ERS HONDA CIVIC 2003 7.G Workshop Manual

sRs
DTG Troubleshooting (cont'dl
37. Check resistance between the No. 15 terminal of
gauge assembly connector A (22P) and body
ground. There should be an open circuit, or at least
1M0.
GAUGE ASSEMBLY CONNECTOR A I22PI
ls the resistance as specified?
YES-Short to ground in the side airbag cutoff
indicator circuit; replace the gauge assembly.l
NO Short to ground in the dashboard wire
harness A, floor wire harness, or OPDS unit
harness; replace the faulty harness.l
Wire side of female terminals
23-104
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DTC 15-3: Faulty OPDS Sensor
1. Erase the DTC memory {see page 23-261.
2. Turn the ignition switch ON (ll), and check that the
SRS indicator comes on for about 6 seconds and
then goes off.
Does the SRS indicator stay on?
YES-Go to step 3.
NO Intermittent failure, system is OK at this time.
Go to Troubleshooting Intermittent Failures (see
page 23-26).
NOTE: Aftermarket devices (fluorescent lights,
laptop computers, etc.) used near the front
passenger's seat-back can interfere with the seat-
back sensors and cause a false DTC 15-3. lf one of
these devices was used, erase the DTC, operate the
device near the seat-back, and recheck for DTCs. lf
DTC 15-3 is reset, erase it, and do not use the
device near the seat-back.
3.
4.
Check the connection at the OPDS sensor harness
connector and the OPDS unit connector.
Are the connections OK?
YES-Go to step 4.
NO Reconnect the OPDS sensor harness
connector, and clear the DTC.I
Replace the OPDS sensor/seat-back foam (see page
20-141, and initialize the OPDS (see page 23-27).
Erase the DTC memory, then check for DTC 15-3.
ls DTC 15-3 indicated?
YES Replace the OPDS unit (see page 23-1241.a
NO The system is OK.l
{

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The SRS lndicator Stays On When ln "SCS"
Menu Method
NOTE:. lf you cannot retrieve DTCSwith the PGM Tester
using the SRS menu method. retrieve the flash codeswith the Tester in SCS mode {see page 23-24|,.. A new SRS unit must sense the entire system is OK
before completing its initial self-test. The most
common cause of an incomplete self-test is the
failure to replace all deployed parts after a collision,
in particular, seat belt tensioners and seat belt buckletenstoners.. An incomplete self-test prevents the PGM Tester fromretrieving DTCS, although flash codes are available in
the Tester's SCS mode.
1 . Erase the DTC memory using the MES connector(see page 23-26).
Does the SRS indicator go off while you are
erasing the DTC memory?
YES-Go to step 42.
NO Go to step 2.
Check the No. '13 { 10A) fuse in the under-dash
fuse/relay box.
lsthe f use OK?
YES--Go to step 19.
NO Go to step 3.
Replacethe No. 13 (10A) fuse.
Turn the ignition switch ON (ll), and wait for 30
seconds. Then turn the ignition switch OFF.
Check rhe No. 13 (10A) fuse.
ls the f use OK?
YES The system is OK at this time.I
NO Go to step 6.
3.
I
6. Replace the No. 13 (10A) fuse.
7. Turn the ignition switch OFF. Disconnect the
battery negative cable, and wait for 3 minutes.
8. Disconnect the driver's airbag 4P connector (see
step 2 on page 23-21).
9. Disconnect the front passenger's airbag 4P
connector (see step 3 on page 23,21).
10. Disconnect both seat belt tensioner 2P connectors(see step 5 on page 23-221.
'11. DisconnectSRS unitconnectorA{18P)fromthe
SRS unit (see step 7 on page 23-22],.
'12. Reconnect the battery negative cable.
13. Turn the ignition switch ON (ll), and wait for 30
seconds. Then turn the ignition switch OFF.
14. Checkthe No. 13 ('10A) fuse.
ls the f use OK?
YES-Short to ground in the SRS unit; replace the
SRS unit (see page 23-122).a
NO Go to step 15.
15. Replace the No. 13 (10A) fuse.
{cont'd)
23-107

