Service Bulletin Applies To: 2003 05 MDX ALL 2006 MDX From VIN 2HNYD18..6H500001 thru 2HNYD18..6H535538 06-028 July 13, 2007 MIL Comes On With DTC P0335, P0339, P0385, or P0389, and the Engine Runs Roughly or Stalls (Supersedes 06-028, dated August 2, 2006, to update the information marked by the black bars) SYMPTOM The engine runs roughly or stalls, and one or more of these DTCs are set: P0335 (crankshaft position sensor [CKP] sensor A no signal) P0339 (crankshaft position sensor [CKP] sensor A intermittent interruption) P0385 (crankshaft position sensor [CKP] sensor B no signal) P0389 (crankshaft position sensor [CKP] sensor B intermittent interruption) PROBABLE CAUSE Moisture enters the CKP sensor, crank sensor subharness connector, or the engine wire harness, causing corrosion in the sensor terminals. CORRECTIVE ACTION Replace the CKP sensor, the crank sensor subharness, and the engine wire PARTS INFORMATION Crank Sensor Assembly (1-2) (CKP Sensor): P/N 37500-RCA-A01 Crank Sensor Subharness: P/N 37501-RCA-A01 Engine Wire Harness: 2003 models - P/N 32110-RDJ-305 2004 models - P/N 32110-RDJ-307 2005 06 models - P/N 32110-RDJ-A53 Intake Manifold Gasket (2 required): P/N 17105-RCA-A01 Intake Manifold Upper Cover Gasket: P/N 17146-RCA-A01 Throttle Body Gasket: P/N 16176-RCA-A02 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. OP# Description FRT Template ID 737109 Replace the CKP sensor, the crank sensor subharness, and the engine wire 3.6 hr. 2004 06 Models: 06-028A 2003 Models: 06 028B Failed Part: P/N 32110-RDJ-A53 Defect Code: 06601 Symptom Code: 03203 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. Make sure you have the anti-theft codes for the audio system and the navigation system. Write down the client s audio presets. 2. Disconnect and isolate the negative battery cable from the battery. 3. Remove the CKP sensor and the crank sensor subharness: Refer to page 11-239 of the 03 06 MDX Service Manual, or Online, enter keyword CKP, and select CKP Sensor Replacement from the list. 4. Check the CKP sensor and subharness terminals for corrosion. If there is corrosion on the sensor or any of the terminals, go to REPAIR PROCEDURE. If there is no corrosion on the sensor or any of the terminals, continue with normal troubleshooting. 2007 American Honda Motor Co., Inc. All Rights Reserved BTB 32524-35205 (0707) 1 of 5 CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by do-it-yourselfers, and you should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer.
REPAIR PROCEDURE 1. Replace the CKP sensor and the crank sensor sub Do not reinstall the drive belt yet. 2. Reinstall all removed parts, except the drive belt. 3. Lower the vehicle. 4. Remove the throttle body: Refer to page 11-338 of the service manual, or Online, enter keyword THROTTLE REM, and select Throttle Body Removal/Installation from the list. 5. Remove the intake manifold: Refer to page 9-2 of the service manual, or Online, enter keyword INTAKE REM, and select Intake Manifold Removal and Installation from the list. 6. Remove the two bolts holding the power steering pump, then carefully set the pump aside. DRIVE BELT POWER STEERING PUMP BOLTS 7. Remove the bolt (#12 on the next page) that holds the engine harness to the transmission. 8. Remove the bolt (#29 on the next page) that holds the engine grounding strap, then remove the two bolts that hold the engine harness to the top of the rear cylinder head cover. 2 of 5 06-028
9. Starting at the transmission and starter side of the engine wire harness, disconnect all of the engine wire harness connectors. Work your way around the rear of the engine, then remove the connectors from the front of the engine, working toward the PCM connector. The recommended sequence is shown in the illustration below and on the table that follows. Remove the NOTE: Pull up the transmission side of the engine harness behind the rear cylinder head cover. Remove the clips and bolts that secure the Remove the ground connections for the harness, and make sure the ground locations are clean before installing the grounds for the new 10. Install the new harness, and note the following: Reinstall the clips and bolts that secure the harness, and reinstall the harness ground bolts. Torque the bolts to 12 N. m (8.7 lb-ft). Make sure the connectors are plugged in securely. Use the illustration or the following table as a checklist to confirm you ve reconnected all the connectors. 30 28 26 24 27 25 23 22 21 20 14 15 16 17 29 18* 12 31 43 44 47 48 32 33 49 14 13 11 10 45 46 ENGINE WIRE HARNESS 34 35 37 38 39 35 40 41 42 1 2 3 4 5 8 6 7 9 * 2003-04 Models only 06-028 3 of 5
