2011 Honda CR-Z Service and Repair Manual

Engine and Drivetrain

• 1.5L SOHC i-VTEC 4-Cylinder LEA Engine: Complete mechanical repair, teardown, and assembly procedures for the launching 16-valve aluminum-alloy block.
• Integrated Motor Assist (IMA): Full high-voltage system diagnosis, original 10-kilowatt DC brushless electric motor assembly, and servicing guidelines for the 100.8V Nickel-Metal Hydride (Ni-MH) battery pack baseline layout.
• PGM-FI (Programmed Fuel Injection): Comprehensive fuel delivery testing, fuel pressure checks, and electronic throttle Drive-By-Wire (DBW) diagnostics.
• 6-Speed Manual Transmission: Specific repair workflows covering the original production gear ratios, clutch assembly replacement, and mechanical linkage setups.
• Continuously Variable Transmission (CVT): Complete belt, pulley, and fluid flush protocols alongside steering-wheel mounted paddle shifters regulating 7 simulated gear ratios.
• Drivetrain Components: Half-shafts, front hub assemblies, CV axle replacement, and differential seal repairs.

Chassis and Suspension

• Front Suspension: Detailed repair maps for the MacPherson strut layout, stabilizer bars, and lower control arms.
• Rear Suspension: Component specifications and removal steps for the rigid H-shaped torsion beam rear axle configuration.
• Electric Power Steering (EPS): Steering rack replacement, torque sensor calibration, and electronic control unit diagnostics for the electric-assist system.
• Wheel Alignment: Precise front toe and rear alignment adjustment specifications optimized for standard 16-inch or available EX 17-inch alloy wheel variants.

Braking Systems

• Vehicle Stability Assist (VSA): Integrated VSA module testing, wheel speed sensor cleaning, and active actuator bleed steps.
• Electronic Brake Distribution (EBD): Dynamic proportioning diagnostics and brake pedal stroke sensor troubleshooting.
• Brake Components: Front 262 mm ventilated discs, rear 260 mm solid discs, and caliper rebuild instructions.
• Regenerative Braking Coordination: Critical software calibration linking hydraulic braking forces with baseline 10-kW IMA motor resistance.

Electrical and Wiring

• EWD Library: Complete, high-resolution factory color electrical wiring diagrams.
• Dual-Battery Management: Detailed wiring paths for the high-voltage 100.8V Ni-MH array and standard 12V under-hood starter battery.
• Multiplex Integrated Control System (MICS): BCM networking layout, internal fuse box schematics, and pin-out configurations.
• 3-Mode Drive and Eco Assist: Diagnostics for the Sport, Normal, and ECON mode cluster toggles alongside the multi-color digital ambient coaching lighting loops.

Air Conditioning and HVAC

• Automatic Climate Control System: Eco Assist integration protocols regulating automatic compressor load reduction during idle-stop sequences.
• Refrigerant Specs: Detailed R-134a charging limits, component placement, and hybrid-safe non-conductive oil criteria.

Body and Interior

• Instrument Display Panel: Disassembly guides for the dynamic illuminating 3D digital instrument cluster and center console mapping (noting gray interior panel finishes).
• Supplemental Restraint System (SRS): Airbag mapping, clock spring setup, and impact sensor replacement benchmarks.
• Honda Satellite-Linked Navigation: Comprehensive wiring layouts, rear navigation brain units, and voice control diagnostics for the optional hard-drive based navigation screen.

Diagnostics and Troubleshooting

• DTC Lookups: Step-by-step diagnostic flowcharts mapping symptom to mechanical cause.
• Honda Diagnostic System (HDS): Factory scan tool interface procedures, live data list values, and component snapshot parameters.

Common Error Codes Covered

Engine and Hybrid System Codes

• P0A7F: Hybrid Battery Pack Deterioration (IMA Ni-MH pack capacity loss testing).
• P1448: IMA Intelligent Power Module (IPM) Battery Module Cooling Fan Malfunction.
• P1570: IMA Battery Module Individual Voltage Input Malfunction.
• P1634: Motor Power Inverter (MPI) Signal Circuit Malfunction.
• P0300: Random/Multiple Cylinder Misfire Detected (i-VTEC valvetrain diagnostics).

Transmission Codes

• P0705: Transmission Range Sensor Circuit Malfunction (CVT gear selection fault).
• P0840: Transmission Fluid Pressure Sensor/Switch ‘A’ Circuit.
• P2714: Pressure Control Solenoid ‘D’ Performance or Stuck Off.

ABS and VSA Chassis Codes

• 81-01: Central Processing Unit (CPU) Internal Error (VSA/ABS Module).
• 22-01: Left Rear Wheel Speed Sensor Circuit Malfunction.
• 61-01: Battery Voltage Low (Common VSA module trigger code).

Network Communication Codes

• U0100: Lost Communication with ECM/PCM.
• U0110: Lost Communication with Drive Motor Control Module (IMA Power Control Unit).

Body Control Codes

• B1000: Interior Multiplex Control Unit Internal Error.
• B1241: A/C Climate Control Electric Air Mix Motor Circuit Malfunction.

And thousands of additional diagnostic codes, test procedures, wiring diagrams, and repair instructions.

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