Part Two
Installation
31. Steering Wheel Release
1. Remove the steering wheel holder tool (A).
32. Steering Joint - Reconnection
1. Set the rack in the straight ahead driving position.
2. Slip the lower end of the steering joint (A) onto the pinion shaft (B).
NOTE:
* Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).
* Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.
3. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.
4. Loosely install the steering joint bolt (C).
5. Be sure that the joint bolt is securely in the groove in the pinion shaft.
6. Pull on the steering joint to make sure that the steering joint is fully seated.
33. Steering Joint Bolt - Tighten
1. Tighten the steering joint bolt (A) to the specified torque.
34. Steering Joint Cover
1. Install the steering joint cover (A) in the sequence shown.
35. Heater Hose - Reconnection Engine Side
1. Connect the upper radiator hose (A) and the heater hoses (B).
36. Bulkhead - Temporary Remove
1. Remove the front bulkhead.
37. Radiator Assembly
1. Install the radiator assembly.
2. Check the quick connector (A) and the set ring (B) for cracks or damage. If the quick connector and/or the set ring are cracked or damaged, replace the quick connector.
3. Make sure the set ring is in place inside the quick connector. If the set ring is off the quick connector, replace the quick connector.
4. Replace a new O-ring (C) in the quick connector.
5. Check the lock (D). If the lock is damaged or deformed, replace it. When installing the new lock on the quick connector, push it straight down along the groove.
6. Clean the connecting surface of the thermostat cover (E), then apply clean engine coolant around the connecting surface.
7. Install the harness clamp (A).
8. Connect the lower radiator hose (B).
9. Connect the upper radiator hose (A).
38. Bulkhead - Installation
1. Install the bulkhead (A).
2. Install the harness clamps (A).
3. Connect the connectors (B).
39. Radiator Mounting Bracket, Upper Both
1. Install the radiator mount upper bracket/cushion (A), and the brackets (B).
40. Idler Pulley Base Assembly
1. Install the idler pulley base.
41. Drive Belt
1. Install the drive belt.
42. Shift Cable Bracket
1. Apply a light coat of silicone grease (P/N 08C30- B0234M) to the shift cable ends (A).
NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
2. Connect the shift cable ends to the change lever assembly (B).
3. Install the shift cable bracket (C).
4. Install the lock pins (D).
43. Clutch Slave Cylinder
1. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod (A) of the slave cylinder (B).
2. Install the slave cylinder.
3. Install the clutch line bracket (C).
NOTE: Be careful not to bend the clutch line.
44. Engine Peripheral Hose - Reconnection
1. Connect the EVAP canister hose (A) and the brake booster vacuum hose (B).
45. Engine Cover
1. Install the engine cover.
46. Engine Wire Harness Connector - Reconnection
1. Connect the connector and the harness clamps.
47. ECM Assembly
1. Connect ECM connectors A, B, and C.
NOTE: ECM connectors A, B, and C have symbols (A=(square), B=(triangle), C=(circle)) embossed on them for identification.
2. Install the ECM (D).
3. Install the cover (A).
48. Battery Cable - Reconnection From Fuse/Relay Box
1. Connect the cable.
49. Intake Air Pipe
1. Install the intake air pipe.
50. Under Cowl Panel
1. Install the under cowl panel (A).
51. Center Cowl Cover
1. If necessary, install the hood rear seal (A).
2. Connect the windshield washer tube (B).
3. Install the center cowl cover (C).
52. Both Side Cowl Covers
1. Install the side cowl cover (A).
2. The left side is shown; repeat on the right side.
53. Wiper Arm Assembly
NOTE: Set the wiper arms to the auto-stop position before installation.
1. Install the wiper arms (A).
2. Install the cowl top wiper covers (B).
54. Air Cleaner Assembly
1. Install the air cleaner (A).
2. Install the harness clamp (B).
3. Connect the intake air pipe (C) and the intake air duct (D).
55. Intake Air Duct
1. Install the intake air duct.
56. Front Wheel
1. Install both front wheels.
NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.
57. Battery
1. Install the battery (A) and the battery setting plate (B).
NOTE: Do not deform the battery setting plate by over-tightening the nuts.
58. Battery Terminal - Reconnection
NOTE: If the battery performs abnormally, test the battery.
1. Clean the battery terminals.
2. Connect the positive cable (A) to the battery.
NOTE: Always connect the positive side first.
3. Connect the negative cable and battery sensor (B) to the battery.
4. Apply multipurpose grease to the terminals to prevent corrosion.
59. Fuel Filler Cap
1. Install the fuel fill cap.
60. HDS DLC - Connection
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
61. Fuel Pump On
1. From the INSPECTION MENU of the HDS, select Fuel Pump ON.
NOTE: Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
2. Turn the ignition switch to LOCK (0).
62. Fuel Line Leak Check
1. Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.
