• HEADINGS
  • Component Location Index
  • Symptom Troubleshooting Index
  • Circuit Diagram
  • Starter System Circuit Troubleshooting
  • Clutch Interlock Switch Test
  • Starter Performance Test
  • Starter Removal and Installation
    • Removal
    • Installation
  • Starter Overhaul
    • Disassembly/Reassembly
    • Armature Inspection and Test
• FIGURES
  • Fig. 1: Identifying Starting System Component Location
  • Fig. 2: Starting System - Circuit Diagram
  • Fig. 3: Connecting Ammeter And Voltage To Battery
  • Fig. 4: Identifying Solenoid Terminals (04-05 Models)
  • Fig. 5: Identifying Solenoid Terminals (06-08 Models)
  • Fig. 6: Identifying Clutch Interlock Switch 2P Connector
  • Fig. 7: Checking Continuity Between Terminals
  • Fig. 8: Connecting Battery Terminal To Starter
  • Fig. 9: Disconnecting Battery Terminal From Starter
  • Fig. 10: Connecting Starter To Battery
  • Fig. 11: Disconnecting Starter Cable From B Terminal (04-05 Models)
  • Fig. 12: Disconnecting Starter Cable From B Terminal (06-08 Models)
  • Fig. 13: Connecting Starter Cable To B Terminal With Torque Specifications (04-05 Models)
  • Fig. 14: Connecting Starter Cable To B Terminal With Torque Specifications (06-08 Models)
  • Fig. 15: Disassembly/Reassembly Of Starter Overhaul
  • Fig. 16: Identifying Armature
  • Fig. 17: Checking Commutator Surface
  • Fig. 18: Checking Commutator Diameter
  • Fig. 19: Checking Commutator Runout
  • Fig. 20: Checking Commutator Mica Depth
  • Fig. 21: Checking Continuity Between Segments Of Commutator
  • Fig. 22: Identifying Armature Core
  • Fig. 23: Checking Continuity Between Commutator And Armature Coil Core & Between Commutator And Armature Shaft
  • Fig. 24: Measuring Brush Length
  • Fig. 25: Checking Continuity Between Brushes
  • Fig. 26: Identifying Planetary Gears And Internal Ring Gear
  • Fig. 27: Turning Gear Shaft
  • Fig. 28: Installing Brush Into Brush Holder
• TABLES
  • SYMPTOM TROUBLESHOOTING

2004-08 ENGINE

Starting System - TSX

Component Location Index

Fig. 1: Identifying Starting System Component Location
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Symptom Troubleshooting Index

SYMPTOM TROUBLESHOOTING

Symptom	Diagnostic procedure	Also check for
Engine does not start (does not crank)	Check for loose battery terminals or connections. Test the battery for a low charge (see BATTERY TEST ). Check the starter (see STARTER SYSTEM CIRCUIT TROUBLESHOOTING ). Check the starter cut relay (see POWER RELAY TEST ). Check the transmission range switch (A/T) (see TRANSMISSION RANGE SWITCH TEST ). Check the clutch interlock switch (M/T) (see CLUTCH INTERLOCK SWITCH TEST ). Check the ignition switch or wire (see TEST ).	Poor ground at G101 (A/T) or G501 (M/T)
Engine cranks, but does not start	Check for PGM-FI DTCs (see DTC TROUBLESHOOTING ). Check the fuel pressure (see FUEL PRESSURE TEST ). Check for a plugged or damaged fuel line (see FUEL LINE INSPECTION ). Check for a plugged fuel filter (see FUEL FILTER REPLACEMENT ). Check the throttle body (see THROTTLE BODY TEST ). Check for low engine compression (see ENGINE COMPRESSION INSPECTION ). Check for a damaged or broken cam chain.	Fuel level in tank
Engine is hard to start	Check for PGM-FI DTCs (see DTC TROUBLESHOOTING ). Check the fuel pressure (see FUEL PRESSURE TEST ). Check for a plugged or damaged fuel line (see FUEL LINE INSPECTION ). Check for a plugged fuel filter (see FUEL FILTER REPLACEMENT ).
Engine cranks slowly	Check for loose battery terminals or connections. Test the battery for a low charge (see BATTERY TEST ). Check the starter for binding (see STARTER OVERHAUL ). Check for excessive drag in the engine.

