0.0752 in.) When worn or damaged

B 1.93 mm (0.0760 in.) When worn or damaged

C 1.95 mm (0.0768 in.) When worn or damaged

D 1.97 mm (0.0776 in.) When worn or damaged

E 1.99 mm (0.0783 in.) When worn or damaged

F 2.01 mm (0.0791 in.) When worn or damaged

G 2.03 mm (0.0794 in.) When worn or damaged

H 2.05 mm (0.0807 in.) When worn or damaged

I 2.07 mm (0.0815 in.) When worn or damaged

J 2.09 mm (0.0823 in.) When worn or damaged

K 2.11 mm (0.0831 in.) When worn or damaged

L 2.13 mm (0.0839 in.) When worn or damaged

M 2.15 mm (0.0846 in.) When worn or damaged

N 2.17 mm (0.0854 in.) When worn or damaged

O 2.19 mm (0.0862 in.) When worn or damaged

P 2.21 mm (0.0870 in.) When worn or damaged

Q 2.23 mm (0.0878 in.) When worn or damaged

R 2.25 mm (0.0886 in.) When worn or damaged

S 2.27 mm (0.0894 in.) When worn or damaged

T 2.29 mm (0.0902 in.) When worn or damaged

U 2.31 mm (0.0909 in.) When worn or damaged

V 2.33 mm (0.0917 in.) When worn or damaged

W 2.35 mm (0.0925 in.) When worn or damaged

X 2.37 mm (0.0933 in.) When worn or damaged

Y 2.39 mm (0.0941 in.) When worn or damaged

Z 2.41 mm (0.0949 in.) When worn or damaged

AA 2.43 mm (0.0957 in.) When worn or damaged

AB 2.45 mm (0.0965 in.) When worn or damaged 35 x 47 mm thrust washer thickness

−−

40.505 40.515 mm (1.5947 1.5951 in.) When worn or damaged

−−

61.975 61.991 mm (2.2400 2.2406 in.) When worn or damaged

−−

− − ―――

−−

− − ―――

5.97 6.00 mm (0.2350 0.2362 in.) When worn or damaged

−−

2-8

Page 24

Item Measurement Qualification Standard or New Service Limit

Secondary shaft Diameter at bearing contact area 2nd gear 43.986 43.999 mm (1.7317 1.7322 in.) When worn or damaged

Torque converter

housing bearing

Torque converter

housing bearing

(shaft end side) Diameter of 1st gear collar at needle bearing contact area I.D. of gears 1st gear 44.000 44.013 mm (1.7323 1.7328 in.) When worn or damaged

2nd gear 50.00 50.02 mm (1.9685 1.9693 in.) When worn or damaged Axial clearance of gears 1st gear 0.100 0.130 mm (0.0039 0.0051 in.)

2nd gear 0.060 0.228 mm (0.0024 0.0090 in.) 52 mm thrust washer thickness M 2.405 mm (0.095 in.) When worn or damaged

L 2.430 mm (0.096 in.) When worn or damaged

K 2.455 mm (0.097 in.) When worn or damaged

J 2.480 mm (0.098 in.) When worn or damaged

I 2.505 mm (0.099 in.) When worn or damaged

H 2.530 mm (0.100 in.) When worn or damaged

G 2.555 mm (0.101 in.) When worn or damaged

F 2.580 mm (0.102 in.) When worn or damaged

E 2.605 mm (0.103 in.) When worn or damaged

D 2.630 mm (0.104 in.) When worn or damaged

C 2.655 mm (0.105 in.) When worn or damaged

B 2.680 mm (0.106 in.) When worn or damaged

A 2.705 mm (0.106 in.) When worn or damaged 1st gear collar length 63.3 63.4 mm (2.4921 2.4961 in.) Sealing ring thickness 1.91 1.97 mm (0.075 0.078 in.) 1.86 mm (0.073 in.) Sealing ring groove width 2.025 2.060 mm (0.080 0.081 in.) 2.08 mm (0.082 in.) ATF feed pipe O.D. 1st clutch 11.47 11.48 mm (0.4516 0.4520 in.) 11.45 mm (0.4508 in.)

1st-hold clutch 5.97 5.98 mm (0.2350 0.2354 in.) 5.95 mm (0.2343 in.) Feed pipe bushing I.D. 1st clutch 11.518 11.530 mm (0.4535 0.4539 in.) 11.545 mm (0.4545 in.)

1st-hold clutch 6.018 6.030 mm (0.2369 0.2374 in.) 6.045 mm (0.2380 in.)

−−

32.002 32.015 mm (1.2599 1.2604 in.) When worn or damaged

28.592 28.608 mm (1.1257 1.1263 in.) When worn or damaged

−−

38.975 38.991 mm (1.5344 1.5351 in.) When worn or damaged

−−

− − ―――

−−

(cont’d)

2-9

Page 25

Standards and Service Limits

Automatic Transmission and A/T Differential (cont’d)

Item Measurement Qualification Standard or New Service Limit

Secondary shaft (cont’d)

65 mm thrust shim thickness 0A 0.80 mm (0.031 in.) When worn or damaged

A 0.84 mm (0.033 in.) When worn or damaged

B 0.88 mm (0.035 in.) When worn or damaged

C 0.92 mm (0.036 in.) When worn or damaged

D 0.96 mm (0.038 in.) When worn or damaged

E 1.00 mm (0.039 in.) When worn or damaged

F 1.04 mm (0.041 in.) When worn or damaged

G 1.08 mm (0.043 in.) When worn or damaged

H 1.12 mm (0.044 in.) When worn or damaged

I 1.16 mm (0.046 in.) When worn or damaged

J 1.20 mm (0.047 in.) When worn or damaged

K 1.24 mm (0.049 in.) When worn or damaged

L 1.28 mm (0.050 in.) When worn or damaged

M 1.32 mm (0.052 in.) When worn or damaged

N 1.36 mm (0.054 in.) When worn or damaged

O 1.40 mm (0.055 in.) When worn or damaged

P 1.44 mm (0.057 in.) When worn or damaged

Q 1.48 mm (0.058 in.) When worn or damaged

R 1.52 mm (0.060 in.) When worn or damaged

S 1.56 mm (0.061 in.) When worn or damaged

T 1.60 mm (0.063 in.) When worn or damaged

U 1.64 mm (0.065 in.) When worn or damaged

V 1.68 mm (0.066 in.) When worn or damaged

W 1.72 mm (0.068 in.) When worn or damaged

X 1.76 mm (0.069 in.) When worn or damaged

Y 1.80 mm (0.071 in.) When worn or damaged

Z 1.84 mm (0.072 in.) When worn or damaged

AA 1.88 mm (0.074 in.) When worn or damaged

AB 1.92 mm (0.076 in.) When worn or damaged

AC 1.96 mm (0.077 in.) When worn or damaged

AD 2.00 mm (0.079 in.) When worn or damaged

AE 2.04 mm (0.080 in.) When worn or damaged

AF 2.08 mm (0.082 in.) When worn or damaged

AG 2.12 mm (0.083 in.) When worn or damaged

AH 2.16 mm (0.085 in.) When worn or damaged

AI 2.20 mm (0.087 in.) When worn or damaged

AJ 2.24 mm (0.088 in.) When worn or damaged

AK 2.28 mm (0.090 in.) When worn or damaged

AL 2.32 mm (0.091 in.) When worn or damaged

2-10

Page 26

Item Measurement Qualification Standard or New Service Limit

Intermediary shaft

Reverse idler gear

I.D. of 3rd gear 36.000 36.016 mm (1.4173 1.4179 in.) When worn or damaged Axial clearance of 3rd gear 0.005 0.045 mm (0.0002 0.0018 in.) Cotter thickness 2.99 3.02 mm (0.1177 0.1189 in.) Sealing ring thickness 1.89 1.95 mm (0.0744 0.0768 in.) 1.84 mm (0.0724 in.) Sealing ring groove width 2.025 2.060 mm (0.080 0.081 in.) 2.08 mm (0.082 in.) 53 mm splined washer thickness A 3.995 mm (0.1573 in.) When worn or damaged

B 4.015 mm (0.1581 in.) When worn or damaged

C 4.035 mm (0.1589 in.) When worn or damaged

D 4.055 mm (0.1596 in.) When worn or damaged

E 4.075 mm (0.1604 in.) When worn or damaged

F 4.095 mm (0.1612 in.) When worn or damaged

G 4.115 mm (0.1620 in.) When worn or damaged

H 4.135 mm (0.1628 in.) When worn or damaged

I 4.155 mm (0.1636 in.) When worn or damaged

J 4.175 mm (0.1644 in.) When worn or damaged

K 4.195 mm (0.1652 in.) When worn or damaged

L 4.215 mm (0.1659 in.) When worn or damaged

M 4.235 mm (0.1667 in.) When worn or damaged

N 4.255 mm (0.1675 in.) When worn or damaged

26.5 mm washer thickness A 1.05 mm (0.041 in.) When worn or damaged

B 1.13 mm (0.044 in.) When worn or damaged

C 1.21 mm (0.048 in.) When worn or damaged

D 1.29 mm (0.051 in.) When worn or damaged

E 1.37 mm (0.054 in.) When worn or damaged

F 1.45 mm (0.057 in.) When worn or damaged

G 1.53 mm (0.060 in.) When worn or damaged

H 1.61 mm (0.063 in.) When worn or damaged

I 1.69 mm (0.067 in.) When worn or damaged

J 1.77 mm (0.070 in.) When worn or damaged

K 1.85 mm (0.073 in.) When worn or damaged

L 1.93 mm (0.076 in.) When worn or damaged

M 2.01 mm (0.079 in.) When worn or damaged

N 2.09 mm (0.082 in.) When worn or damaged Gear shaft O.D. 13.99 14.00 mm (0.5508 0.5512 in.) When worn or damaged I.D. of transmission housing of gear shaft contact area I.D. 18.007 18.020 mm (0.7089 0.7094 in.) When worn or damaged Axial clearance 0.07 0.38 mm (0.003 0.015 in.) Thrust washer thickness Transmission

housing

Holder side 0.97 1.05 mm (0.038 0.041 in.)

−−

− − ―――

−−

14.006 14.024 mm (0.5514 0.5521 in.)

− − ―――

−−

− − ―――

0.97 1.05 mm (0.038 0.041 in.)

− − ―――

(cont’d)

2-11

Page 27

Standards and Service Limits

Automatic Transmission and A/T Differential (cont’d)

Item Measurement Qualification Standard or New

Wire Diameter O.D. Free Length No. of Coil

Main valve body spring (see page 14-307)

Secondary valve body spring (see page 14-309)

Regulator valve body spring (see page 14-310)

Cooler check valve spring 0.6 mm

(0.024 in.)

Lock-up timing valve spring 0.65 mm

(0.026 in.)

Shift valve D spring 0.7 mm

(0.028 in.)

Shift valve B spring 0.8 mm

(0.031 in.)

Shift valve A spring 0.8 mm

(0.031 in.)

Modulator valve spring 1.6 mm

(0.063 in.)

CPC valve C spring 0.7 mm

(0.028 in.)

Shift valve E spring 0.8 mm

(0.031 in.)

Torque converter check valve spring 1.1 mm

(0.043 in.)

Relief valve spring 1.1 mm

(0.043 in.)

Lubrication control valve spring 0.7 mm

(0.028 in.)

Lock-up shift valve spring 0.9 mm

(0.035 in.)

Reverse CPC valve spring 0.7 mm

(0.028 in.)

Servo control valve spring 0.7 mm

(0.028 in.)

Shift valve C spring 0.8 mm

(0.031 in.)

CPC valve A spring 0.7 mm

(0.028 in.)

Kick-down valve spring 0.8 mm

(0.031 in.)

