engine HONDA S2000 2004 2.G Workshop Manual

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No. Amps.No. Amps. Circuits Protected
Circuits Protected
1
2
3
4
5
6
7
8
9
10
11
12
13 7.5 A
15 A
10 A
20 A
7.5 A 15 A
7.5 A
15 A
7.5 A 15 A
10 A 14
15
16
17
18
19
20
21
22
23
24
25
26
2710 A
10 A
7.5 A
7.5 A 10 A
15 A
7.5 A
7.5 A
7.5 A 20 A
20 A Daytime Running Lights
Keyless Entry
Back-up
Interior Light
Small Lights
Radio
Starter Signal
Heater Control,
Cooling Fan Relay
Power Mirrors
Right Power Window
Lef t Power Window
Not used
Not used
Not used
Windshield Wiper,
Auto Stop Signal
Washer Motor
Not used
Not used
Accessory Socket
Windshield Wiper
Turn signal Light
ACG
Instrument Light, Backup
Lights
Ignition Coil
Engine Start
Fuel Pump, SRS
SRS
: Canadian Model
Fuse Locations
T aking Care of t he Unexpect ed172
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RI IOOR R F
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BOOX X

Your vehicle has several identif ying
numbers located in various places.
The Vehicle Identif ication Number
(VIN) is the 17-digit number your
Honda dealer uses to register your
vehicle f or warranty purposes. It is
also necessary f or licensing and
insuring your vehicle. The easiest
placetofindtheVINisonaplate
fastened to the top of the dashboard.
Youcanseeitbylookingthrough
the windshield on the driver’s side. It
is also on the Certification label at-
tached to the driver’s doorjamb, and
is stamped on the engine com-
partment bulkhead. The VIN is also
provided in bar code on the
Certif ication label.
Identif ication Numbers
T echnical Inf ormation178
VEHICLE IDENTIFICATION NUMBERCERTIFICATION LABEL

The Transmission Number is on a
label underneath the transmission. The Engine Number is stamped on
the back lef t corner of the engine
block, below the rear valve cover.
Identif ication Numbers
T echnical Inf ormation179
TRANSMISSION NUMBERENGINE NUMBER

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Specif ications
T echnical Inf ormation180
Dimensions
WeightsCapacities
Engine 162.0 in (4,115 mm)
68.9 in (1,750 mm)
50.6 in (1,285 mm)
94.5 in (2,400 mm)
57.9 in (1,470 mm)
59.4 in (1,510 mm)
13.2 US gal (50)
131.6 cu-in (2,157 cm
)
11.1 : 1 1.72 US gal (6.5
)
2.01 US gal (7.6)
5.1 US qt (4.8
)
5.1 US qt (4.8)
5.9 US qt (5.6)
1.7 US qt (1.6)
1.7 US qt (1.6)
0.78 US qt (0.74
)
0.81 US qt (0.77)
2.7 US qt (2.6)
4.4 US qt (4.2)
3.43 x 3.57 in (87.0 x 90.7 mm)
Length
Width
Height
Wheelbase
Track
Gross vehicle weight rating
Fuel tank
Engine coolant
Engine oil
Manual
transmission
fluid
Differential
oil
Windshield
washer
reservoir
See the certification label attached
to the driver’s doorjamb.
Water cooled 4-stroke DOHC
VTEC 4-cylinder gasoline engine
Type
BorexStroke
Displacement
Compression ratio
Spark plugs
Spark Plug Gap
0.04 in (1.1 mm)PK22PR-L11S PFR7G-11S
Including the coolant in the reserve tank and that remaining in the
engine.
Reserve tank capacity:
0.16 US gal (0.6
)
Excluding the oil remaining in the engine.
Front
Rear
1:
2:
NGK :
DENSO : Change
Total
Change
Total
Change
Total
Change
Total
U.S. Vehicles
Canadian
Vehicles
0mm
0.1 mm
1
2
Including filter
Without filter