REF CONNECTOR OR TERMINAL CAVITIES/ COLOR LOCATION CONNECTS TO 1 Starter solenoid 1-BLK Left side of engine compartment 2 C110 5-BLK Transmission housing Solenoid wire harness 3 Input shaft (mainshaft) speed sensor 3-BLU Transmission housing 4 3rd clutch transmission fluid pressure switch 1-BLK Transmission housing 5 Output shaft (countershaft) speed sensor 3-BLK Transmission housing 6 ATF temperature sensor 2-GRY Transmission housing 7 Transmission range switch 10-BLK Transmission housing 8 A/T clutch pressure control solenoid valve A 2-BLK Transmission housing 9 A/T clutch pressure control solenoid valve B 2-BRN Transmission housing 10 4th clutch transmission fluid pressure switch 1-BRN Transmission housing 11 A/T clutch pressure control solenoid valve C 2-BLK Transmission housing 12 G101 Left side of engine compartment 13 EGR valve and EGR valve position sensor 6-GRY Left side of engine compartment 14 ECT sensor 2-BLK Left side of engine compartment 15 IAT sensor 2 (2003 04 models) 2-BLK Left side of engine compartment 15 IAT sensor (2005 06 models) 2-BLK Left side of engine compartment 16 MAP sensor 3-BLK Left side of engine compartment 17 Throttle actuator control module 16-GRY Left side of engine compartment 18 IAT sensor 2 (2003 04 models) 2-BLK Left side of engine compartment 19 Rear secondary HO2S (B1, S2) 4-GRY Left side of engine compartment 20 Rear A/F sensor (B1, S2) 8-GRY Left side of engine compartment 21 EVAP canister purge valve (2003 models) 2-GRN Left side of engine compartment 21 EVAP canister purge valve (2004 06 models) 2-BRN Left side of engine compartment 22 Ignition coil no. 3 3-BLK Middle of engine compartment 23 C104 (junction connector) 24-BLK Middle of engine compartment 24 Injector no. 3 2-BLK Middle of engine compartment 25 C103 (junction connector) 24-BLK Middle of engine compartment 26 Ignition coil no. 2 3-BLK Middle of engine compartment 27 Injector no. 2 2-BLK Middle of engine compartment 28 Ignition coil no. 1 3-BLK Middle of engine compartment 29 Injector no. 1 2-BLK Middle of engine compartment 30 G102 Right side of engine compartment Engine ground via engine wire harness 31 IMT valve 5-GRY Right side of engine compartment 32 CMP sensor 3-BLU Right side of engine compartment 33 C161 1-BLK Right side of engine compartment Knock sensor subharness 34 Injector no. 4 2-BLK Middle of engine compartment 35 Injector no. 5 2-BLK Middle of engine compartment 36 Injector no. 6 2-BLK Middle of engine compartment 37 Alternator 4-LT GRN Middle of engine compartment 38 Ignition coil no. 4 3-BLK Middle of engine compartment 39 Ignition coil no. 5 3-BLK Middle of engine compartment 40 Ignition coil no. 6 3-BLK Middle of engine compartment 41 Front A/F sensor (B2, S1) 8-GRY Left side of engine compartment 42 Front secondary HO2S (B2, S2) 4-GRY Left side of engine compartment 43 C171 6-BLK Right side of engine compartment CKP sensor subharness 44 VTEC solenoid valve 1-BLK/GRY Right side of engine compartment 45 Oil pressure switch 1-NAT Right side of engine compartment 46 VTEC oil pressure switch 2-GRY Right side of engine compartment 47 C101 23-BLK Right side of engine compartment Right engine compartment wire harness 48 C102 1-GRY Right side of engine compartment Right engine compartment wire harness 49 PCM connector A 73-BLK Right side of engine compartment 4 of 5 06-028
11. Reinstall the power steering pump, and torque the bolts to 24 N. m (17 lb-ft). 12. Reinstall the drive belt. 13. Install a new intake manifold gasket, and reinstall the intake manifold. Torque the bolts to 22 N. m (16 lb-ft). 14. Install a new upper cover gasket, and reinstall the upper cover. Torque the bolts to 12 N. m (8.7 lb-ft). 15. Install a new throttle body gasket, and reinstall the throttle body. Torque the bolts to 22 N. m (16 lb-ft). 16. Reinstall the intake manifold cover, and torque the bolts to 12 N. m (8.7 lb-ft). 17. Reconnect the negative cable to the battery. 18. Enter the anti-theft codes for the audio system and the navigation system, and set the clock (on vehicles without navigation). Enter the audio presets. 19. Use the HDS to clear the DTCs. 20. Use the HDS to do the CKP PATTERN CLEAR. 21. 2003 05 models: Do the low-rpm CKP-pattern learn procedure: Test-drive the vehicle on a level road. With the transmission in second gear, decelerate (with the throttle fully closed) from an engine speed of 2,500 rpm down to 1,000 rpm. Stop the vehicle, and put the transmission into Park or Neutral. Set the parking brake. Do not turn the ignition off. 22. 2003 05 models: Connect the HDS to the DLC, and check the status of PULSER F/B LEARN: On the Selection Menu, select PGM-FI. On the Mode Menu, select Data List. Check the value of PULSER F/B LEARN. If the value is Completed, go to step 23. If the value is Not Completed, make sure the engine is at normal operating temperature (the ECT SENSOR [1] value is 176 or higher), and repeat step 21. 23. 2003 05 models: Do the high-rpm CKP-pattern learn procedure: NOTE: The low-rpm CKP-pattern learn must be completed before you do the high-rpm CKP-pattern learn. Test-drive the vehicle on a level road. With the transmission in first gear, decelerate (with the throttle fully closed) from an engine speed of 5,000 rpm down to 3,000 rpm. Stop the vehicle, and put the transmission into P or N. Set the parking brake. Do not turn the ignition off. 24. 2003 05 models: Connect the HDS to the DLC (if not already connected), and check the status of PULSER F/B LEARN (HIGH RPM): On the Selection Menu, select PGM-FI. On the Mode Menu, select Data List. Check the value of PULSER F/B LEARN (HIGH RPM). If the value is Completed, you ve completed the CKP-pattern learn procedure. If the value is Not Completed, make sure the engine is at normal operating temperature (the ECT SENSOR [1] value is 176 or higher), and repeat step 23. 25. 2006 models: Use the HDS to do the CKP-pattern learn procedure. In the ADJUSTMENT MENU, select CRANK PATTERN LEARN. Select CRANK PATTERN LEARNING, and follow the screen prompts. 06-028 5 of 5