CPC valve B spring 0.7 mm

(0.028 in.)

3rd accumulator spring 3.1 mm

(0.122 in.)

Lock-up control valve spring 0.7 mm

(0.028 in.)

0.8 mm (0.031 in.)

Regulator valve spring B 1.4 mm

(0.055 in.)

Regulator valve spring A 1.85 mm

(0.073 in.)

Stator reaction spring 5.5 mm

(0.217 in.)

5.8 mm (0.228 in.)

6.6 mm (0.260 in.)

10.4 mm (0.409 in.)

6.1 mm (0.240 in.)

7.1 mm (0.280 in.)

8.6 mm (0.339 in.)

7.7 mm (0.303 in.)

7.6 mm (0.299 in.)

6.1 mm (0.240 in.)

6.6 mm (0.260 in.)

6.1 mm (0.240 in.)

6.6 mm (0.260 in.)

6.1 mm (0.240 in.)

19.6 mm (0.772 in.)

6.6 mm (0.260 in.)

8.8 mm (0.346 in.)

14.7 mm (0.579 in.)

37.4 mm (1.472 in.)

14.5 mm (0.571 in.)

34.8 mm (1.370 in.)

32.2 mm (1.268 in.)

49.1 mm (1.933 in.)

33.5 mm (1.319 in.)

17.8 mm (0.701 in.)

49.0 mm (1.929 in.)

35.0 mm (1.378 in.)

32.1 mm (1.264 in.)

28.8 mm (1.134 in.)

63.0 mm (2.480 in.)

17.8 mm (0.701 in.)

35.7 mm (1.406 in.)

49.1 mm (1.933 in.)

17.8 mm (0.701 in.)

49.1 mm (1.933 in.)

17.8 mm (0.701 in.)

41.4 mm (1.630 in.)

42.9 mm (1.689 in.)

44.3 mm (1.744 in.)

44.0 mm (1.732 in.)

86.9 mm (3.421 in.)

30.3 mm (1.193 in.)

6.8

15.6

13.4

21.7

9.8

7.9

17.2

12.6

11.2

10.4

22.4

7.9

17.2

21.7

7.9

21.7

7.9

5.5

14.2

25.5

12.0

16.2

2.1

2-12

Page 28

Item Measurement Qualification Standard or New

Wire Diameter O.D. Free Length No. of Coil

Accumulator body spring (see page 14-311)

Item Measurement Qualification Standard or New Service Limit

A/T differential carrier

A/T differential pinion gear

1st-hold accumulator spring 2.0 mm

(0.079 in.)

4th accumulator spring 3.0 mm

(0.118 in.)

1st accumulator spring A 2.2 mm

(0.087 in.)

1st accumulator spring B 2.0 mm

(0.079 in.)

2nd accumulator spring 3.1 mm

(0.122 in.)

5th accumulator spring A 2.2 mm

(0.087 in.)

5th accumulator spring B 2.0 mm

(0.079 in.)

Pinion shaft contact area I.D. 18.000 18.025 mm (0.7087 0.7096 in.) Carrier-to-pinion shaft clearance 0.013 0.054 mm (0.0005 0.0021 in.) 0.1 mm (0.004 in.) Driveshaft contact area I.D. 30.025 30.055 mm (1.182 1.183 in.) Carrier-to-driveshaft clearance 0.045 0.096 mm (0.002 0.004 in.) 0.13 mm (0.005 in.) Carrier-to-intermediate shaft clearance 0.080 0.126 mm (0.003 0.005 in.) Tapered roller bearing starting torque (preload)

Backlash 0.05 0.15 mm (0.002 0.006 in.) I.D. 18.042 18.066 mm (0.7103 0.7113 in.) Pinion gear-to-pinion shaft clearance 0.055 0.095 mm (0.0022 0.0037 in.) 0.12 mm (0.005 in.)

For new bearing 3.9 5.1 N·m

For used bearing 3.6 4.8 N·m

− − ―――

−−

− − ―――

−−

− − ―――

−

(40 52 kgf·cm, 35 45 lbf·in.)

−−

−

−−

(37 49 kgf·cm, 32 43 lbf·in.)

− − ―――

−−

13.1 mm (0.516 in.)

19.6 mm (0.772 in.)

17.7 mm (0.697 in.)

11.1 mm (0.437 in.)

19.6 mm (0.772 in.)

16.4 mm (0.646 in.)

10.0 mm (0.394 in.)

42.9 mm (1.689 in.)

45.3 mm (1.783 in.)

77.6 mm (3.055 in.)

49.0 mm (1.929 in.)

53.4 mm (2.102 in.)

75.7 mm (2.980 in.)

45.5 mm (1.791 in.)

Adjust

9.8

6.4

12.1

10.0

7.5

14.2

11.6

(cont’d)

2-13

Page 29

Standards and Service Limits

Automatic Transmission and A/T Differential (cont’d)

Item Measurement Qualification Standard or New Service Limit

Transfer output shaft

Transfer assembly fluid Transfer assembly

Diameter at bearing contact area Transmission

housing side

Torque converter

housing side Axial clearance 0 0.39 mm (0 0.015 in.)

28.5 mm thrust washer thickness A 1.82 mm (0.0717 in.) When worn or damaged

B 1.84 mm (0.0724 in.) When worn or damaged

C 1.86 mm (0.0732 in.) When worn or damaged

D 1.88 mm (0.0740 in.) When worn or damaged

E 1.90 mm (0.0748 in.) When worn or damaged

F 1.92 mm (0.0756 in.) When worn or damaged

G 1.94 mm (0.0764 in.) When worn or damaged

H 1.96 mm (0.0772 in.) When worn or damaged

I 1.98 mm (0.0780 in.) When worn or damaged

J 2.00 mm (0.0787 in.) When worn or damaged

K 2.02 mm (0.0795 in.) When worn or damaged

L 2.04 mm (0.0803 in.) When worn or damaged

M 2.06 mm (0.0811 in.) When worn or damaged

N 2.08 mm (0.0819 in.) When worn or damaged

O 2.10 mm (0.0827 in.) When worn or damaged

P 2.12 mm (0.0835 in.) When worn or damaged

Q 2.14 mm (0.0843 in.) When worn or damaged

R 2.16 mm (0.0850 in.) When worn or damaged

S 2.18 mm (0.0858 in.) When worn or damaged

T 2.20 mm (0.0866 in.) When worn or damaged

U 2.22 mm (0.0874 in.) When worn or damaged

V 2.24 mm (0.0882 in.) When worn or damaged

W 2.26 mm (0.0890 in.) When worn or damaged

X 2.28 mm (0.0898 in.) When worn or damaged

Y 2.30 mm (0.0906 in.) When worn or damaged

Z 2.32 mm (0.0913 in.) When worn or damaged

AA 2.34 mm (0.0921 in.) When worn or damaged Capacity Fluid change 0.43 L (0.45 us qt)

Overhaul 0.45 L (0.48 us qt) Diameter of transfer hypoid drive gear/shaft assembly at tapered roller bearing contact area

Diameter of transfer output shaft (hypoid gear) at tapered roller bearing contact area

Transfer gear backlash 0.06 0.17 mm (0.002 0.007 in.) Adjust Tapered roller bearing total starting torque (preload)

Transfer cover

side

Transfer gear

side

Transfer gear

side

Companion

flange side

−−

21.977 21.990 mm (0.8652 0.8657 in.) 21.92 mm (0.8630 in.)

−−

40.002 40.018 mm (1.5749 1.5755 in.) 39.95 mm (1.5728 in.)

− − ―――

50.002 50.018 mm (1.9686 1.9692 in.) 49.95 mm (1.9665 in.)

−−

24.987 25.000 mm (0.9837 0.9843 in.) 24.93 mm (0.9815 in.)

−−

40.002 40.018 mm (1.5749 1.5755 in.) 39.95 mm (1.5728 in.)

−−

27.975 27.990 mm (1.1014 1.1020 in.) 27.92 mm (1.0992 in.)

−−

3.20 4.16 N·m

−

(32.6 42.4 kgf·cm, 28.3 36.8 lbf·in.)

−−

Adjust

2-14

Page 30

Rear Differential

Item Measurement Qualification Standard or New

Rear differential fluid

Capacity Use Honda VTM-4 Differential Fluid

Fluid replacement

2.64 L (2.79 US qt)

Steering

Item Measurement Qualification Standard or New

Steering wheel Rotational play measured at outside

edge Starting load measured at outside edge

Gearbox Angle of rack guide screw loosened

from locked position

Pump Output pressure with shut-off valve

closed

Power steering fluid

Capacity Use Honda Power Steering Fluid

With engine running With engine running

System overhaul 1.15 L (1.22 US qt) Reservoir capacity

010mm(00.39in.)

−−

29 N (3.0 kgf, 6.6 lbf)

20 ° max.

−− −

8,850 9,350 kPa (90 95 kgf/cm , 1,280 1,350 psi)

0.34 L (0.36 US qt)

Suspension

Item Measurement Qualification Standard or New Service Limit

Wheel alignment Camber Front 0 ° 30 ’ 1 °

Rear 0 ° 30 ’ 45 ’ Camber (Maximum difference left to right) Caster Front 1 ° 53 ’ 1 ° Total toe-in Front 0 2 mm (0 0.08 in.)

Front wheel turning angle Inward wheel 37 ° 54 ’ 2 °

Wheel Aluminum wheel runout Axial 0 0.7 mm (0 0.03 in.) 2.0 mm (0.08 in.)

Steel wheel runout Axial 0 1.0 mm (0 0.04 in.) 2.0 mm (0.08 in.)

Wheel bearing End play Front 0 0.05 mm (0 0.002 in.)

Tire Front and rear size P245/65R17 105S

Spare tire size T165/90R17 105M Pressure Front/Rear 220 kPa (2.2 kgf/cm , 32 psi)

Front 1 ° 00 ’

Rear 0 2 mm (0 0.08 in.)

Outward wheel 30 ° 16 ’ (reference)

Radial 0 0.7 mm (0 0.03 in.) 1.5 mm (0.06 in.)

Radial 0 1.0 mm (0 0.04 in.) 1.5 mm (0.06 in.)

Rear 0 0.05 mm (0 0.002 in.)

Spare 420 kPa (4.3 kgf/cm , 60 psi)

−±

± ±± ±±

−−

2-15

Page 31

Standards and Service Limits

Brakes

Item Measurement Qualification Standard or New Service Limit

Parking brake Distance traveled when pedal pressed

with 294 N (30 kgf, 66 lbf) of force Shoe lining thickness 3.6 4.3 mm (0.14 0.17 in.) 1.0 mm (0.04 in.) Drum I.D. 209.9 210.0 mm (8.264 8.268 in.) 211.0 mm (8.307 in.)

Brake pedal Pedal height (carpet removed) 155 mm (6 1/8 in.)

Free play 1 5 mm (1/16 3/16 in.)

Brake disc Thickness Front 27.9 28.1 mm (1.10 1.11 in.) 26.0 mm (1.02 in.)

Rear 10.9 11.1 mm (0.43 0.44 in.) 9.0 mm (0.35 in.) Runout Front and rear 0.04 mm (0.0016 in.) Parallelism Front and rear 0.015 mm (0.0006 in.)

Brake pad Thickness Front 11.6 12.2 mm (0.46 0.48 in.) 1.0 mm (0.04 in.)

Rear 9.6 10.4 mm (0.38 0.41 in.) 1.0 mm (0.04 in.)