Circuit Diagram

Fig. 2: Starting System - Circuit Diagram
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Starter System Circuit Troubleshooting

NOTE:

Air temperature must be between 59 and 100°F (15 and 38°C) during this procedure. After the inspection, you must reset the engine control module (ECM)/powertrain control module (PCM). Otherwise, the ECM/PCM, will continue to stop the fuel injectors from operating. 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)

     Fig. 3: Connecting Ammeter And Voltage To Battery
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC) (see step 2 ofHOW TO USE THE HDS (HONDA DIAGNOSTIC SYSTEM) ).
3. Turn the ignition switch ON (II).
4. '07-08 models: Make sure the HDS communicates with the vehicle and ECM/PCM. If it doesn't communicate, troubleshoot the DLC circuit (see '07-08 MODELS ).
5. Select PGM-FI, INSPECTION, then ALL INJECTORS OFF on the HDS.
6. Set the parking brake, then with the shift lever in the N or P position (A/T), or the clutch pedal pressed (M/T), turn the ignition switch to START (III).

   Does the starter crank the engine normally?

   YES - The starting system is OK. Go to step 12.

   NO - Go to step 7.

7. Check the battery condition. 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 crank the engine?

   YES - Repairing the loose connection corrected the problem. The starting system is OK. Go to step 12.

   NO - Based on the following symptoms, take the appropriate action:

   • If the starter will not crank the engine at all, go to step 8.
   • If the starter cranks the engine erratically or too slowly, go to step 10.
   • If the starter does not disengage from the flywheel ring gear (M/T), or torque converter ring gear (A/T) when you release the key, replace the starter, or remove and disassemble it, and check for the following:
     • Starter solenoid and switch malfunction
     • Dirty drive gear or damaged overrunning clutch
8. Make sure the shift lever is in the N or P position (A/T), or neutral (M/T) and set the parking brake, then disconnect the BLK/WHT wire from the starter solenoid S terminal. Connect a jumper wire from the battery positive terminal to the solenoid S terminal.

   '04-05 models

   Fig. 4: Identifying Solenoid Terminals (04-05 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   '06-08 models

   Fig. 5: Identifying Solenoid Terminals (06-08 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Does the starter crank the engine?

   YES - Go to step 9.

   NO - Repair or replace as necessary.

9. Check the following items in the order listed until you find the open circuit:
   • Check the BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter.
   • Check the ignition switch (see TEST ).
   • Check the transmission range switch and connector (A/T) or the clutch interlock switch and connector (M/T).
   • Check the starter cut relay (see POWER RELAY TEST ).
10. While cranking the engine, check the cranking voltage and the current draw.

    Is the cranking voltage greater than or equal to 8.5 V and is the current draw less than or equal to 380 A?

    YES - Go to step 11.

    NO - Replace the starter, or remove and disassemble it, and check for these problems:

    • Drag in the starter armature
    • Shorted armature winding
    • Excessive drag in the engine
    • Open circuit in the 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
11. Remove the starter, and inspect its drive gear and the flywheel ring gear (M/T), or the torque converter ring gear (A/T) for damage. Replace any damaged parts.
12. Select ECM/PCM reset (see ECM/PCM RESET ) to cancel the ALL INJECTORS OFF function on the HDS.

Clutch Interlock Switch Test

1. Disconnect the clutch interlock switch 2P connector (A).

   Fig. 6: Identifying Clutch Interlock Switch 2P Connector
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Remove the clutch interlock switch (B).
3. Check for continuity between the terminals according to the table.
   • If the continuity is not as specified, replace the clutch interlock switch.
   • If OK, install the clutch interlock switch, and adjust the pedal height (see CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT ).

     Fig. 7: Checking Continuity Between Terminals
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

Starter Performance Test

1. 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.

   Fig. 8: Connecting Battery Terminal To Starter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Connect the battery as shown. If the starter pinion moves out, it is working properly.
3. Disconnect the battery terminal from the starter as shown. If the pinion retracts immediately, it is working properly.

   Fig. 9: Disconnecting Battery Terminal From Starter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Clamp the starter firmly in a vise.
5. Connect the starter to the battery as shown, and confirm that the motor starts and keeps rotating.