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The burning of gasoline in your
vehicle’s engine produces several by-
products. Some of these are carbon
monoxide (CO), oxides of nitrogen
(NOx) and hydrocarbons (HC).
Gasoline evaporating f rom the tank
also produces hydrocarbons. Con-
trolling the production of NOx, CO,
and HC is important to the environ-
ment. Under certain conditions of
sunlight and climate, NOx and HC
react to f orm photochemical ‘‘smog.’’
Carbon monoxide does not contri-
bute to smog creation, but it is a
poisonous gas.
In Canada, Honda vehicles comply
with the Canadian emission
requirements, as specif ied in an
agreement with Environment
Canada, at the time they are
manuf actured.
Your vehicle has a Positive
Crankcase Ventilation System. This
keeps gasses that build up in the
engine’s crankcase f rom going into
the atmosphere. The Positive Crank- case Ventilation valve routes them
from the crankcase back to the
intake manif old. They are then
drawn into the engine and burned.
As gasoline evaporates in the f uel
tank, an evaporative emissions
control canister f illed with charcoal
adsorbs the vapor. It is stored in this
canister while the engine is of f . Af ter
the engine is started and warmed up,
the vapor is drawn into the engine
and burned during driving.
The United States Clean Air Act
sets standards f or automobile
emissions. It also requires that
automobile manufacturers explain to
owners how their emissions controls
workandwhattodotomaintain
them. This section summarizes how
the emissions controls work.
Scheduled maintenance is on page
.
123
Emissions Cont rols
T echnical Inf ormation
Crankcase Emissions Control
System Evaporative Emissions Control
System
The Clean Air Act
185

The exhaust emissions controls
include f our systems: PGM-FI,
Ignition Timing Control, Secondary
Air Injection System, and Three Way
Catalytic Converter. These four
systems work together to control the
engine’s combustion and minimize
the amount of HC, CO, and NOx that
comes out the tailpipe. The exhaust
emissions control systems are
separate f rom the crankcase and
evaporative emissions control
systems.
The PGM-FI System uses sequential
multiport f uel injection.
It has three subsystems: Air Intake,
Engine Control, and Fuel Control.
The Engine Control Module (ECM)
uses various sensors to determine
how much air is going into the
engine. It then controls how much
f uel to inject under all operating con-
ditions.During engine warm-up, air is
pumped into the exhaust to reduce
emissions when the engine is cold.
The three way catalytic converter is
in the exhaust system. Through
chemical reactions, it converts HC,
CO, and NOx in the engine’s exhaust
to carbon dioxide (CO ), nitrogen
(N ), and water vapor.
The emissions control systems are
designed and certif ied to work to-
gether in reducing emissions to
levels that comply with the Clean Air
Act. To make sure the emissions
remain low, you should use only new
Honda replacement parts or their
equivalent f or repairs. Using lower
qualitypartsmayincreasethe
emissions f rom your vehicle.
The emissions control systems are
covered by warranties separate from
the rest of your vehicle. Read your
warranty manual f or more informa-
tion.
The Onboard Ref ueling Vapor
Recovery (ORVR) system captures
the f uel vapors during ref ueling. The
vapors are adsorbed in a canister
f illed with activated carbon. While
driving, the f uel vapors are drawn
into the engine and burned of f .
This system constantly adjusts the
ignition timing, reducing the amount
of HC, CO, and NOx produced.
2
2
Emissions Cont rols
T echnical Inf ormation
Exhaust Emissions Controls
Onboard Ref ueling Vapor
Recovery Replacement Parts
PGM-FI Syst emSecondary A ir Inject ion Syst em
Three Way Catalytic Converter
Ignit ion T iming Cont rol Syst em
186

The three way catalytic converter
contains precious metals that serve
as catalysts, promoting chemical
reactions to convert the exhaust
gasses without af f ecting the metals.
The catalytic converter is ref erred to
as a three-way catalyst, since it acts
on HC, CO, and NOx. A replacement
unit must be an original Honda part
or its equivalent.
The three way catalytic converter
must operate at a high temperature
for the chemical reactions to take
place. It can set on f ire any com-
bustible materials that come near it.
Parkyourvehicleawayfromhigh
grass, dry leaves, or other f lamma-
bles.A defective three way catalytic
converter contributes to air pollution,
and can impair your engine’s per-
f ormance. Follow these guidelines to
protect your vehicle’s three way
catalytic converter.
Always use unleaded gasoline.
Even a small amount of leaded
gasoline can contaminate the
catalyst metals, making the three
way catalytic converter inef f ective. Keep the engine tuned-up.
Have your vehicle diagnosed and
repaired if it is misf iring, back-
f iring, stalling, or otherwise not
running properly.
Three Way Catalytic Converter
T echnical Inf ormation187
THREE WAY CATALYTIC CONVERTER