Air Conditioning

Item Measurement Qualification Standard or New

Refrigerant Type HFC-134a (R-134a)

Capacity of system Dual 600 650 g (20.3 22.0 oz)

Refrigerant oil Type DENSO ND-OIL 8 (P/N 38897-PR7-A01AH or 38899-PR7-A01)

Capacity of components Condenser 45 mL (1 1/2 fl·oz)

Evaporator 45 mL (1 1/2 fl·oz)

Each line and

hose

Compressor 180 195 mL (6 6 1/2 fl·oz)

Compressor Field coil resistance At 68 °F (20 °C) 3.9 4.3

Pulley-to-pressure plate clearance 0.35 0.60 mm (0.014 0.024 in.)

10 to 12 clicks

−−

−− ――― ―――

−−

10 mL (1/3 fl·oz)

−−

−

−−

2-16

Page 32

Design Specifications

Item Measurement Qualification Specification

DIMENSIONS Overall length 5,251 mm (206.7 in.)

Overall width 1,976 mm (77.8 in.) Overall height 1,785 mm (70.3 in.) Wheelbase 3,100 mm (122.0 in.) Track Front 1,705 mm (67.1 in.)

Rear 1,700 mm (66.9 in.) Ground clearance 208 mm (8.2 in.) Seating capacity Five (5)

WEIGHT Gross Vehicle Weight Rating

(GVWR)

ENGINE Type Water-cooled, 4-stroke SOHC VTEC V6 gasoline engine

Cylinder arrangement 60 ° V6-cylinder, transverse Bore and stroke 89.0 x 93.0 mm (3.50 x 3.66 in.) Displacement 3,471 cm (mL) (222 cu in.) Compression ratio 10.0 Valve train Belt driven, SOHC VTEC 4 valves per cylinder Ignition system DLI (Distributorless Ignition) Lubrication system Forced, wet sump, with trochoid pump Oil pump displacement At 6,000 rpm 48.9 L (51.7 US qt)/minute Water pump displacement At 6,000 rpm 176 L (186 US qt)/minute Fuel required Normal driving Unleaded gasoline with 86 Pump Octane Number or

Towing Towing performance can be affected by high altitude,

STARTER Type Gear reduction

Normal output 1.6 kW Nominal voltage 12 V Hour rating 30 seconds Direction of rotation Clockwise as viewed from gear end

2,745 kg (6,050 lbs)

higher

high temperature, or when climbing steep grades. Therefore, premium fuel is recommended when towing more than 1,590 kg (3,500 lbs).

(cont’d)

2-17

Page 33

Design Specifications

Item Measurement Qualification Specification

AUTOMATIC TRANSMISSION

STEERING Type Hydraulic power-assisted rack and pinion

SUSPENSION Type Front Strut with ‘‘L’’ (lower) arm

WHEEL ALIGNMENT

BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc

TIRES Size of front and rear tires P245/65R17 105S

AIR CONDITIONING

Type BJFA Electronically-controlled automatic, 5-speed forward, 1

reverse Primary reduction Direct 1:1 Gear ratio 1st 2.693

2nd 1.565 3rd 1.023 4th 0.729 5th 0.530 Reverse 1.888

Final reduction Type Single helical gear

Gear ratio 4.533

Gear ratio 42.3 Overall ratio 17.9 Turns, lock-to-lock 3.38 Steering wheel diameter 390 mm (15.4 in.)

Rear Multi-link with trailing arm

Shock absorber Front Twin tube gas

Rear Twin tube gas

Camber Front 0 ° 30 ’

Rear 0 ° 30 ’ Camber (Max difference left to right) Caster Front 1 ° 53 ’ Total toe Front 0 mm (0 in.)

Front wheel turning angle Inside wheel 37 ° 54 ’

SAI at camber (kingpin axis) 12 ° 24 ’

Type of parking brake Foot type mechanical actuating, rear wheels Pad friction surface area (swept area) Parking brake shoe friction surface area

Size of spare tire T165/90R17 105M Tire pressure Front/Rear 220 kPa (2.2 kgf/cm , 32 psi)

Cooling capacity Front 4,375 Kcal/h (17,300 BTU/h)

Compressor Type/Manufacturer Swash plate/DENSO

Condenser Type Corrugated fin Evaporator Type Corrugated fin

Front 1 ° 00 ’

Rear 0mm(0in.)

Outside wheel 30 ° 16 ’

Rear Power-assisted self-adjusting solid disc

Front 59.2 cm (9.18 sq in.) x 2

Rear 34.4 cm (5.33 sq in.) x 2

Spare 420 kPa (4.3 kgf/cm , 61 psi)

Rear 3,119 Kcal/h (12,400 BTU/h)

Number of cylinders 10

Capacity 214.7 mL/rev. (13.09 cu in./rev.)

Maximum speed 7,600 rpm

Lubricant capacity 180 mL (6 fl·oz)

Lubricant type DENSO ND-OIL 8

−

60.2 cm (9.33 sq in.) x 2

2-18

Page 34

Item Measurement Qualification Specification

AIR CONDITIONING (cont’d)

ELECTRICAL RATINGS

Blower Type Sirocco fan

Motor input (Front) 228 W/12 V

Speed control (Front) Infinite variable

Maximum capacity (Front) 490 m /h (17,300 cu ft/h) Temperature control Air-mix type Compressor clutch Type Dry, single plate, Poly-V belt drive

Electrical power

consumption at 68 °F

(20 °C) Refrigerant Type HFC-134a (R-134a)

Quantity (Dual) 600 650 g (20 22 fl·oz) Battery 12 V 72 Ah/20 HR (12 V 60 Ah/5 HR) Fuses Under-hood fuse/relay box 120 A, 50 A, 40 A, 30 A, 20 A, 15 A, 10 A, 7.5 A

Under-dash fuse/relay box 30 A, 20 A, 15 A, 10 A, 7.5 A

Auxiliary under-hood relay

box Light bulbs Headlight high beam 12 V 60 W

Headlight low beam 12 V 55 W

Front turn signal/front side

marker lights

Rear turn signal lights 12 V 21 W

Brake/taillights 12 V 21/5 W (two filaments)

High mount brake light 12 V 3 CP

Back-up lights 12 V 18 W

Cargoarealights 12V 3CP

License plate light 12 V 3 CP

Ceiling light 12 V 5 W

Maplights 12V 8W

Console box light 1 12 V 3.8 W

Console box light 2 12 V 1.4 W

Door courtesy lights 12 V 3.8 W

Glove box light 12 V 3.4 W

Vanity mirror light 12 V 2 W

Gauge lights 12 V LED (non-replaceable)

Indicator, panel, ambient

light Clock non-navigation system equipped vehicles

Washer reservoir Capacity 4.5 L (4.7 US qt)

Clock standard daily

difference

Electrical characteristics 2.0 seconds per day or less

Temperature characteristics 20 0 degrees C 4.0 seconds per day or less

35 W maximum at 12 V

−−

40 A, 20 A, 15 A, 7.5 A

−

12 V 28/8 W (two filaments)

−

Amber color

−

Amber color

−

12 V LED, 14 V 0.56 W, 0.84 W

−−

2.0 seconds per day or less

−− ±

0 40 degrees C 2.0 seconds per day or less

−±

40 60 degrees C 4.0 seconds per day or less

−±

2-19

Page 35

Design Specifications

Body Specifications

1,785 mm (70.3 in.)

1,705 mm (67.1 in.) 1,976 mm (77.8 in.)

2-20

3,100 mm (122.0 in.) 5,251 mm (206.7 in.)

1,700 mm (66.9 in.)

Page 36

Maintenance

............................................................................Lubricants and Fluids . 3-2

Maintenance Minder

....................................................

General Information . 3-4 Maintenance Main Items . 3-7 Maintenance Sub Items . 3-8

....................................................

............................................

..............................................

Page 37

Lubricants and Fluids

For details of the lubrication points and type of lubricants to be applied, refer to the illustrated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

Lubrication Points Lubricant

A Engine Honda Motor Oil: American Honda P/N 08798-9023,

Honda Canada P/N CA66806 Use 5W-20 motor oil. Look for the API certification seal on the oil container as shown below. Make sure it says ‘‘For Gasoline Engines.’’ SAE Viscosity: See chart.

B Automatic transmission Honda Automatic Transmission Fluid (ATF-Z1):

American Honda P/N 08200-9001, Honda Canada P/N CA66689 Always use Honda ATF-Z1. Using a non-Honda ATF can affect shift quality.

C Transfer assembly Hypoid gear oil GL4 or GL5

Use a SAE 90 or SAE 80W-90 viscosity hypoid gear oil, API classified GL4 or GL5 only Viscosity SAE 90: above 0 °F ( 18 °C)

SAE 80W-90: below 0 °F ( 18 °C)

D Rear differential Honda VTM-4 Differential Fluid: P/N 08200-9003

E Brake system (including VSA lines) Honda DOT 3 Brake Fluid: P/N 08798-9008

Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system.

Brake booster clevis pin

Battery terminals

Pedal linkage

Fuel fill door

Hood hinges and hood latch

Tailgate hinges

Sparetiretraybolt

L M Caliper piston boot, caliper pins, and boots Honda Caliper Grease: P/N 08C30-B0234M N Rear brake shoe linkage Molykote Grease 44MA O Power steering system Honda Power Steering Fluid: P/N 08206-9002

P Air conditioning compressor Compressor Oil: DENSO ND-OIL 8 (P/N 38897-PR7-A01) for

Q Cooling system Honda Long Life Antifreeze/Coolant Type 2: P/N OL

Multipurpose Grease

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.

refrigerant HFC-134a (R-134a)

999-9001

−

3-2

API CERTIFICATION SEAL

Recommended Engine Oil

Engine oil viscosity for ambient temperature ranges

Page 38

NOTE:

• Lubricate all hinges, latches, and locks once a year.

• In corrosive areas, more frequent lubrication is necessary.

3-3

Page 39

Maintenance Minder

General Information

Maintenance Display

The maintenance minder is an important feature of the information display. Based on engine operating conditions and accumulated engine revolutions, the Ridgeline’s onboard computer (PCM) calculates the remaining engine oil life. The system also displays the code for other scheduled maintenance items needing service.

INFORMATION DISPLAY

MAINTENANCE MINDER INDICATOR

3-4

Page 40

Service Information

1. The remaining engine oil life is displayed (A) as a percentage on the information display. To see the current engine oil life, turn the ignition switch to ON (II), then push and release the SELECT button repeatedly until the engine oil life is displayed.

2. When the remaining engine oil life is at 15 percent or less, the maintenance message ‘‘SERVICE DUE SOON,’’ along with the maintenance items currently requiring service are displayed. The service message alternates between SERVICE and DUE SOON repeatedly.

3. When the remaining oil life is less than 5 percent, the maintenance message ‘‘SERVICE DUE NOW,’’ along with the items shown in ‘‘SERVICE DUE SOON’’ display. At this point, the indicated maintenance must be performed as soon as possible. The service message alternates between SERVICE and DUE NOW repeatedly.

4. When the remaining oil life is 0 percent, the display shows a ‘‘SERVICE PAST DUE’’ message. The service message alternates between SERVICE and PAST DUE repeatedly.

• Complete list of maintenance main items ‘‘A’’ (see page 3-7).

• Complete list of maintenance sub items ‘‘B’’ (see page 3-8).

NEGATIVE MILEAGE

5. If the indicated maintenance is not performed the display shows ‘‘SERVICE DUE NOW’’ message, then the display will show negative mileage for example ‘‘34MI.’’ This means that the indicated maintenance item should have been performed 34 miles ago.

(cont’d)

3-5

Page 41

Maintenance Minder

General Information (cont’d)

Resetting the Engine Oil Life Indicator

1. Turn the ignition switch to ON (II).

2. Press the SELECT button repeatedly until the oil life is displayed (if oil life is more than 15 %) or the maintenance message is displayed (if oil life is less than 15 %).

3. Press the RESET button for about 10 seconds. You will see a service message to reset the maintenance item code(s) ‘‘MAINT RESET.’’