sRs
Component Replacement/lnspection After Deployment
NOTE: Before doing any SRS repairs. use the PGM
Tester SRS menu method to check for DTCS; refer to the
DTC Troubleshooting Index for the less obvious
deployed parts (seat beit tensioners, front sensors, side
airbag sensors, etc.)
After a collision where the seat belt tensioners
deployed, replace these items:' Seat belt tensioners. Seat belt buckle tensioners. SRS unit. Front impact sensors
After a collision where the front airbag(s) deployed.
replace these items:. SRS unit. Deployed airbag(s). Seat belt tensioners. Seat belt buckle tensioners. Front impact sensors
After a collision where the side airbag{s) deployed,
replace these items:. SRS unit. Deployed side airbag(s). Side impact senso(s)for the side(s) that deployed
During the repair process, inspect these areas:
. lnspect allthe SRS wire harnesses. Replace, don't
repair, any damaged harnesses.. Inspectthecable reelfor heatdamage. lf there is any
damage, replace the cable reel.
Afterthe vehicle is completely repaired, turn the
ignition switch ON (ll). lf the SRS indicator comes on for
about 6 seconds and then goes off, the SRS airbag
system is OK. lf the indicator does not function properly,
use the PGM Tester SRS Menu Method to read the DTC
(see page 23-23). lf this doesn't retrieve any codes, use
the Tester's SCS menu method (see page 23-24). lf you
still cannot retrieve a code, go to SRS Indicator Circuit
Troubleshooting.
23-112
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sRs
Airbag Disposal
Special Tool Required
Deployment tool 07HAz-SG00500
Before scrapping any airbags, side airbags, seat belt
tensioners, or seat belt buckle tensioners (including
those in a whole vehicle to be scrapped), the airbags,
side airbags, seat belt tensioners, or seat belt buckle
tensioners must be deployed. lf the vehicle is still within
the warranty period, the Honda District Service
Manager must give approval and/or special instruction
before deploying the airbags, side airbags, seat belt
tensioners, or seat belt buckle tensioners. Only after the
airbags, side airbags, seat belt tensioners, or seat belt
buckle tensioners have been deployed (as the result of
vehicle collision, for example), can they be scrapped.
lf the airbags, side airbags, seat belt tensioners, and
seat belt buckle tensioners appear intact (not deployed),
treat them with extreme caution. Follow this Drocedure.
Deploying Airbags in the Vehicle
lf an SRS equipped vehicle is to be entirely scrapped, its
airbags, side airbags. seat belt tensioners. and seat belt
buckle tensioners should be deoloved while still in the
vehicle. The airbags, side airbags, seat belttensioners,
and seat belt buckle tensioners should not be
considered as salvageable parts and should never be
installed in another vehicle.
1. Turn the ignition switch OFF, then disconnect the
battery negative cable, and wait at least 3 minutes.
2. Confirm that each airbag, side airbag, or seat belt
tensioner is securely mounted.
3. Conf irm that the specia I tool isfunctioning properly
by following the check procedure on the tool label.
23-116
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Driver's Airbag:
4. Remove the access panel f rom the steering wheel,
then disconnect the driver's airbag 4P connector
from the cable reel (see step 2 on page 23-21).
Front Passenger's Airbag:
5. Lowerthe glove box, then disconnectthe front
passenger's airbag 4P connector from dashboard
wire harness B (see step 3 on page 23-211.
Side Airbag:
6. Disconnect the side airbag 2P connectors from the
floor wire harness (see step 4 on page 23-211.
Seat belt tensioner:
7. Disconnect the seat belt tensioner 2P connectors
from the floor wire harness {see step 5 on page 23-
22). Pull the seat belt out all the way, and cut it off.
Seat belt buckle tensioner:
8, Disconnect the seat belt buckle tensioner 4P
connectors from the floor wire harness (see step 6
on page 23-221.

)
9. Cut off each connector, strip the ends of the wires,
and connect the deployment tool alligator clips (A)
to the wires. Place the deployment tool at least 30
feet (10 meters) away from the vehicle.
NOTE: The driver's airbag and the front passenger's
airbag each have four wires, two yellow and two
red. Twist each Dair of unlike colored wires
together, and connect an alligator clip to each pair.
I
!
10. Connect a 12 volt battery to the tool.
. lf the green light on the tool comes on, the igniter
circuit is defective and cannot deDlov the
component. Go to Disposal of Damaged
ComDonents.. lf the red light on the tool comes on, the
component is ready to be deployed.
11. Push the tool's deployment switch. The airbags and
tensioners should deploy (deployment is both
highly audible and visible: a loud noise and rapid
inflation of the bag, followed by slow deflation).
. lf the components deploy and the green light on
the tool comes on, continue with this procedure.
. lf a component doesn't deploy, yet the green
light comes on, its igniter is defective. Go to
Disposal of Damaged components.. During deployment, the airbags can become hot
enough to burn you. Wait 30 minutes after
deployment before touching the airbags.
12. Dispose ofthe complete airbag. No pan of it can be
reused. Place it in a sturdy plastic bag (A), and seal
rt securery.
(cont'd)
/:
i'..-':
23-117

