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Where is the Main Relay and what
does it look like?
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The
Main Relay will click three times during the starting process. When
problems arise, one of those clicks (usually the third) is missing,
making those clicks a handy diagnostics tool. If you consistently hear/feel all
three clicks, the Relay is fine. DO NOT REPLACE IT.
- Turn ignition to ON (but not to START):
Click 1
- Check Engine light goes off: Click 2
- You now turn the key to START: Click 3
Waaay up under
the dash on
the driver's side, up behind the dash in a diabolically difficult
place to get at lurks a critical device known as a PGM-FI
Main Relay, or EFI
Main Relay. Honda
usually places the Main Relay very close to the ignition switch, for
obvious reasons, and they all look the same (albeit with slightly
different colors and part numbers), so these photos should help you
locate yours.
The
photo sequence below shows the PGM-FI Main Relay location for the
'90-'93
Integra, one of the easier vehicles to deal with for this item.
Many
other Hondas very frustratingly have their Main Relay in basically the same location, but
above the hood latch, which seems innocuous enough, but creates huge
headaches (see more photos below).
In all
cases, you need to
remove a large piece of plastic trim called the Knee Bolster. This trim
covers all
the wiring and structural members that festoon the area immediately
under the
steering column.

1) View of
under-dash of '90-'93 Integra. The knee bolster is the filler panel
under the steering
wheel. The coin box is in it.
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2) Pop coin box loose on one side
with a screwdriver to push the pin out of its recess.
Careful not to mark up the dash or break something. It doesn't take
much effort to release the pin.
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3) Remove remaining screws and
pull rearwards to carefully pop tabs loose on top. Knee bolster is now
free.
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4) It's under there! It's always
close to the ignition switch.
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5) There are two relays in this
particular location. It's the larger one behind the small one.
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6) Another view. Camera was held
near floor and
pointed upwards.
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Two
quite awful locations chosen by Honda

'88-'91
Civic/CRX.
THIS
is the "diabolically difficult place" the text above refers to.
Here, you are the center console (you always wanted to be one, didn't
you?), and are looking towards the left (driver's) side of the car.
In this car, you have a choice:
1) You can pop the guts out of the casing (see below),
leaving the casing in place, or
2) You can remove it by undoing the fixing bolt (see below).
Neither method is fun, and either will take you about a half-hour of
fiddling
back-and-forth.
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'92-'03 Civic/CRX.
It's a bit better
than the '88-'91 Civic, but not as good as the '90-'93 Integra. Yours
may be
here if it's not in the Integra's location. The knee bolster has been
removed here as well.
Notice this particular Relay housing is grey instead of black, and the
bracket is pointing upwards.
In
these two pictures, you'll
notice the plastic
trim that's in front of the bolt that holds the Main Relay on. It's
this trim that makes the Relay so hard to get off the car, since it
prevents the application of a socket to the Relay's bolt.
It appears to me that you could easily unbolt this Relay by heating up
a very small wrench with a torch, and bending it right behind the head..
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Tips
for the '88-'91 Civic:
Removing
guts from the casing
If
you are unable to remove or flex
the trim in order to get at the
bolt, you can simply remove the guts of the Relay from its casing. Get
a very small flat-blade screwdriver, and pull the locking lugs outward
(the lugs are on the short sides of the Relay).
Start with one side. Push the screwdriver gently between the Relay
housing and its bottom plate, and pry outwards until that side
releases. Tilt the bottom plate on an angle to keep the lock from
re-engaging, then do the other side. After the guts have been removed,
you may unplug the electrical connector.
This approach may be more trouble than it's worth though, so you might
just want to try unbolting it anyway. Read on...
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Unbolting the entire Main Relay
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In this pic, you're lying down on
the floor of your car, looking skyward. The mounting bolt is directly
vertical above the outboard edge of the hood release in the pic. The
Relay's mount bracket points downwards, so the bolt is lower than the
Relay.
From jim beam:
"It's one
of those guys you unscrew half a flat at a time, then flip the wrench over - you
know the type? it helps to get the hood release
out of
the way too. Then the next most fun thing is unplugging the
wiring. It's
held by cable tie to the body, about 1" from the plug, so
you have
no room to
maneuver. But there's room to pop the mounting
for that
tie-mount with a screwdriver or pair of needle-nosed pliers. Once the Relay's free
to move, then puzzling it out is merely
an exercise
in patience. Even if you know where the wretched thing
is & what
you're doing, it's still a half-hour job!!!"
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What
the Main Relay looks like up close:
Some of the casings
seem
to be grey and some black. Sometimes the bracket points up and
sometimes down. Incidentally, the bracket can be easily pushed off and
remounted the other way if you need to do that.

This particular one is out
of a Honda CRX but I don't know of any Hondas that don't use one of
these things. Inside its casing there are actually two relays mounted
to a printed circuit board. Here's a picture of the beast with its
cover removed.

Since relay coils are
relatively heavy, and the relay assembly is bolted solidly to the car,
vibration sometimes causes hairline cracks to form in the solder joints
on that printed circuit board. This can cause intermittent failures,
which are especially likely to happen when the car has been parked in
the sun on hot days.
When you turn the engine
over, there is
enough pressure in the main fuel rail to supply the injectors, so the
engine starts, the ECU re-applies the ground to the second relay and
the fuel pump runs continuously from then on. So if your car won't
start, listen for that fuel pump! If it doesn't run for two seconds
each time the key is turned from the off to the run position, you're
not going anywhere, and it's probably a sulking main relay that's the
cause.
Another common problem also
caused by the
main relay is that the car starts fine, but stalls as soon as you
release the key. In this situation, it may take many attempts at
starting before the car will continue to run with the key released.
Posts complaining of this seem to peak during warm-weather months.
How does the Main
Relay work? Click here.
(Has pictures too!)
How to fix? Well you can
just replace
the damn thing, or pay a mechanic to do it. Or if you know how to pilot
a soldering iron, you can touch up those soldered connections on the
printed circuit board. It's not hard to get the cover off, it's just
held on by plastic tabs at the edges. The main difficulty is just
getting at the thing. For fault finding instructions here's a good site
And here's
a site with more info on fixing it.
Another possible cause of
the same
symptoms can be lurking
further up the same chain of interconnections. The ground that the ECU
supplies to the second relay isn't anywhere near the ECU. It is in fact
way up front on the engine! There are several wires originating from
the ECU that are grounded on the engine block (probably so there won't
be problems with bad engine to bodywork ground straps). On the CRX
these wires are attached near the thermostat housing. Other models may
differ. If the connection of these wires to ground is loose or
corroded, you can get symptoms similar to a bad main relay.
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