NOTE: If you are resetting the display when the oil life is more than 15 %, or if the maintenance message ‘‘SERVICE DUE SOON’’ is displayed, make sure the maintenance items requiring service have been performed before resetting this display.

4. Select the appropriate answer, ‘‘MAINT RESET N’’ (NO) or ‘‘MAINT RESET Y’’ (YES) by pressing the SELECT button repeatedly. ‘‘ N’’ or ‘‘ Y’’ is displayed on the outside temperature display.

5. Select the ‘‘MAINT RESET Y’’ (YES) and press the RESET button again to reset the engine oil life to ‘‘100.’’

＞

＞＞

＞

NOTE:

• If the required service is performed and the display is not reset, or if the display is reset without performing the service, the system will not show the proper maintenance levels. This can lead to serious mechanical problems because there will be no record of when maintenance is needed.

• The engine oil life and the maintenance items may be reset independently only with the HDS.

＞

3-6

Page 42

Maintenance Main Items

If the message ‘‘SERVICE DUE NOW’’ does not appear more than 12 months after the display is reset, change the engine oil every year.

NOTE:

•

Independent of the maintenance messages in the information display, replace the brake fluid every 3 years.

•

Inspect idle speed every 160,000 miles (256,000 km).

•

Adjust the valves during services A, B, 1, 2, or 3, only if they are noisy.

Symbol Maintenance Main Items

A Replace engine oil (see page 8-6).

Engine oil capacity without oil filter: 4.0 L (4.2 US qt).

B Replace engine oil and oil filter (see page 8-7).

Engine oil capacity with oil filter: 4.3 L (4.5 US qt).

Check front and rear brakes (see page 19-4).

Check pads and discs for wear (thickness), damage, and cracks.

• Check calipers for damage, leaks, and tightness of mounting bolts.

•

Check parking brake adjustment (see page 19-7).

Check the number of clicks (10 to 12) when the parking brake pedal is pressed with 294 N (30 kgf, 66 lbf) of force.

Inspect tie-rod ends, steering gearbox, and gearbox boots (see page 17-8).

Check rack grease and steering linkage.

• Check boots for damage and leaking grease.

• Check fluid lines for damage or leaks.

•

Inspect suspension components (see page 18-3).

Check bolts for tightness.

• Check condition of ball joint boots for deterioration and damage.

•

Inspect driveshaft boots (see page 16-4).

Check boots for cracks and boot bands for tightness.

Inspect brake hoses and lines including VSA (see page 19-33).

Check the master cylinder and VSA modulator-control unit for damage and leakage.

Inspect all fluid levels and condition of fluids.

Engine coolant (see page 10-6).

• Automatic transmission fluid (ATF) (see page 14-209).

• VTM-4 rear differential fluid (Honda VTM-4 Differential Fluid) (see page 15-47).

• Power steering fluid (see page 17-12).

• Brake fluid (see page 19-9).

• Windshield washer fluid.

•

Inspect exhaust system (see page 9-7) .

Check catalytic converter heat shields, exhaust pipes, and muffler for damage, leaks, and tightness.

Inspect fuel lines (see page 11-290) and connections (see page 11-292) .

Check for loose connections, cracks, and deterioration; retighten loose connections and replace damaged parts.

NOTE: According to state and federal regulations, failure to do the maintenance items marked with an asterisk ( ) will not void the customer’s emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval, to ensure long-term reliability.

3-7

Page 43

Maintenance Minder

Maintenance Sub Items

Number Maintenance Sub Items

1 Rotate tires, and check tire inflation and condition.

Follow the pattern shown in the Owner’s Manual.

2 Replace air cleaner element (see page 11-315).

If the vehicle is regularly driven in dusty conditions, replace the element every 15,000 miles (24,000 km).

Replace dust and pollen filter (see page 21-58).

If the vehicle is driven mostly in areas that have high concentrations of dust, pollen, or

•

the air, replace every 15,000 miles (24,000km).

Replace the filter whenever airflow from the heating and air conditioning control system is less than

• normal.

Inspect drive belt (see page 4-31).

Look for cracks and damage, then check the position of the drive belt auto-tensioner indicator.

3 Replace automatic transmission (see page 14-210) and transfer (see page 14-211) fluid.

Driving in mountainous areas at very low vehicle speeds or trailer towing results in higher

• transmission and transfer fluid temperatures. This requires transmission fluid changes more frequently than recommended by the Maintenance Minder. If the vehicle is regularly driven in these conditions, replace the transmission and transfer fluid every 30,000 miles (48,000 km). Automatic transmission fluid capacity: 3.1 L (3.3 US qt), use Honda automatic transmission fluid

• (ATF-Z1). Transfer fluid capacity: 0.43 L (0.45 US qt), use hypoid gear oil GL4 or GL5.

•

4 Replace spark plugs (see page 4-22).

Use IZFR5K11 (NGK) or SKJ16DR-M11 (DENSO).

Replace timing belt (see page 6-20). If the vehicle is regularly driven in very high temperatures (over 110 °F, 43 °C), or in very low temperatures (under 20 °F, 29 °C), or towing a trailer, replace every 60,000 miles (USA models)/100,000 km (Canada models) and inspect water pump (see page 10-5). Inspect the valve clearance (cold) (see page 6-8). Intake: 0.20 0.24 mm (0.008 0.009 in.), Exhaust:

0.28 0.32 mm (0.011 0.013 in.).

−−

5 Replace engine coolant (see page 10-6).

Capacity (including the reservoir tank): 6.2 L (1.64 US gal), use Honda Long Life Antifreeze/Coolant Type 2.

6 Replace VTM-4 rear differential fluid (see page 15-47).

•

Driving in mountainous areas at very low speeds, towing a trailer, or frequently driving fully loaded results in a higher level of mechanical (shear) stress to fluid. This requires differential fluid changes more frequently than recommended by the Maintenance Minder. If you regularly drive your vehicle under these conditions, have the differential fluid changed at 7,500 miles (12,000 km), then every 15,000 miles (24,000 km). Capacity: 2.64 L (2.79 US qt), use Honda VTM-4 Differential Fluid.

•

−−

soot in

−−

3-8

Page 44

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If engine electrical maintenance is required)

• Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags.

Page 45

Engine Electrical

......................................................Special Tools . 4-2

Starting System

Component Location Index . 4-3 Symptom Troubleshooting

Index . 4-4 Circuit Diagram . 4-5 Starter System Circuit

Troubleshooting . 4-6 Starter Solenoid Test . 4-8 Starter Performance Test . 4-9 Starter Removal and

Installation . 4-10 Starter Overhaul . 4-11

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Ignition System

Component Location Index . 4-16 Circuit Diagram . 4-17 Ignition Timing Inspection . 4-18 Ignition Coil Removal/

Installation . 4-19 Ignition Coil Relay Circuit

Troubleshooting . 4-20 Spark Plug Inspection . 4-22

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Charging System

Component Location Index . 4-23 Symptom Troubleshooting

Index . 4-24 Circuit Diagram . 4-25 Charging System Indicator

Circuit Troubleshooting . 4-26 Alternator and Regulator

Circuit Troubleshooting . 4-28 Alternator Control

Circuit Troubleshooting . 4-29 Drive Belt Inspection . 4-31 Drive Belt Replacement . 4-31 Drive Belt Auto-tensioner

Inspection . 4-32 Drive Belt Auto-tensioner

Replacement . 4-33 Tensioner Pulley

Replacement . 4-33 Alternator Removal and

Installation . 4-34 Alternator Overhaul . 4-36

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Cruise Control

Component Location Index . 4-40 Symptom Troubleshooting

Index . 4-41 Circuit Diagram . 4-43 Cruise Control Input Test . 4-44 Cruise Control Main Switch

Test/Replacement . 4-46 Cruise Control Set/decel,

Resume/accel, Cancel

Switch Test/Replacement . 4-46

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Page 46

Engine Electrical

Special Tools

Ref. No. Tool Number Description Qty

07746-0010300 Attachment, 42 x 47 mm 1 07749-0010000 Driver 1

4-2

Page 47

Starting System

Component Location Index

UNDER-DASH FUSE/RELAY BOX

STARTER

Starter System Circuit Troubleshooting, page 4-6 Solenoid Test, page 4-8 Performance Test, page 4-9 Removal and Installation, page 4-10 Overhaul, page 4-11

STARTER CUT RELAY

Test, page 22-75

BATTERY

Test, page 22-74

TRANSMISSION RANGE SWITCH

Test, page 14-272 Replacement, page 14-273

4-3

Page 48

Starting System

Symptom Troubleshooting Index

Symptom Diagnostic procedure Also check for

Engine does not start (does not crank)

Engine cranks, but does not start

Engine is hard to start 1.

Engine cranks slowly 1.

Check for loose battery terminals or connections.

1. Test the battery for a low charge (see page 22-74).

2. Check the starter (see page 4-6).

3. Check the starter cut relay (see page 22-75).

4. Check the transmission range switch (see page 14-272).

5. Check the ignition switch or wire (see page 22-77).

6. Check for PGM-FI DTCs.

1. Check the fuel pressure (see page 11-288).

2. Check for a plugged or damaged fuel line (see page

3. 11-290). Check for a plugged fuel filter (see page 11-299).

4. Check the throttle body (see page 11-314).

5. Check for low engine compression (see page 6-6).

6. Check for a damaged or broken timing belt.

7. Check for PGM-FI DTCs. Check the fuel pressure (see page 11-288).

2. Check for a plugged or damaged fuel line (see page

3. 11-290). Check for a plugged fuel filter (see page 11-299).

4. Check for loose battery terminals or connections. Test the battery for a low charge (see page 22-74).

2. Check the starter for binding (see page 4-11).

3. Check for excessive drag in the engine.

Poor ground at G101, G102

Fuel level in tank

4-4

Page 49

Circuit Diagram

BATTERY

UNDER DASH

−

UNDER HOOD FUSE/RELAY BOX

BLK/YEL WHTBLK/YEL

No.23 (IG) (50 A)No.22 (BAT) (120 A)

−

FUSE/RELAY BOX

B1 A2

WHT

IGNITION SWITCH

BAT

BLK/WHT

STARTER CUT RELAY

X36C1

STHOTinSTART(III)

UNDER DASH FUSE/RELAY BOX

−

BLK/YEL

BLK/WHT

SOLENOIDM

STARTER

BLU/WHT

BLK

TRANSMISSION RANGE SWITCH (Closed:PorN)

G101 G102

4-5

Page 50

Starting System

Starter System Circuit Troubleshooting

NOTE:

• Air temperature must be between 59 and 100 °F (15 and 38 °C) during this procedure.

• After this inspection, you must reset the powertrain control module (PCM), otherwise the PCM will continue to stop the fuel injectors from functioning. Select PCM reset using the Honda Diagnostic System (HDS) (see page 11-4).

• The battery must be in good condition and fully charged.

1. Hook up the following equipment:

• Ammeter, 0 400 A

• Voltmeter, 0 20 V (accurate within 0.1 V)

2. Connect the HDS to the data link connector (DLC) (see step 2 on page 11-3).

−

4. Set the parking brake, then with the shift lever in the N or P position, turn the ignition switch to START (III).

Does the starter crank the engine normally ?

The starting system is OK. Go to step 11.

−

YES

Go to step 5.

−

5. Check the battery condition (see page 22-74). Check the electrical connections at the battery, the negative battery cable to the body, the engine ground cables, and the starter for looseness and corrosion. Then try cranking the engine again.

Does the starter cr ank the engine?

Repairing the loose connection corrected the

−

YES

problem. The starting system is OK. Go to step 11.

Check the following:

−

• If the starter will not crank the engine at all, go to step 6.

• If the starter cranks the engine erratically or too slowly,gotostep8.