sRs
Airbag Disposal (cont'dl
Deploying Components Out of the Vehicle
lf an intact airbag or tensioner has been removed from
a scrapped vehicle, or has been found defective or
damaged during transit, storage, or service, it should be
deoloved as follows:
1. Confirm that the special tool isfunctioning properly
by following the check procedure on this page or
on the tool label.
2. Position the airbag face up, outdoors, on flat
ground, at least 30 feet (10 meters) from any
obstacles or DeoDle.
3. Follow steps 9 through 1 1 of the in-vehicle
deployment procedure.
Disposal of Damaged Components
1. lf installed in a vehicle, follow the removal
procedure for the driver's airbag (see page 23-113),
front passenger's airbag (see page 23-114), side
airbag (see page 23-115). seat belt tensioner (see
page 23-4), and seat belt buckle tensioner.
2. In all cases. make a short circuit by cutting,
stripping, and twisting together the two inflator
wires.
NOTE; The driver's and passenger's airbag each
have four wires: twist each pair of like-colored
wires together
Package the component in the same packaging that
the new reolacement Dart came in.
Mark the outside of the box "DAMAGED AIRBAG
NOT DEPLOYED'" ''DAMAGED SIDE AIRBAG NOT
DEPLOYED", "DAMAGED SEAT BELT TENSIONER
NOT DEPLOYED" or "DAlvlAGED SEAT BELT
BUCKLE TENSIONER NOT DEPLOYED" so it does
not get confused with your parts stock.
Contact your Honda District Service Manager for
how and where to return it for disposal.
23-118
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Deployment Tool Check
1. Connect the yellow clips to both switch protector
handles on the tool; connect the tool to a battery.
2. Push the operation switch: green means the tool is
OK; red means the tool is faulty
3. Disconnectthe battery and the yellow clips.
J

)
3.
4.
Cable Reel Replacement
Removal
1. Make sure the front wheels are aligned straight
ahead.
Disconnect the battery negative cable, and wait at
least 3 minutes.
Remove the driver's airbag {see page 23-113).
Disconnect the connector (Al from the cruise
control sevresume switch, then remove the
steering wheel bolt (B).
Align the front wheels straight ahead, then remove
the steering wheel with a steering wheel puller (see
step 3 on page '17-6).
Do not tap on the steering wheel or steering
column shaftwhen removing the steering wheel.
)
5.
I,
6. Remove the dashboard lower cover (Ai.
Remove the column cover screws (A), then remove
the column covers (8, C).
7.
(cont'd)
23-119

)
Install the steering column covers.
lf necessary, center the cable reel. {New
replacement cable reels come centered.) Do this by
first rotating the cable reel clockwise until it stops,
Then rotate it counterclockwise labout 2 1 12 lurns)
untilthe arrow mark on the cable reel label Doints
straight up.
- A gn the projections on the cable reel with the
noles on the steering wheel, and installthe steering
Ai\eel with a new steering wheel bolt (A).
)c
23-121
8. lnstallthe driver's airbag (see page 23-113).
9. Reconnect the battery negative cable.
10. After installing the cable reel, confirm proper
syslem operalton:
. Turn the ignition switch ON (ll); the SRS indicator
should come on for about 6 seconds and then go
off.. After the SRS indicator has turned off, turn the
steering wheel fully left and right to confirm the
SRS indicator does not come on.. Make sure the horn works.. Make sure the cruise control works,