63. MTF Replacement
1. Remove the filler plug (A) and the sealing washer (B).
2. Refill the transmission with MTF to the proper level (C). Always use Honda Manual Transmission Fluid (MTF).
3. Reinstall the filler plug with a new sealing washer.
64. Manual Transmission After Install - Check
1. Check the shift lever operation.
2. Check the clutch operation.
65. Engine Oil - Replacement
1. Refill the engine with the recommended engine oil.
66. Radiator Coolant - Replacement
1. Pour Honda Long Life Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck.
NOTE (Except K24Z7 engine):
* Always use Honda Long Life Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.
* Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Do not add water.
NOTE (K24Z7 engine):
* Always use Honda Long Life Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail.
* Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Do not add water.
* If the vehicle is regularly driven in very low temperatures (under -31 °F,-35 °C) a 60 % concentration of coolant should be used. To accomplish this, pour 1.6 L (0.4 US gal) of Honda Extreme Cold Weather Antifreeze/Coolant Type 2 into the radiator first, then add Honda Long Life Antifreeze/Coolant Type 2 until the radiator is full.
67. Warm Up The Engine
Start the engine. Hold the engine speed at 3,000 rpm without load (A/T in P or N, M/T in neutral) until the radiator fan comes on, then let it idle.
68. Idle Speed - Inspection
1. Check the idle speed without electrical load: headlights, blower fan, radiator fan, and air conditioner off.
Idle speed should be:
USA and Canada models: 720±50 rpm (A/T in P or N, M/T in neutral)
Mexico models: 710±50 rpm (A/T in P or N, M/T in neutral)
2. Let the engine idle for 1 minute with high electric load (A/C switch on, temperature set to max cool, blower fan on High, and headlights on high beam).
Idle speed should be:
USA and Canada models: 720±50 rpm (A/T in P or N, M/T in neutral)
Mexico models: 710±50 rpm (A/T in P or N, M/T in neutral)
NOTE: If the idle speed is not within specification, do the ECM/PCM idle learn procedure. If the idle speed is still not within specification, go to symptom troubleshooting.
69. CKP Pattern Clear/CKP Pattern Learn
1. Select CRANK PATTERN in the ADJUSTMENT MENU with the HDS.
2. Select CRANK PATTERN CLEAR, and clear the CKP pattern.
3. Select CRANK PATTERN LEARNING with the HDS, and follow the screen prompts.
70. Ignition Timing - Inspection
1. Jump the SCS line with the HDS.
2. Connect the timing light to the service loop (white tape).
3. Aim the light toward the pointer (A) on the cam chain case. Check the ignition timing under a no load condition (headlights, blower fan, rear window defogger, and air conditioner are turned off).
4. If the ignition timing differs from the specification, check the cam timing. If the cam timing is OK, update the ECM if it does not have the latest software, or substitute a known-good ECM, then recheck. If the system works properly, and the ECM was substituted, replace the original ECM.
5. Disconnect the HDS and the timing light.
71. Pre-Alignment Checks
For proper inspection and adjustment of the wheel alignment, do these checks:
1. Release the parking brake to avoid an incorrect measurement.
2. Make sure the suspension is not modified.
3. Make sure the fuel tank is full, and that the spare tire, the jack, and the tools are in place on the vehicle.
4. Check the tire size and tire pressure according to tire information.
72. Caster - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Check the caster angle.
* If the measurement is within specifications, measure the front camber angle.
* If the measurement is not within specifications, check for bent or damaged suspension components.
73. Camber - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Check the camber angle.
* If the measurement is within specification, measure the toe-in.
* If the measurement for the front camber is not within the specification, go to front camber adjustment.
* If the measurement for the rear camber is not within the specification, check for bent or damaged suspension components.
74. Front Toe - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Set the steering column to the middle tilt position and telescopic positions.
2. Center the steering wheel spokes, and install a steering wheel holder tool.
3. Check the toe with the wheels pointed straight ahead.
Front toe-in: 0±2 mm (0±0.08 in)
* If adjustment is required, go to the front toe adjustment.
* If no adjustment is required, remove the alignment equipment.
75. Turning Angle - Inspection
Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.
1. Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.
2. If the measurement is not within the specifications, even up both sides of the tie-rod threaded section length while adjusting the front toe.
3. If it is correct, but the turning angle is not within the specifications, check for bent or damaged suspension components.
76. VSA Sensor Neutral Position - Memorization
1. Park the vehicle on a flat and level surface, with the steering wheel in the straight ahead position.
2. Select VSA ADJUSTMENT, then select ALL SENSORS with the HDS, and follow the screen prompts.
NOTE: See the HDS Help menu for specific instructions.
77. Steering Angle Sensor Neutral Position - Clear
1. Select EPS ADJUSTMENT, then select EPS STEERING ANGLE SENSOR VALUE CLEAR and follow the screen prompts on the HDS.
NOTE: See the HDS Help menu for specific instructions.
78. Maintenance Minder Reset
1. After doing all procedures, select the individual maintenance item you wish to reset with the HDS (See the Maintenance Minder General Information).