• If the starter does not disengage from the torque converter ring gear when you release the key, replace the starter or remove it, and check for the following: – Solenoid plunger and switch malfunction – Dirty drive gear or damaged overrunning

clutch

3. Turn the ignition switch ON (II), and select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.

4-6

Page 51

6. Make sure the shift lever is in the N or P position, and set the parking brake. Disconnect the BLK/WHT wire from the starter solenoid S terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal.

Does the starter crank the engine?

YES

Go to step 7.

−

8. While cranking the engine, check the cranking voltage and the current draw.

Is the cranking voltage greater than or equal to

7.7 V and is the cur rent draw less than or equal to 400 A?

Go to step 9.

YES

−

Replace the starter, or remove and

−

disassemble it, and check for the following:

• Draginthestarterarmature

• Shorted armature winding

• Excessive drag in the engine

9. Check the engine speed while cranking the engine.

Is the engine speed above 100 rpm?

Go to step 10.

YES

−

Replace the starter, or remove and

−

disassemble it, and check the following until you find the problem:

Remove the starter, and repair or replace as

−

necessary.

7. Check the following items in the order listed until youfindtheopencircuit:

NOTE: After the open circuit is found and repaired, go to step 11.

• The BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch.

• The BLK/WHT wire and connectors between the under-dash fuse/relay box and the starter.

• The ignition switch (see page 22-77).

• The transmission range switch and connector (see page 14-272).

• The starter cut relay (see page 22-75).

• Open circuit in starter armature commutator segments

• Excessively worn starter brushes

• Open circuit in the starter brushes

• Dirty or damaged helical splines or drive gear

• Faulty drive gear clutch

10. Remove the starter, and inspect its drive gear and the torque converter ring gear for damage. Replace any damaged parts.

11. Select PCM reset (see page 11-4) to cancel the ALL INJECTORS OFF on the HDS.

4-7

Page 52

Starting System

Starter Solenoid Test

1. Make sure you have anti-theft codes for the audio system and navigation system (if equipped).

2. Disconnect the negative cable from the battery.

3. Remove the starter cable terminal (A), BLK/WHT wire connector (B), and motor cable (C).

8x1.25mm

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

4. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). There should be continuity.

6. Install in the reverse order of removal.

7. Connect the negative cable.

8. Enter the anti-theft codes for the audio system and navigation system (if equipped).

9. Do the power window control unit reset procedure (see page 22-209).

10. Enter the anti-theft codes for the audio system and the navigation system (if equipped). Set the clock (on vehicles without navigation).

• If there is continuity, go to step 5.

• If there is no continuity, replace the solenoid.

5. Check the pull-in coil for continuity between the S terminal and the M terminal. There should be continuity.

• If there is continuity, the solenoid is OK.

• If there is no continuity, replace the solenoid.

4-8

Page 53

Starter Performance Test

1. Disconnect the motor cable from the M terminal.

2. Make a connection for this test using the thickest (gauge) wire possible (preferably the same gauge as used on the vehicle).

NOTE: To avoid damaging the starter, never leave the battery connected for more than 10 seconds.

12 V BATTERY

BODY (GROUND)

3. Connect the battery as shown. Make sure you disconnect the starter motor wire from the solenoid. If the starter pinion moves out, it is working properly.

5. Disconnect the battery from the starter body. If the pinion retracts immediately, it is working properly.

12 V BATTERY

BODY (GROUND)

6. Firmly clamp the starter in a vise.

7. Reconnect the wire to the M terminal.

8. Connect the starter to the battery as shown, and check that the motor turns and keeps rotating.

4. Disconnect the battery from the M terminal. If the pinion does not retract, the hold-in coil of the solenoid is working properly.

12 V BATTERY

BODY (GROUND)

STARTER

12 V BATTERY

9. If the electric current meets the specification when the battery voltage is at 11 V, the starter is working properly.

Specifications Electric Current: 90 A or less

4-9

Page 54

Starting System

Starter Removal and Installation

Removal Installation

1. Make sure you have anti-theft codes for the audio system and navigation system (if equipped).

2. Disconnect the negative cable from the battery.

3. Remove the automatic transmission fluid (ATF) dipstick.

4. Remove the harness clamp (A).

1. Install the starter (A) using a new gasket (C), then install the harness clamp (D), and connect the B terminal and BLK/WHT wire (E). Make sure the crimped side of the B terminal faces away from the starter when you connect it.

10x1.25mm 45 N·m (4.5 kgf·m, 33 lbf·ft)

Install the automatic transmission fluid (ATF) dipstick.

8x1.25mm

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

5. Disconnect the starter cable (B) from the B terminal, then disconnect the BLK/WHT wire (C) from the Sterminal.

6. Remove the two bolts holding the starter.

Connect the negative cable.

4. Start the engine to make sure the starter works properly.

5. Enter the anti-theft codes for the audio system and navigation system (if equipped).

6. Do the power window control unit reset procedure (see page 22-209).

7. Enter the anti-theft codes for the audio system and the navigation system (if equipped). Set the clock (on vehicles without navigation).

4-10

Page 55

Starter Overhaul

Disassembly/Reassembly

END COVER

ARMATURE HOUSING

PLANETARY GEAR

(Apply molybdenum disulfide.)

BRUSH HOLDER

ARMATURE

(Apply molybdenum disulfide.)

IDLER GEAR SHAFT

(Apply molybdenum disulfide.)

OVERRUNNING CLUTCH ASSEMBLY

STARTER SOLENOID

(Apply molybdenum disulfide.)

STARTER LEVER

(Apply molybdenum disulfide.)

IDLER GEAR

GEAR HOUSING

(Apply molybdenum disulfide.)

(cont’d)

4-11

Page 56

Starting System

Starter Overhaul (cont’d)

Brush Holder Removal Armature Inspection and Test

1. Remove the starter (see page 4-10).

2. Disconnect the wire from the M terminal, and remove the end cover.

3. Place a plastic pipe with an outside diameter of

29.4 mm (1.16 in.) on the armature.

4. Move the brush holder (A) up to the pipe (B) while holding the pipe so the brushes do not pop out from the holder.

1. Remove the starter (see page 4-10).

2. Disassemble the starter as shown at the beginning of this procedure.

3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 5, or recondition with 500 or 600 sandpaper (B).

♯♯

4-12

Page 57

5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

Commutator Diameter Standard (New): 29.3 29.5 mm (1.154 1.161 in.) Service Limit: 28.8 mm (1.134 in.)

−−

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).

Commutator Mica Depth Standard (New): 0.40 0.50 mm (0.016 0.020 in.) Service Limit: 0.20 mm (0.008 in.)

−−

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.

Commutator Runout Standard (New): 0.05 mm (0.002 in.) max. Service Limit: 0.1 mm (0.004 in.)

8. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.

(cont’d)

4-13

Page 58

Starting System

Starter Overhaul (cont’d)

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. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

Starter Brush Inspection

11. Measure the brush length (A). If it is shorter than the service limit, replace the brush holder assembly.

Brush Length Standard (New): 7.7 8.0 mm (0.30 0.31 in.) Service Limit: 0.9 mm (0.04 in.)

Starter Brush Holder Test

12. Check for continuity between the ( ) brush (A) and ( ) brush (B). If there is continuity, replace the

−

brush holder assembly.

−−

＋

4-14

Page 59

Planetary Gear Inspection

Starter Reassembly

13. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged.

Overrunning Clutch Inspection

14. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.

17. Install the armature in the housing.

18. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.

19. Install the end cover to retain the brush holder.

15. Hold the overrunning clutch, and turn the drive gear (B) in the direction shown to make sure it turns freely. Also make sure the drive gear locks in the opposite direction. If it does not lock in either direction, or it locks in both directions, replace it.

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 idler gear and drive plate ring gear to see if the starter drive gear teeth are damaged.

4-15

Page 60

Ignition System

Component Location Index

UNDER-DASH FUSE/RELAY BOX

IGNITION COIL RELAY

Circuit Troubleshooting, page 4-20

SPARK PLUG

Inspection, page 4-22

IGNITION COIL

Ignition Timing Inspection, page 4-18 Removal/Installation, page 4-19

4-16

Page 61

Circuit Diagram

BATTERY

BLK/YEL

PCM

IGPLS6 IGPLS5 IGPLS4 IGPLS3 IGPLS2 IGPLS1 MRLY B11 B10 A6

BRN/WHT

UNDER HOOD

−

FUSE/RELAY BOX

No.17 (40A)

BLK/RED

GRN/WHT

B21

BRN

UNDER DASH FUSE/RELAY BOX

−

No.2 (15A)

WHT/BLU

B20

IGNITION COIL RELAY

X32B2

2C1

B27

BLK/WHT

RED/YEL

B26

YEL/GRNBLU/RED

BLK/WHT BLK/WHT

ICM

No.6

BLK BLK

No.5

BLK

BLK/WHT

ICMICM

No.4

BLK

ICM

BLK/WHT

No.3

BLK

ICM

No.2

BLK/WHT

BLK

BLK/WHT

IGPLS1IGPLS2IGPLS3IGPLS4IGPLS5IGPLS6

ICM

No.1

IGINITION COILS

SPARK PLUGS

G101G101 G102

ICM : Ignition Conotrol Module

4-17

Page 62

Ignition System

Ignition Timing Inspection

1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on page 11-3).

2. Start the engine. Hold the engine speed at 3,000 rpm with no load (in Park or Neutral) until the radiator fan comes on, then let it idle.

3. Check the idle speed (see page 11-272).

4. Jump the SCS line with the HDS.

5. Connect the timing light to the No. 1 ignition coil harness.

6. Aim the light toward the pointer (A) on the timing belt cover. Check the ignition timing under a no load condition (headlights, blower fan, rear window defogger, and air conditioner are turned off).

Ignition Timing

10 ° 2 ° BTDC (RED mark (B)) at idle in Park or Neutral

7. If the ignition timing differs from the specification, check the cam timing. If the cam timing is OK, update the powertrain control module (PCM). If it does not have the latest software (see page 11-7), or substitute a known-good PCM (see page 11-8), then recheck. If the system works properly, and the PCM was substituted, replace the original PCM (see page 11-205).

4-18

8. Disconnect the HDS and the timing light.

Page 63

Ignition Coil Removal/Installation

1. Remove the engine cover.

2. Disconnect the ignition coil connectors (A), then remove the front bank ignition coils (B).

3. Disconnect the ignition coil connectors (A), then remove the rear bank ignition coils (B).

6x1.0mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)

4. Install the ignition coils in the reverse order of removal.

6x1.0mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)

4-19

Page 64

Ignition System

Ignition Coil Relay Circuit Troubleshooting

1. Check the No. 2 (15 A) fuse in the under-dash fuse/ relay box.

IsthefuseOK?

YES

Go to step 2.

−

Replace the fuse . If the fuse continues to

−

blow, locate and repair the short in the circuit between the subfuse box and the ignition coils.

2. Remove the ignition coil relay from the under-dash fuse/relay box, and test it (see page 22-75).

Is the relay OK?

YES

Go to step 3.

−

Replace the ignition coil relay.

−

3. Measure the voltage between ignition coil relay 4P socket terminal No. 1 and body ground, then terminal No. 4 and body ground.

IGNITION COIL RELAY 4P SOCKET

4. Check for continuity between ignition coil relay 4P socket terminal No. 2 and the No. 1 ignition coil 3P connector terminal No. 3.

IGNITION COIL RELAY 4P SOCKET

Terminal side of female terminals

Wire side of female terminals

No.1 IGNITION COIL 3P CONNECTOR

Is there continuity?

Go to step 5.

YES

−

Repair open in the wire between ignition coil

−

relay 4P socket terminal No. 2 and No. 1 ignition coil 3P connector terminal No. 3.

5. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on page 11-3).

Terminal side of female terminals

Is there battery voltage?

Go to step 4.

YES

−

Replace the under-dash fuse/relay box.

−

6. Turn the ignition switch OFF.

7. Jump the SCS line with the HDS.

NOTE: This step must be done to protect the powertrain control module (PCM) from damage.

8. Disconnect PCM connector A (44P).

4-20

Page 65

9. Check for continuity between ignition coil relay 4P socket terminal No. 3 and body ground.

IGNITION COIL RELAY 4P SOCKET

Terminal side of female terminals

Is there continuity?

−

YES

Repair short in the wire between ignition coil

relay 4P socket terminal No. 3 and the PCM (A6).

Go to step 10.

−

10. Check for continuity between ignition coil relay 4P socket terminal No. 3 and PCM connector terminal A6.

IGNITION COIL RELAY 4P SOCKET

Terminal side of female terminals

MRLY (RED/YEL)

Terminal side of female terminals

PCM CONNECTOR A (44P)

Is there continuity?

The system is OK at this time. Check for

−

YES

loose or poor connections at the ignition coil relay and the PCM (A6).

Repair open in the wire between ignition coil

−

relay 4P socket terminal No. 3 and the PCM (A6).

4-21

Page 66

Ignition System

Spark Plug Inspection

1. Remove the spark plugs and inspect the electrodes and the ceramic insulator.

• Burned or worn electrodes may be caused by: – Advanced ignition timing – Loose spark plug – Plug heat range too hot – Insufficient cooling

• Fouled plugs may be caused by: – Retarded ignition timing – Oil in combustion chamber – Incorrect spark plug gap – Plug heat range too cold – Excessive idling/low speed running – Clogged air cleaner element – Deteriorated ignition coils

Worn or deformed electrodes

•Impropergap

• Oil-fouling

• Carbon deposits

• Cracked center

Damaged gasket

Cracked insulator

electrode insulator

3. Replace the spark plug if the gap is out of specification.

NOTE: Do not adjust the gap of iridium tip plugs.

Electrode Gap Standard (New): 1.0 1.1 mm (0.039 0.043 in.)

4. Replace the plug at the specified interval, or when the center electrode is rounded (A). Use only the listed spark plugs.

Spark Plugs NGK: IZFR5K-11 DENSO: SKJ16DR-M11

−−

2. If the spark plug electrode is dirty or contaminated, clean the electrode with a plug cleaner.

NOTE:

• Do not use a wire brush or scrape the iridium electrode since this will damage the electrode.

• When using a sand blaster spark plug cleaner, do not clean for more than 20 seconds to avoid damaging the electrode.

4-22

5. Apply a small amount of anti-seize compound to the plug threads, and screw the plugs into the cylinder head, finger-tight. Torque them to 18 N·m (1.8 kgf·m, 13 lbf·ft).

Page 67

Charging System

Component Location Index

UNDER-HOOD FUSE/RELAY BOX (Has built-in ELECTRICAL LOAD DETECTOR (ELD) UNIT)

CHARGING SYSTEM INDICATOR (In the gauge control module)

TENSIONER PULLEY

Replacement, page 4-33

AUTO-TENSIONER

Inspection, page 4-32 Replacement, page 4-33

ALTERNATOR

Removal and Installation, page 4-34 Overhaul, page 4-36

DRIVE BELT

Inspection, page 4-31 Replacement, page 4-31

BATTERY

Test, page 22-74

4-23

Page 68

Charging System

Symptom Troubleshooting Index

Symptom Diagnostic procedure Also check for

Charging system indicator does not come on with the ignition switch ON (II) Charging system indicator stays on

Battery discharged 1.

Battery overcharged 1.2.Troubleshoot the alternator and regulator circuit

Troubleshoot the charging system indicator circuit (see page 4-26).

Troubleshoot the charging system indicator circuit

1. (see page 4-26). Check for a broken drive belt (see page 4-31).

2. Check the drive belt auto-tensioner (see page 4-32).

3. Check for excessive parasitic electrical current draw with the ignition switch OFF, and the key removed. The multiplex control unit may take up to 10 minutes to turn off (sleep mode) for some models. Check for a broken drive belt (see page 4-31).

2. Check the drive belt auto-tensioner (see page 4-32).

3. Troubleshoot the alternator and regulator circuit

4. (see page 4-28). Check for a poor connection at the battery terminal.

5. Test the battery (see page 22-74).

(see page 4-28). Test the battery (see page 22-74).

4-24

Page 69

Circuit Diagram

BATTERY

UNDER HOOD FUSE/RELAY BOX

−

BLK/YEL BLK/YELWHT

No.22 (120 A)

BLK

G202

No.23 (50 A)

ELD UNIT

BLU/BLK

A2A3

PCM

A23

ELD

BLK/YEL

ALTF ALTL ALTC C41 C38

IGNITION SWITCH

BAT

IG1

IG1HOTinON(II) and START (III)

GAUGE CONTROL MODULE

B8 A20

CPU

DRIVER

REDWHT

A1A36 CANLCANH

B42

CHARGING SYSTEM INDICATOR

DRIVER’S UNDER DASH FUSE/RELAY BOX

No.18 (15 A)

YEL

−

No.21 (7.5 A)

X34D1

RECTIFIER

BLK

WHT/RED WHT/GRN

WHT/BLU

FR C

LIG

VOLTAGE REGULATOR

24B

BLK/YEL

1ALTERNATOR

4-25

Page 70

Charging System

Charging System Indicator Circuit Troubleshooting

1. Turn the ignition switch ON (II).

Does the char ging system indicator come on?

YES

Go to step 2.

−

Go to step 12.

−

2. Start the engine. Hold the engine speed at 2,000 rpm for 1 minute.

Does the char ging system indicator go off?

YES

Charging system indicator circuit is OK. Go

−

to the alternator and regulator circuit troubleshooting (see page 4-28).

Go to step 3.

−

3. Do the gauge control module self-diagnostic function procedure (see page 22-244).

Does the char ging system indicator flash?

Go to step 4.

YES

−

Replace the gauge control module (see page

−

22-263).

7. Turn the ignition switch OFF.

8. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC).

9. Jump the SCS line with the HDS.

NOTE: This step must be done to protect the powertrain control module (PCM) from damage.

10. Disconnect PCM connector B (44P).

11. Check for continuity between PCM connector terminal B42 and body ground.

PCM CONNECTOR B (44P)

ALT L (WHT/BLU)

Terminal side of female terminals

4. Turn the ignition switch OFF.

5. Disconnect the alternator 4P connector.

6. Turn the ignition switch ON (II).

NOTE: The charging system indicator may come on andthengooff.

Does the char ging system indicator go off?

Replace the alternator (see page 4-34) or

YES

−

repair the alternator (see page 4-36).

Go to step 7.

−

Is there continuity?

Repair short in the wire between the

YES

−

alternator and the PCM.

Update the PCM if it does not have the latest

−

software (see page 11-7), or substitute a knowngood PCM (see page 11-8), then recheck. If the symptom/indication goes away with a known-good PCM, replace the original PCM (see page 11-205).

4-26

Page 71

12. Do the gauge control module self-diagnostic function procedure (see page 22-244).

Does the char ging system indicator flash?

17. Turn the ignition switch OFF.

18. Connect the HDS to the DLC (see step 2 on page 11-3).

Go to step 13.

YES

−

Replace the gauge control module (see page

−

22-263).

13. Turn the ignition switch OFF.

14. Disconnect the alternator 4P connector.

15. Connect alternator 4P connector terminal No. 3 and body ground with a jumper wire.

ALTERNATOR 4P CONNECTOR

L (WHT/BLU)

JUMPER WIRE

Wire side of female terminals

16. Turn the ignition switch ON (II).

Does the char ging system indicator come on?

YES

−

Replace the alternator (see page 4-34) or

repair the alternator (see page 4-36).

−

Go to step 17.

19. Jump the SCS line with the HDS.

NOTE: This step must be done to protect the PCM from damage.

20. Disconnect PCM connector B (44P).

21. Check for continuity between PCM connector terminal B42 and alternator 4P connector terminal No. 3.

PCM CONNECTOR B (44P)

ALT L (WHT/BLU)

ALTERNATOR 4P CONNECTOR

Terminal side of female terminals

Is there continuity?

YES

Update the PCM if it does not have the latest

−

software (see page 11-7), or substitute a knowngood PCM (see page 11-8), then recheck. If the symptom/indication goes away with a known-good PCM, replace the original PCM (see page 11-205).

Repair open in the wire between the

−

alternator and the PCM.

4-27

Page 72

Charging System

Alternator and Regulator Circuit Troubleshooting

1. Make sure the battery connections are good and the battery is sufficiently charged (see page 22-74).

2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting).

VOLT SELECTOR

FIELD SELECTOR

INDUCTIVE PICKUP

LOAD ADJUSTER (CARBON PILE)

TEST SELECTOR SWITCH

FULL FIELD TESTER LEAD (BLU)

VOLTMETER NEGATIVE LEAD (BLK)

VOLTMETER POSITIVE LEAD (RED)

NEGATIVE TERMINAL CABLE (BLK)

POSITIVE TERMINAL CABLE (RED)

INDUCTIVE PICKUP (GRN)

5. Release the accelerator pedal, and let the engine idle.

6. Turn off all the accessories. Select the charging test on the tester.

7. Remove the inductive pickup, and zero the ammeter.

8. Place the inductive pickup over the B terminal wire of the alternator so the arrow points away from the alternator.

9. Raise the engine speed to 2,000 rpm, and hold it there.

Is the voltage less than 13.5 V?

Go to alternator control circuit

−

YES

troubleshooting (see page 4-29).

Go to step 10.

−

10. Apply a load with the VAT-40 until the battery voltage drops to between 12 13.5 V.

−

Istheamperage87.5Aormore?

The charging system is OK.

−

YES

BTERMINAL

3. Start the engine. Hold the engine speed at 3,000 rpm, with no load until the radiator fan comes on, thenletitidle.

4. Raise the engine speed to 2,000 rpm, and hold it there.

Is the voltage over 15.1 V?

Check the alternator mounting bolt torque. If

−

YES

they are loose, retorque them. If the bolts are tight, replace the alternator (see page 4-34) or rear housing assembly (see page 4-36).

Go to step 5.

−

NOTE: If the charging system indicator is still on, replace the alternator (see page 4-34).

Replace the alternator (see page 4-34) or

−

repair the alternator (see page 4-36).

4-28

Page 73

Alternator Control Circuit Troubleshooting

1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC), and check for DTCs (see page 11-3). If a DTC is present, diagnose and repair the cause before continuing with this test.

2. Disconnect the alternator 4P connector from the alternator.

3. Start the engine, and turn on the headlights to high beam.

4. Measure the voltage between alternator 4P connector terminal No. 2 and the positive terminal of the battery.

BATTERY

C (WHT/GRN)

ALTERNATOR 4P CONNECTOR

Wire side of female terminals

8. Check for continuity between PCM connector terminal C38 and body ground.

PCM CONNECTOR C (44P)

ALT C (WHT/GRN)

Terminal side of female terminals

Is there continuity?

Repair short in the wire between the

−

YES

alternator and the PCM.

Update the PCM if it does not have the latest

−

software (see page 11-7), or substitute a knowngood PCM (see page 11-8), then recheck. If the symptom/indication goes away with a known-good PCM, replace the original PCM (see page 11-205).

Is there 1 V or less?

Go to step 9.

−

YES

Go to step 5.

−

5. Turn the ignition switch OFF.

6. Jump the SCS line with the HDS.

NOTE: This step must be done to protect the powertrain control module (PCM) from damage.