If you take your vehicle f or a state
emissions test shortly af ter the
battery has been disconnected or
gone dead, it may not pass the test.
This is because of certain ‘‘readiness
codes’’ that must be set in the on-
board diagnostics f or the emissions
systems. These codes are erased
when the battery is disconnected,
and set again only after several days
of driving under a variety of
conditions.If the testing f acility determines that
the readiness codes are not set, you
will be requested to return at a later
date to complete the test. If you must
get the vehicle re-tested within the
next two or three days, you can
condition the vehicle for re-testing
by doing the f ollowing.
Make sure the gas tank is nearly,
but not completely, f ull (around
3/4).
Make sure the vehicle has been
parked with the engine of f f or 8
hours or more.
Make sure the ambient
temperature is between 20° and
95°F. Without touching the accelerator
pedal, start the engine, and let it
idle f or 20 seconds.
Keep the vehicle in Neutral.
Increase the engine speed to 2,000
rpm,andholditthereuntilthe
temperature gauge rises to at least
1/4of thescale(about3minutes).
St at e Emissions T est ing
T echnical Inf ormation
T esting of Readiness Codes
188

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#
) This manual covers maintenance and recommended
procedures f or repair to engine and chassis components.
It is written f or the journeyman mechanic, but is simple
enough f or most mechanically-inclined owners to under-
stand.
This manual complements the Service Manual by
providing in-depth troubleshooting inf ormation f or each
electrical circuit in your vehicle.
This manual describes the procedures involved in the
replacement of damaged body parts.
Authorized Manuals
Service Manual:
Electrical T roubleshooting Manual:
Body Repair Manual:
196
NOTE: Dealers and Companies please provide dealer or company name,
and also the name of the person to whose attention the shipment should
be sent. For purchases outside U.S.A. please write to the address shown
below for a quotation.
P.O. BOX 07280·DETROIT, MICHIGAN 48207·1-800-782-4356
Customer Name Attention
Apartment Number
State & Zip Code
City
Daytime Telephone Number
Check or money order enclosed payable to Helm Inc U.S. funds only.
Do not send cash
Master
Card VISA
Check here if your billing address is different
from the shipping address shown above.
Account Number Expiration: Mo. Yr.
CUSTOMER SIGNATURE DATE
Street Address No P.O. Box Number
()
These Publications cannot be returned for credit without receiving advance authorization within 14
days of delivery. On returns, a restocking fee may be applied against the original order.

CONT INUED
Accessories.................................
Installation .105
...............
Accessory Power Socket . 70
ACCESSORY (Ignition Key .......................................
Position) .53
....................
Additives, Engine Oil . 130
...............................
Airbag (SRS) .9, 18
..............................
Air Conditioning .74
.......................
Air Pressure, Tires .146
.............................
Alarm, Anti-theft .53
......................................
Antif reeze .132
Anti-lock Brakes (ABS) ....................
Indicator Light .41, 118
...................................
Operation .117
.
Anti-thef t Steering Column Lock . 53
............................
Anti-thef t System .94
......................................
Audio Panel .71
..................................
Audio System .78
...............
Automatic Speed Control . 95 ............................
Capacities Chart .180
.............
Carbon Monoxide Hazard . 34
........................
Cargo, .107
..............
CAUTION, Explanation of . ii
...........................................
CD Care .85
........................
CD Error Messages .86
.....................................
CD Changer .84
.......
CD Changer Error Messages . 87
.........................................
CD Player .83
........................
Certif ication Label .178
...................................
Chains, .150
Changing Oil ........................................
How to .130
......................................
When to .121
....................
Changing a Flat Tire .155
...
Charging System Indicator . 40,166
............
Checklist, Bef ore Driving . 112
........
Back-up Light Replacement . 141Battery
Charging System ...........................
Indicator .40, 166
............................
Jump Starting .162
..............................
Maintenance .151
............................
Specif ications .181
................................
Bef ore Driving .99
....................................
Belts,Seat .8,15
.............................
Beverage Holder .70
..................................
Booster Seats .31
............................................
Brakes .116
...........
Anti-lock System (ABS) . 117
.............
Break-in, New Linings . 100
...........................................
Fluid .136
.........................................
Parking .67
.................
System Indicator . 40,168
..............
Wear Indicators, Disc . 117
.............................
Braking System .116
.................
Break-in, New Vehicle . 100
..
Brightness Control, Instruments . 49
........................
Brights, Headlights .48
.........................
Bulb Replacement .137
..........................
Back-up Lights .141
.................................
Headlights .137
...........
Side Turn Signal Lights . 139
............................
Specif ications .181 ............
Turn Signal Lights . 139,141
..............................
Bulbs, Halogen .137
how to carry
tires
Index
B A C
I