vacuum tank HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Under-hood Emissions Control Label
Emission Group ldentification
(1997 modell
Example:
VACUUM HOSE ROUTING DIAGRAM
LOADED IM TEST]NG OF PERMANENT fOUB WHEEL OSVE OR TRACT ON CONTROL'EOLJIPPEDVEHTCLES MUST BE CONDUCTED ON A IOUR WHEEL DR VE SPEEO SYNCHRON ZED
ANON LOADEDTESTPBO(EOUBEMUSIBEPERFORMEO
50ST (50 Statesl:
THIS VEHICLE CONFOBMS TO U.S. EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE TO 1997
MODEL YEAR NEW LIGHT DUTY TRUCKS.
49ST {49 Statos/Federall:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1997 IVIODEL YEAR NEW LIGHT DUTY
TRUCKS.
CAL (Calitornial:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALIFORN IA REGULATIONS APPLICABLE TO '1997
MODEL YEAR NEW TLEV LIGHT DUTY TRUCKS
PROVIDED THAT THIS VEHICLE IS ONLY INTRODUCED
INTO COMMERCE FOR SALE IN THE STATE OF
CALIFORNIA.
Ii/PORTANT VEHICLE INFORIMATIONENGINE FAMILY VHN2 OIJCrcKDISPIACEMENT'2 OLITEREVAPORAT VE f AM]LY VNNl0778YMBP
CATALYSTREfERTOSEBVICEMANUALfORAODITIONAL NFORMATON.TUNT I-]P CONDITIONSENGINE AT NORI\,!AL OPERATNG TEMPERATURE,ALLACCESSOR ES TL]RNED OFF COOLING FAN OIFTRANSM1SSION NNEUTRALNO OTHEB ADJUSTMENIS NEEDED
ap' | \6( Zror '. ND \. 61F L r
TNIS VENICLE CONFORMS TO U.S EPA REGUI.ATIONSAPPI CASLE TO I99] MODET YEAR N€W L GNI DUTY TRACKS
@
Engine Family: vHN2.o l JGKE
Engine and Evaporative Families
T_fT
Model Year I Iv:1s97 | LManufaqturer iHN: Honda I
Displacement
Class
1: Light Duty Vehicle
Fuol Systom ,nd Numb€r of valves
J: Electronic Sequential Multiport
Injection (three or more valves per
cylinder)
Fuel Type
G: Gasoline
Standard
F: 49 or 50 States Tier 1
K: 49 or 50 States Tier 1
1: California Tier 1
2: California TLEV
3: California LEV
4: California ULEV
"r0", "*,
T|
V: 1997
Manufacturer
HN: Honda
Catalyst
E, F, G, H: Three Way Catalyst
OBD
K - T: OBD Equipped
Evaporative Family:
Storago System
1: Canister
Canistor Working Capacity (gramsl
Canister Conf igulation
A: Plastic Housing (Closed Bottom)
B: Plastic Housing (OPen Bottom)
Fusl System
Y: Fuel Injection
FuelTank
M: Metal
Standard
A: Current Evap
B: Enhanced Evap
Wild C.rd
VHNlOTTBYMBP
1-1 5
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Standards andService Limits
Engine LubricationSection 8
CoolingSection 10
Fuel and EmissionsSection 11
MEASUREMENTSTANDARO {NEWISERVICE LIMIT
Engine oilCapacityf (US qt, lmp qt)4.6 (4.9, 4.0)Ior engine overhaul3.8 {4.0,3.3)for oilchange, including filter3.5 (3.7, 3.1) for oil change, without Iilter
OilpumpInner-to-outer rotor clearancePump housing-to-outer rotor clearancePump housing-to rotor axial clearance
0.04 - 0.16 (0.002 - 0.006)0.10 -0.19 (0.004 - 0.007)0.02 -0.07 (0.001 - 0.003i
0.20 (0.008)
0.20 (0.008)
0.15 (0.006)
Relief valvePressure setting at engine oil temp. 176'F (80'C)kPa (kgt/cm,, psi) At ldleAt 3,000 rpm70 (0.7, 10) min.340 {3.5,50) min.
MEASUREMENTSTANDARO INEW}
RadiatorCoolant capacity , (US q1, lmp qt)
llncluding engine, heater, ILcooling line and reservoirlReservoir capacity:0.61 (0.63 US qt,0.53lmp qt)
M/T
5.9 {6.2, 5.2}tor overhaul3.9 (4.1, 3.4ifor coolant change6.0 (6.3, 5.3ifor overhaul4.0 (4.2, 3.5) for coolant change
Radiator capOpening pressure kPa (kgf/cm?, psi)93 - 123 (0.95 - 1.25, 14 18)
ThermostatStarts to open 'F 1"C)Fully open 'F ("C)
Valve lift at tully open
169 - 176 (76 - 80)194 (90)
8.0 (0.31imin.