7. Disconnect PCM connector C (44P).

9. Turn the ignition switch OFF.

10. Jump the SCS line with the HDS.

NOTE: This step must be done to protect the PCM from damage.

11. Disconnect PCM connector C (44P).

(cont’d)

4-29

Page 74

Charging System

Alternator Control Circuit Troubleshooting (cont’d)

12. Check for continuity between PCM connector terminal C38 and alternator 4P connector terminal No. 2.

PCM CONNECTOR C (44P)

Terminal side of female terminals

ALT C (WHT/GRN)

C (WHT/GRN)

ALTERNATOR 4P CONNECTOR

Is there continuity?

Replace the alternator (see page 4-34) or

−

YES

repair the alternator (see page 4-36).

Repair open in the wire between the

−

alternator and the PCM.

Wire side of female terminals

4-30

Page 75

Drive Belt Inspection Drive Belt Replacement

1. Inspect the belt for cracks or damage. If the belt is cracked or damaged, replace it.

2. Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If it is out of the standard range, replace the drive belt (see page 4-31).

1. Move the auto-tensioner (A) to relieve tension from the drive belt, then remove the drive belt.

2. Install the new belt in the reverse order of removal.

4-314-31

Page 76

Charging System

Drive Belt Auto-tensioner Inspection

1. Check the position of the auto-tensioner indicator’s pointer (A), start the engine, then check the position of the pointer again. If the position changes, replace the auto-tensioner.

2. Check for abnormal noise from the tensioner pulley. If you hear abnormal noise, replace the autotensioner pulley (see page 4-33).

5. Remove the auto-tensioner (see page 4-33).

6. Clamp the auto-tensioner (A) by using a 10 mm bolt (B), 8 mm bolt (C), and a vise (D) as shown. Do not clamp the auto-tensioner itself.

7. Attach a torque wrench (A) to the pulley bolt. Measure the torque when the tensioner is turned counterclockwise and begins to move. If the torque is less than the specified value, replace the autotensioner (see page 4-33).

3. Remove the drive belt (see page 4-31).

4. Move the auto-tensioner within its limit using the belt tension release tool in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. If the tensioner does not move smoothly, or you hear abnormal noises, replace the auto-tensioner (see page 4-33).

Auto-tensioner Spring Torque:

50.5 N·m (5.15 kgf·m, 37.2 lbf·ft)

4-32

Page 77

Drive Belt Auto-tensioner Replacement

Tensioner Pulley Replacement

1. Remove the auto-tensioner (see page 4-33).

1. Remove the drive belt (see page 4-31).

2. Remove the splash shield (see step 30 on page 5-5).

3. Remove the auto-tensioner.

8x1.25mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

10x1.25mm 45 N·m (4.5 kgf·m, 33 lbf·ft)

4. Install the auto-tensioner in the reverse order of removal.

2. Remove the pulley bolt (A) (left-hand threads), and remove the tensioner pulley (B).

A 10x1.5mm 80 N·m (8.2 kgf·m, 59 lbf·ft)

3. Install the tensioner pulley in the reverse order of removal.

4-334-33

Page 78

Charging System

Alternator Removal and Installation

Removal

1. Make sure you have anti-theft codes for the audio system and the navigation system (if equipped).

2. Disconnect the negative cable from the battery.

3. Remove the engine manifold cover (see step 1 on page 4-19).

4. Remove the drive belt (see page 4-31).

5. Remove the harness clamp (A) and harness clamp bracket (B), then remove the harness holder (C).

7. Remove the mounting bolt (A) and alternator bracket mounting bolt (B), then remove the alternator.

6. Disconnect the alternator connector (D) and the BLK wire (E) from the alternator.

4-34

Page 79

Installation

1. Install the alternator.

3. Install the harness holder (C), then install the harness clamp bracket (D) and harness clamp (E).

4. Install the drive belt (see page 4-31).

5. Install the engine cover (see step 1 on page 4-19).

6. Connect the negative cable.

7. Enter the anti-theft codes for the audio system and navigation system (if equipped).

8. Do the power window control unit reset procedure (see page 22-209).

9. Set the clock (on vehicles without navigation).

10x1.25mm 45 N·m (4.5 kgf·m, 33 lbf·ft)

8x1.25mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

2. Connect the alternator connector (A) and the BLK wire (B) to the alternator.

6x1.0mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)

8x1.25mm 12 N·m (1.2 kgf·m,

8.7 lbf·ft)

6x1.0mm 12 N·m (1.2 kgf·m, 8.7 lbf·ft)

4-35

Page 80

Charging System

Alternator Overhaul

Exploded View

BEARING RETAINER

FRONT BEARING

DRIVE-END HOUSING

PULLEY

TERMINAL INSULATOR

BRUSH HOLDER ASSEMBLY

PULLEY LOCKNUT

REAR HOUSING ASSEMBLY

ROTOR

4-36

END COVER

Page 81

Special Tools Required

• Driver 07749-0010000

• Attachment, 42 x 47 mm 07746-0010300

NOTE: Refer to the Exploded View as needed during this procedure.

Alternator Disassembly

1. Test the alternator and regulator before you remove them (see page 4-28).

2. Remove the alternator (see page 4-34).

3. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.

5. Remove the end cover (A) and the insulator (B).

6. Remove the brush holder (A).

4. Remove the three flange nuts.

(cont’d)

4-37

Page 82

Charging System

Alternator Overhaul (cont’d)

7. Remove the four bolts, then remove the rear housing assembly (A) and washer (B).

8. If you are not replacing the front bearing, go to step 13. Remove the rotor from the drive-end housing.

9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.

• If the rotor is damaged, replace the rotor assembly.

• If the rotor is OK, go to step 10.

10. Remove the front bearing retainer plate.

11. Drive out the front bearing with a brass drift and hammer.

4-38

Page 83

12. Install a new front bearing in the drive end housing with a hammer, driver handle, and attachment.

07749-0010000

07746-0010300

Rotor Slip Ring Test

14. Check for continuity between the slip rings (A).

• If there is continuity, go to step 15.

• If there is no continuity, replace the rotor assembly.

Alternator Brush Inspection

13. Measure the length of both brushes (A) with a vernier caliper (B).

• If either brush is shorter than the service limit, replace the brush holder assembly.

• If the brush length is OK, go to step 14.

Alternator Brush Length Standard (New): 10.5 mm (0.41 in.) Service Limit: 1.5 mm (0.06 in.)

15. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).

• If there is no continuity, replace the rear housing assembly, and go to step 16.

• If there is continuity, replace the rotor assembly.

16. Assemble the alternator in the reverse order of disassembly, and note these items:

• Be careful not to get any grease or oil on the slip rings.

• If you removed the pulley, tighten its locknut to 110 N·m (11.2 kgf·m, 81.0 lbf·ft) when you reinstall it.

4-39

Page 84

Cruise Control

Component Location Index

CRUISE CONTROL INDICATOR (Built into gauge control module)

CRUISE CONTROL SET/DECEL, RESUME/ACCEL, CANCEL SWITCH

Test/Replacement, page 4-46

BRAKE PEDAL POSITION SWITCH

Test, page 22-174 Pedal Height Adjustment, page 19-6

CRUISE CONTROL MAIN SWITCH

Test/Replacement, page 4-46

POWERTRAIN CONTROL MODULE (PCM)

Cruise Control Input Test, page 4-44

TRANSMISSION RANGE SWITCH

Test, page 14-272 Replacement, page 14-273

4-40

Page 85

Symptom Troubleshooting Index

Symptom Diagnostic procedure Also check for

Cruise control cannot be set

Cruise control can be set, but the cruise control main switch indicator does not come on Cruise control can be set, but the cruise control indicator does not come on

Vehicle does not decelerate or accelerate accordingly when the set/ decel or resume/accel switch is pressed

Set speed does not cancel when the brake pedal is pressed

Set speed does not cancel when the cruise control main switch is pressed Set speed does not cancel when the cancel switch is pressed

Check for PGM-FI and body DTCs.

Check the No. 13 (20 A) fuse in the under-hood fuse/ relay box, and No. 18 (15 A) fuse in the under-dash fuse/ relay box. Do the cruise control input test (see page 4-44).

3. Do the cruise control main switch test (see page 4-46).

1.2.Do the cruise control main switch test (see page 4-46). Checkforafaultycruisecontrolmainswitch illumination bulb.

Check for PGM-FI and body DTCs.

Do the gauge control module self-diagnostic function (see page 22-244). Do the cruise control input test (see page 4-44).

3. Test the cruise control indicator signal input.

Check for PGM-FI and body DTCs.

Do the cruise control input test (see page 4-44). Test the cruise control set/decel, resume/accel switch signal input. Do the cruise control set/decel, resume/accel, cancel

3. switch test (see page 4-46). Check for PGM-FI and body DTCs.

1. Do the cruise control input test (see page 4-44).

2. Test the brake pedal position switch signal input. Do the brake pedal position switch test (see page

3. 22-174). Check for PGM-FI and body DTCs.

1. Do the cruise control input test (see page 4-44).

2. Test the cruise control main switch signal input. Do the cruise control main switch test (see page 4-46).

3. Check for PGM-FI and body DTCs.

1. Do the cruise control input test (see page 4-44).

2. Test the cruise control cancel switch signal input. Do the cruise control set/decel, resume/accel, cancel

3. switch test (see page 4-46).

Faulty cruise control main switch

Faulty gauge control module

Open circuit, loose or disconnected terminals: GRY/RED or LT GRN/BLK

Short to power on

• the BRN/YEL wire Faulty brake pedal

• position switch

Short to power on the LT GRN wire

Open circuit, loose or disconnected terminals: GRY/RED or LT GRN/BLK

(cont’d)

4-41

Page 86

Cruise Control

Symptom Troubleshooting Index (cont’d)

Symptom Diagnostic procedure Also check for

Set speed will not resume when the resume/accel switch is pressed (with the cruise control main switch turned on, and set speed temporarily canceled by pressing the brake pedal) With the ignition switch ON (II), and the lighting switch turned on, the cruise control main switch illumination does not come on With the ignition switch ON (II), and the lighting switch turned on, the cruise control set/decel, resume/accel, cancel switch illumination does not come on

Check for PGM-FI and body DTCs.

Check the brake pedal position switch adjustment (see page 19-6).

Do the cruise control input test (see page 4-44). Test the cruise control resume/accel switch signal input. Test the brake pedal position switch signal input. Do the cruise control set/decel, resume/accel, cancel

4. switch test (see page 4-46).

1.2.Replace the cruise control main switch illumination bulb (see page 4-46). Do the cruise control main switch test (see page 4-46).

Replace the cruise control set/decel, resume/accel, cancel switch (see page 4-46).