Service Manual lndex
)s
NOTE: Referto the lollowing listto look up A/C Pressure Switch CircuitDTCS, symptoms, fuses, connectors, wire Troubleshooting ......... ...-.-....-...-.-.-....-..21-32 Bharnesses, specifications, maintenanceschedules, and general serviceinlormation:
DTC Troubleshooting Indexes
A/C Signal CircuitTroubleshooting.........................-...... 11-'133 Back-up Light SwitchTest .......................................................... 13'3A/F lAir Fuel Ratiol SensorABS/TCS Components ........................ 19-34 Replacement ....................................... 1 1-113 Back-up Li9ht3EPS Components ................................. '17-22 Circuit DiagramFueland Emissions11-i A-Dillar Corner Trim
ABS Indicator Circuit
Heating/Ventilation ................................ 21-9 Replacement ...............-.....-..............-.... 20,96 Ball Joint BootssRS ........................................................ 23-28Replacement ......
... 19-52 Ball Joints
22-75
18 16
Remova1.............-.......... . ...........18-10Symptom Troubleshooting Indexes TroubleshootingABS/TCSComponents........................ 19 35Cruise Control System ..........................4 38 ABS Modulator-contml UnitEPS Components ................................. 17-23 Bemoval/lnstallation ............................ 19-57 BettervFan Controls10,12
Accessory Powor Socket Front
Blowor Pow€r Transistor
.......22 50
Blower UnitRemoval/lnstallation ............................ 21-39
Fuel and Em issions .............................. 11-10 ABS/TCS ComoonentsHeating/Ventilation..............................21 10 Component Location Index ................. 19-30 Beverage Holder
SRS ........................................................ 23'30 CircuitDiaqram.......................... 19'42Blower MotorReplacement .....21 41
21-38
Power 0istribution ...............................22-46 TesVReplacement .............................. 22'149Under-dash Fuse/Relay Box ............... 22 45Under-hood Fuse/Belay Box ...............22 44 Accessory Power Sockets
Fuse/Relay lndexes
(to harness)
Connector and Wire Harness lndexesComponent Connectors
Circuit Oiagram .................................. 22-149
Air Cleaner......2214 Rep1acemen1.....................................11-162
Air MixControl MotorMeintenence section .................... Section 3 Replacement ......................................... 21'34 Brake CelipersTest......................21-34 Overhaul19-14,23Gene.al lnlormation section........ Section 1
21.57
Airbag. Driver's
Ahernator FR Signal CircuitTroubleshooting .... .........-..........11 134
AntennaReplacement
Inspection ............................................. 19-24Rep|acement................. .................... 19-25
Bieke Meder Cylinder
Irake Discs
A
Replacement ....................................... 23 1 'l3 Inspection .................... ................... 19-13,22Repair ...........-...................................... 23 1 16Brake Fluid Level SwitchAirbag. Front Passenger's TestBeplacement....................................... 23-1 14AIC Brake LightsComponent Location fndex ...................21-3 Altemator CircuitDiagram....................................22-74Description.....................................-....21'1'l Beplacement ................ ........................... 4 29CircuitDiagram....................................21-14 Overhaul .................................................4-30 Brake Lines and Hoses
19.10
A/C CompressolReplacement .......-...-............................. 21 -41
A/C Compr€ssor ClulchRep1acement......................................... 19-15.........22-103 Inspection ............................................. 19-16Inspecton........Overhaul ..........
A/C CondenserReplacement,.,
21-442l-49 Audio Unit
Replacement
Brake PadsRemoval/lnstallation .. ........................22-100 Inspection/Rep1acement................ 19-11,20A/C Compressor Clutch CircuitTroubleshooting ................................... 21-30 Audio Unit Connector Brake Pedal22101 Adjustment..............19,6ArfC Comoressor Relief ValvcReplacement ..........-...-.......................... 21-51 Audio/Entertainment
A/C Compr$sor Thermal Protector Circuit DiagramReplacement............-............................ 21-51
Component Location In dex .................22-9A Test .......-.............. 22-84Breke Pedal Posilion Switch
Brake Pedal Position Switch Signal Clrcuit11-137
.....21 52
A/C Condenser Fan CircuitTroubleshooting ................... . . . . . .....21-28
)s
Troubleshooting
(cont'd)