   Fig. 10: Connecting Starter To Battery
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. If the electric current meets the specification when the battery voltage is at 11.5 V, the starter is working properly.

   Specification:

   Electric Current: 80 A or less

Starter Removal and Installation

Removal

1. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
2. Disconnect the negative cable from the battery.
3. Remove the intake manifold, '04-05 models (see REMOVAL ('04-05 MODELS) ), '06-08 models (see REMOVAL ('06-08 MODELS) ).
4. Disconnect the starter cable (A) from the B terminal, and disconnect the BLK/WHT wire (B) from the starter solenoid S terminal.

   '04-05 models

   Fig. 11: Disconnecting Starter Cable From B Terminal (04-05 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   '06-08 models

   Fig. 12: Disconnecting Starter Cable From B Terminal (06-08 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the harness clamp (C) and the harness holder (D).
6. Remove the two bolts holding the starter, then remove the starter.

Installation

1. Install the starter, then connect the starter cable (A) to the B terminal, and connect the BLK/WHT wire (B) to the starter solenoid S terminal. Make sure the crimped side of the ring terminal faces away from the starter when you connect it.

   '04-05 models

   Fig. 13: Connecting Starter Cable To B Terminal With Torque Specifications (04-05 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   '06-08 models

   Fig. 14: Connecting Starter Cable To B Terminal With Torque Specifications (06-08 Models)
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Install the harness holder (C) and the harness clamp (D).
3. Install the intake manifold, '04-05 models (see INSTALLATION ('04-05 MODELS) ), '06-08 models (see INSTALLATION ('06-08 MODELS) ).
4. Connect the negative cable to the battery.
5. Start the engine to make sure the starter works properly.
6. Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the audio presets. Set the clock (on vehicles without navigation).

Starter Overhaul

Disassembly/Reassembly

Fig. 15: Disassembly/Reassembly Of Starter Overhaul
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Armature Inspection and Test

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
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.

   Fig. 16: Identifying Armature
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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).

   Fig. 17: Checking Commutator Surface
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

   Commutator Diameter

   Standard (New): 28.0-28.1 mm (1.10-1.11 in.)

   Service Limit: 27.5 mm (1.08 in.)

   Fig. 18: Checking Commutator Diameter
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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): 0.02 mm (0.001 in.) max.

   Service Limit: 0.05 mm (0.002 in.)

   Fig. 19: Checking Commutator Runout
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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: 0.15 mm (0.006 in.)

   Fig. 20: Checking Commutator Mica Depth
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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

   Fig. 21: Checking Continuity Between Segments Of Commutator
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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.

   Fig. 22: Identifying Armature Core
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

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.

    Fig. 23: Checking Continuity Between Commutator And Armature Coil Core & Between Commutator And Armature Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Inspection

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

    Brush Length

    Standard (New): 11.1-11.5 mm (0.44-0.45 in.)

    Service Limit: 4.3 mm (0.17 in.)

    Fig. 24: Measuring Brush Length
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Starter Brush Holder Test

12. Check for continuity between the (+) brushes (A) and (-) brushes (B). If there is continuity, replace the brush holder assembly.

    Fig. 25: Checking Continuity Between Brushes
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Planetary Gear Inspection

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

    Fig. 26: Identifying Planetary Gears And Internal Ring Gear
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Overrunning Clutch Inspection

14. While holding the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover assembly.

    Fig. 27: Turning Gear Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

15. While holding the drive gear, turn the gear shaft clockwise. The gear shaft should rotate freely. If the gear shaft does not rotate smoothly, replace the gear cover assembly.
16. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly, the gear is not available separately.

    Check the condition of the flywheel ring gear (M/T), or the torque converter ring gear (A/T) to see if the starter drive gear teeth are damaged.

    Starter Reassembly

17. Install the brush into the brush holder, and set the armature (A) in the brush holder (B).

    NOTE:

    To seat the new brushes, slip a strip of # 500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

    Fig. 28: Installing Brush Into Brush Holder
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. While squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E, and F).
19. Install the armature and brush holder assembly into the housing.

    NOTE:

    Make sure the armature stays in the holder.