Faulty brake pedal

• position switch Open circuit, loose or

• disconnected terminals: LT GRN/BLK

4-42

Page 87

Circuit Diagram

BATTERY

BLK/YEL

WHT

RED

WHT/BLK

PCM

IGNITION

BAT

SWITCH

IG1

IG1 HOT in ON (II)

and START (III)

BLK/YEL

No.18 (15 A)

N29 X1 F19

BLK/YEL

BRAKE PEDAL POSITION

SWITCH

No.13 (20A)

No.22 (BAT) (120 A)

No.23 (IG) (50 A)

WHT/GRN YEL/BLK

YEL/BLK

RED/YELBRN/YEL

MRLY

HORN RELAY

No.9 (15A)

No.8 (15 A)

UNDER DASH FUSE/RELAY BOX

D10A6

PGM FI MAIN RELAY 1

IGP1

−

UNDER HOOD FUSE/R ELAY BOX

BLU/RED

BLU/RED HORN

GRY/YEL

RELAY CONTROL

THROTTLE CONTROL RELAY

F17E10X8E6

−

YEL/GRN

BRN

ETCSRLY

MODULE

TAILLIGHT RELAY

BLK/YEL RED/BLK

CRUISE CONTROL MAIN SWITCH

INDICATOR

25 4

G401

A14 C20 C1A12A13

WHT

LIGHT

REDBLKLT GRN

POWER SUPPLY/CONTROLLERAREANETWORK CONTROLLER

A8 A 1

RED

A1A3 6C4A20B3A6A7A8

CANHIG1ETCSBKSWNCBKSW

CANL

CRUISE CONTROL SET/DECEL, RESUME/ACCEL CANCEL SWITCH

HORN

GRY/YEL

SET/ DECEL

GRY/RED LT GRN/BLK

763

−

CAN CEL

LT GRN/BLK

CRUISE CONTROLINDICATOR

TAILLIGHT RELAY

RED/BLK

HORN SWITCH

RESUME/ ACCEL

RED/BLU

RED/BLUGRY/RED

CRUISE DIMMING CIRCUITDRIVE CIRCUIT

GAUGE CONTROLMODULE

CABLE REEL

LIGHTS 54

367

CABLE REEL

BLU BLU/YEL

OUTPUT SHAFT SPEED SENSOR

12 V5V

−＋

C17B40 B34B12

TRANSMISSION RANGE SWITCH

THROTTLE ACUTUATOR

B19 B17C2

BLUGRNBLU

RED/BLK

TP SENSOR

GRNRED/BLU

THROTTLE BODY

SGTHL2THL1VCCETCSMETCSMATPFWDNC

431256

4-43

Page 88

Cruise Control

Cruise Control Input Test

1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 on page 11-3).

2. Turn the ignition switch ON (II).

3. Go to PGM-FI, and check for DTCs.

4. Do the following tests while monitoring parameters in the PGM-FI DATA LIST with the HDS.

NOTE: Intermitent failures are often caused by loose circuit connections. While monitoring cruise control inputs, flex their circuits, and note if any of the test results change.

Signal to be tested Parameter: Desired result

Brake switch signal

Transmission range switch signal

Cruise control main switch signal

Set switch signal

Test condition Possible cause if result is not obtained

Brake pedal pressed, then released

Shift lever in D SHIFT/CLUTCH SW

Cruise control main switch ON and OFF

Set/decel switch pressed and released

CRUISE BRAKE SW should indicate OFF when the brake pedal is pressed and ON when the brake pedal is released.

should indicate ON in P, R, N, 2, and 1 and OFF in D.

CRUISE CONTROL MAIN SW should indicate ON when the cruise control main switch is turned ON and OFF when the cruise control main switch is turned OFF.

CRUISE CONTROL SET SW should indicate ON when the set/decel switch is pressed and OFF when the set/decel switch is released.

Faulty brake pedal position switch

• Blown No. 18 (15 A) fuse in the under-

• dash fuse/relay box An open in the wire between the

• powertrain control module (PCM) and the brake pedal position switch A wire shorted to ground between the

• PCM and the brake pedal position switch Faulty transmission range switch

• An open in the wire between the PCM

• and the transmission range switch A wire shorted to ground between the

• PCM and the transmission range switch Poor ground G101 and G102

• Faulty cruise control main switch

• An open in the wire between the gauge

• control module and the cruise control main switch A wire shorted to ground between the

• gauge control module and the cruise control main switch An open in the wire between the cruise

• control main switch and ground Faulty cruise control set/decel, resume/

• accel, cancel switch An open in the wire between the gauge

• control module and the cruise control set/decel, resume/accel, cancel switch A wire shorted to ground between the

• gauge control module and the cruise control set/decel, resume/accel, cancel switch

4-44

Page 89

Signal to be tested Parameter: Desired result

Resume switch signal

Cancel switch signal

Cruise control indicator signal

Test condition Possible cause if result is not obtained

Resume/accel switch pressed and released

Cancel switch pressed and released

Start the engine, turn thecruisecontrol main switch on and drive the vehicle above 25 mph (40 km/h). Set and cancel the cruise control.

CRUISE CONTROL RESUME SW should indicate ON when the resume/accel switch is pressed and OFF when the resume/accel switch is released.

CRUISE CONTROL CANCEL SW should indicate ON when the cancel switch is pressed and OFF when the cancel switch is released. CRUISE INDICATOR should indicate ON when the cruise control is set and OFF when thecruisecontrolis canceled.

•

Faulty cruise control set/decel, resume/ accel, cancel switch An open in the wire between the gauge

• control module and the cruise control set/decel, resume/accel, cancel switch A wire shorted to ground between the

• gauge control module and the cruise control set/decel, resume/accel, cancel switch

Faulty cruise control set/decel, resume/ accel, cancel switch

Faulty gauge control module

4-45

Page 90

Cruise Control

Cruise Control Main Switch Test/ Replacement

1. Release the clips of the cruise control main switch, and push the cruise control main switch (A) out of the driver’s dashboard lower cover.

2. Disconnect the 5P connector (B), then remove the cruise control main switch.

3. Check for continuity between the terminals in each switch position according to the table. If there is no continuity, replace illumination bulbs (A) or the switch.

Cruise Control Set/decel, Resume/ accel, Cancel Switch Test/ Replacement

SRS components are located in this area. Review the SRS component locations (see page 24-14), and the precautions and procedures (see page 24-16), in the SRS before doing repairs or service.

1. Remove the driver’s airbag (see page 24-174).

2. Remove the steering wheel (see page 17-21).

3. Remove the steering wheel trim.

Position

OFF

Terminal side of male terminals

Terminal

1234

4. Disconnect the 7P connector (A), then remove the cruise control set/decel, resume/accel, cancel switch (B).

4-464-46

Page 91

5. Check for continuity between the terminals in each switch position according to the table.

• If there is continuity, and it matches the table, but switch failure occurred on the cruise control input test, check and repair the wire harness on the switch circuit.

• If there is no continuity in one or more positions, replace the switch.

Terminal

Position

Set/decel (ON)

Resume/accel (ON)

Cancel (ON)

Terminal side of male terminals

123

4-47

Page 92

Engine Mechanical

Engine Assembly

..........................................................

Engine Removal . 5-2 Engine Installation . 5-12 Engine Mount Replacement . 5-23

..........................................................

.......................................................

.......................................

......................................................................................................Cylinder Head . 6-1

........................................................................................................Engine Block . 7-1

....................................................................................Engine Lubrication . 8-1

........................Intake Manifold and Exhaust System . 9-1

Page 93

Engine Assembly

Engine Removal

Special Tools Required

• Front subframe adapter EQS02BMDXSB0

• Engine support hanger, A and Reds AAR-T-12566

• Engine hanger balance bar VSB02C000019

• Engine hanger adapter set VSB02C000024 These special tools are available through the Honda Tool and Equipment program, 1-888-424-6857.

NOTE:

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring, hoses, or interfere with other parts.

1. Secure the hood in the wide open position (position the support rod in the lower hole).

5. Make sure you have the anti-theft codes for the audio system and navigation system (if equipped). Make sure the ignition switch is OFF.

6. Disconnect the negative cable from the battery, then disconnect the positive cable.

7. Remove the battery.

8. Remove the engine cover.

2. Relieve the fuel pressure (see page 11-286).

3. Drain the power steering system fluid, then plug the fluid reservoir and return hose (see page 17-12).

4. Remove the bulkhead cover (see page 20-171).

9. Disconnect the breather pipe (A), then remove the air intake duct (B).

5-2

Page 94

10. Remove the harness clamps (A), then remove the battery base (B).

13. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose (B) (see page 11-293).

14. Remove the transfer breather tube box (A) and disconnect brake booster vacuum hose (B).

11. Remove the ground cable (A), harness clamp (B) and starter motor cable (C).

12. Removetheshiftcable(seestep19onpage 14-219).

15. Disconnect the evaporative emission (EVAP) canister hose (C), then remove the purge joint (D).

(cont’d)

5-3

Page 95

Engine Assembly

Engine Removal (cont’d)

16. Remove the steering wheel (see page 17-21).

17. Remove the steering joint cover (A).

18. Make a reference mark (B) across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt (C), and loosen the steering joint bolt (D), then disconnect the steering joint from the steering gearbox pinion shaft (E).

19. Remove the alternator cable (A) from the underhood fuse/relay box.

21. Remove the coolant reservoir from the bracket.

22. Remove the powertrain control module (PCM) cover.

23. Remove the harness clamps (A), then disconnect the two PCM connectors (B).

20. Disconnect the harness connectors (B).

5-4

Page 96

24. Remove the drive belt (see page 4-31).

25. Remove the power steering (P/S) pump inlet hose (A) and P/S pump outlet hose (B) from the P/S pump, then plug the P/S lines and P/S pump.

31. Loosen the drain plug in the radiator, and drain the engine coolant (see page 10-6).

32. Drain the automatic transmission fluid (ATF) (see page 14-210).

26. Remove the P/S hose clamp (C) from the cylinder head cover.

27. Remove the radiator cap.

28. Raise the vehicle on the lift to full height.

29. Remove the front wheels.

30. Remove the splash shield.

33. Drain the engine oil (see page 8-6).

34. Remove the front subframe stiffener.

35. Remove exhaust pipe A.

(cont’d)

5-5

Page 97

Engine Assembly

Engine Removal (cont’d)

36. Separate the stabilizer links from the dampers (see page 18-20).

37. Separate the tie-rod end ball joints from the

knuckles (see step 9 on page 18-15).

38. Separate the knuckles from the lower arms (see step 13 on page 18-15).

Remove the driveshafts (see page 16-4).

39. Coat all precision-finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.

40. Remove the propeller shaft from the transfer shaft flange (see page 16-40).

41. Remove the transfer assembly (see page 14-213).

42. Disconnect the P/S hose (A), then plug the line and hose.

44. Disconnect the power steering pressure switch connector.

45. Remove the transmission lower front mount nuts and transmission lower rear mount nuts.

43. Unclamp the power steering fluid line clamp (B) on the front subframe.

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46. Remove the rear mount bolts.

49. Disconnect the heater hoses.

47. Remove the A/C compressor without disconnecting the A/C hoses.

48.

Lower the vehicle on the lift.

50. Remove the upper radiator hose (A) and lower radiator hose (B).

(cont’d)

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Engine Assembly

Engine Removal (cont’d)

51. Disconnect the ATF cooler hoses from the transmission, then plug the ATF cooler hoses and lines.

52. Remove the radiator (see page 10-12).

53. Remove the connector bracket from the front cylinder head; use the bracket bolt hole to attach the engine hanger balance bar front arm.

54. Remove the harness clamp bracket from the rear cylinder head; use the bracket bolt hole to attach the engine hanger balance bar rear arm.

55. Remove the service caps (A) for the front damper flange nuts from the cowl cover (B). Position the engine hanger adapters (VSB02C000024) with the ‘‘FRONT’’mark facing forward over the damper flange nuts.

VSB02C000024

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56. Install the engine hanger balance bar (VSB02C000019); then attach the front arm (A) to the front cylinder head with a spacer (B) and 10x1.25mmbolt(C),andattachthereararm(D)to the rear cylinder head with 8 x 1.25 mm bolt (E).

60. Note the reference marks (A) on the body across the marks (B) on the edge of the front subframe (C).

VSB02C000024

AAR-T-12566

VSB02C000024

VSB02C000019

57. Install the engine support hanger (AAR-T-12566) to the vehicle, and attach the hook to the slotted hole in the engine hanger balance bar. Tighten the wing nut (F) by hand to lift and support the engine/ transmission assembly.

Remove the front engine mount nut.

58.

Replace.

61. Loosen the four bolts (A) holding the adjustable arms (B) of the front subframe adapter to its center plate.

EQS02BMDXSB0

59. Raise the vehicle on the lift to full height.

(cont’d)

5-9