Service Manual Index
(cont'dl
Brake System Indicator CircuitCircuit DiagramConventional Brake Components..... 19-9TroubleshootingABS/TCS Components .... ....... ...... 19-55
Bulb, GeugeRep|acemenl................ .. ............2263
Bulb, HeadlightReplacement ......................................... 22-A1
Bumper, FrontRemoval/1nsra11ation ............................ 20 85
Bumper, RearRemoval/lnstallation... ... . .....20.86
Combination Light SwilchTesVReplacement ..............................22 80
Connecting Rod BearingsRep|acement...................... .......-....7-8
Connecting Rod Boltsf nspection ....................-.-.-.-.................... 7 -24
Connecting RodsInspection ........,,.,.,...,.,.,.,.,,,,.,,,.,.,.,.,.,.,.,.. 7 5
Connectors(See first page of this Index)
Conventional Brake Component3Component Location Index ................... 19'3Troub1eshootin9 ..................................... 19-4
Cylinder Head AssemblyComponent Location Index ..................... 6-3Inspection ................................................. 6 6Removal ..........&23Insta11alion .............................................. 6 39
Cylinder Head Cover8emova1 ..............-.-................................. 6-22Installation ..............................................6-41
Cylinder Head, BareInspecton..,.....,.
D
c
Cable ReelReplacement....................................... 23-1 19
CamshaftInspection .......................-...-................... 6-29
Cargo Area LightTesVRep1acement ................................ 22-97
CarpetReplacement.....-...-..... ... ......-.20-55
Ceiling Light-estrReplacement ................................ 22.96
Charging SystemComponent Location Index................... 4-20Circuit Diagram ...................................... 4-21
19-8
CoolantInspection .................. ..... .. 106Replacement................. ... . .. 10 6
Coolant Temperature Gat|geTroub1eshootin9................................... 22 64
Cooling SyslemComponent Location Index................... 10-2
Countershaft BearingsReplacement............... ..................... 13-42
Cowl CoverReplacement............... .. ..... ....20-95
CrankshaftRemoval .................................................. 7 -12
Repair ..................
Inspec(on,,,,,........1 14
Dampers. FrontReplacement................ ..................... 18 20
Oampers, RearRep1acement......................................... 18-34
Dash VentsBemoval/lnstallation .-.......................... 20-64
DashboardBemoval/1nsta11ation ............................ 20-66
Oashboard Center PanelRemoval/1nstaf 1ation ............................ 20 62
Dashboard Lower CoverRemoval/lnstallation ...................... 20-59, 63
Dashboard Under CoverRemoval/lnstallation ............................ 20 60
Diff erential Carrier Bearings, M/TRep1acement,,......,...,...,.,.,,,.,.,,,........,.,. 13-54
Ditferential Oil Seals, M/T8ep1acement......................................... 13-55
Differential Pinion Gears, M/TInspection .,....-,.,,,.,..,.-,.,.........,.,.,,, 13 53
OLC CircuitTroubleshooting ................................ 1 1-109
Door GlassRep1acement.,.,,,,,,,,,,,.,,,,,,,,,,.,.,.,.,.,,,,,,.,, 20-9Adjustment. .. .....................20-11
Door Glass WeathelstripsReplacement .............-.. . . . ..........-......20 10
Door LatchesReplacement ..........-.-.............................. 20-7
Door Lock ActuatorsTest ...................................................... 22-154
Door Lock Knob SwitchesTest -......... . . . - . . . . . . . . ......22-160
Door Lock SwitchesTest ........... ............................ ............. 22-160
Door Outer HandlesRep1acemen1 ........................................... 20-6
3
Child Seat Tether AnchorRemoval/lnstaf lat;on .. ........................ 23 11
CKP (Crankshaft Position) SonsorReplacement....................................... 1 1-116
ClutchComponentLocation 1ndex................... 12-3Rep1acemen1........................................... 12-9
Clutch InteYlock SwitchTest.....-........-...-............. ...---.-.......4-6
Clutch Master CylinderReplacement........................................... 12 5
clutch PedalAdjustment ............................................. 12 4
Clutch Pedal Position SwitchTest.,.,,,,,.,,,.,.,,,,,,.,.,,,,,,,,,.,,,,,.. ......445
lnstallation.................. . ..... .....1-24
Crankshalt Main BearingsReplacement........-.-.................................. 7-6
CrankshaftOil Seal,Transmission End1nstanation .............................................. 7 28
Crankshafl PulleyRemoval/lnstallation -..................-.......... 6-1 1
Cruise Control Actuator
Troubleshooting
Clutch Slave CylindorBeplacemeit...
...................... 4-43
.......4-22
Test
12-1
RepIacement........................................... 4-44
Cruise Control Actuator CableAdjustment ............................................. 4 45
Cruise Control Main SwitchTesVRep1acement .................................. 4 42
Cruise Control Set/Resume/Cancel SwitchTesVRep1acement .................................. 4 42
Cruise Control SystomComponent Localion Inde\................... 4-36Circuit Diagram ....-................................. 4 37
Cruise Control UnitInputTest.............................. .. ...4,40CMP {Camshaft Positionl Senso]Replacement....-...-.............................. 1 1-128
CMP (TDC) SensorsReplacement............-.......................... 1 1 1 14