Cooling fanThermoswitch "ON" temperature "F {'C)Thermoswitch "OFF" temperature 'F ('C)196 - 203 (91 - 95)Subtract 5 - 14 (3 - 8) trom actual "ON" temperature
MEASUREMENTSTANDARD INEW}
Pressure regulatorPressure with regulator vacuum hose disconnectedkPa (kgflcm', psi) '97,'98 models'99, '00 rnodels260 - 31012.7 3.2,38- 46)270 -32012.8 3.3,40 - 471
FueltankCapacity / (US gal, lmp gal)58 (15.3, 12.8)
E ngineldle speed with headlights and cooling fan off rpm'97 model'98 model'99, '00 models
MTAT {E or E position)
750 r 50730 1 50
750 t 50750 r 507301 50
Fast idle rpm '97 model'98 model'99, '00 models1,5001 2001,600 r 200
1,5001 2001,5001 2001,600 r 200
ldle CO %0.1 max.
2-4
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Gruise Control
Component Location Index
CRUISE CONTROL UNITInput Test, page 4 38
CRUISE INDICATOR LIGHT(Built into gauge assembly)Bulb Locations. section 23
swtTcHTest, page 4-44
SET/RESUME SWITCHTest, page 4 40Beplacement, page 4-40
ACTUATOfi ASSEMBLYand VACUUM TANKTest, page 4 41Solenoid Test, page 4 44
CLUTCH INTERLOCKswrTcH {M/T)Test, page 4-43Switch poskion adjustment,section 12
Pedal Height Adjustment,section 19.
ACTUATOR CAELEAdjustment, page 4-43A/T GEAB POSITIONswlTcH (A/TlTest, section '14
+36
I
BAT
(
I
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Cruise Gontrol
Actuator Test (cont'dl
5. With voltage and vacuum still applied, try to pull the
actuator rod out by hand. You should not be able topull it out. lf you can. it is defectrve.
8.
9.
7.
Disconnect ground from the No. 3 terminal. The actu-
ator rod should return. lf it does not return, but the
vent hose and filter are not plugged, the solenoid
valve assembly is defective.
Repeat steps 2 through 5. and disconnect ground
from the No. l terminal. The actuator rod should
return. lf it does not return, but the vent hose and
filter are not plugged, the solenoid valve assembly
is defective.
lf you replace the solenoid valve assembly, be sure
to use new O-rings on each solenoid.
Disconnect power and ground from the 4P connector.
Disconnect the vent hose from the actuator. Connect
a vacuum pump to the actuator vent hose port, and
apply vacuum. The actuator rod should pull in com-pletely. lf not, the vacuum valve is stuck open.
Replace the actuator,
4-42
I
't.
Actuator Replacement
3.
4.
7.
Ar
Pull back the boot. and loosen the locknut. Then dis-
connect the cable from the bracket.
Disconnect the cable end from the actuator rod.
1.
4.
.J.
Disconnect the 4P connector from the actuator.
Disconnect the vacuum hose from the vacuum tank.
Pull out the vent hose.
Remove the three mounting bolts and the actuator
with the bracket.
ACTUATORACTUATOR
CABLE
lf necessary, disconnect the cable end from the link-
age over the accelerator pedal, then turn the grom-
met 90' in the bulkhead. and remove the cable.
Install in the reverse order of removal, and adjust
free play at the actuator rod after connecting the
cable (see page 4-43).
I
6.
I
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Cruise Control
Brake Switch Test
1. Disconnect the 4P connector from the switch,
2. Remove the brake switch.
Terminal side of maletermtnals
Check for continuity between the terminals accord-
ing to the table.
lf necessary, replace the switch or adjust pedal height
(see section 19).
{P CONNECTOR
Terminal
;;;;-t
15
RELEASEDO----o
PUSHEDo--o
4-44
ACTUATOR
Actuator Solenoid Test
1. Disconnect the 4P connector from the actuator.
Terminalside ofmale terminals
Check for resistance between the terminals accord-
ing to the table.
NOTE: Resistance will vary slightly with tempera-
ture; specified resistance is at 68"F (20"C).
VALVE
I
I
I
To VACUUMTANK
Terminal
il',",""*(t)
_\13
VENT SOLENOID
40-600o--o
VACUUM SOLENOIDo---o
30-500
SAFEW SOLENOID
40-600o----o
VACUUM
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Actuator Disassembly
ACTUATOR ERACKET
VALVESTest, page 4-44
VACUUMTANK
)rd'
!
l
l
ACTUATOR CABLE
4-45
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Fuel and Emissions
Special Tools ...................... 11-2
Component Locations
lndex ...................... ....,.... 11-3
Svstem Description
Vacuum Connections ...........,....,.,................. 1 1-9
Electrical Connections ................................... 1 1-15
System Connectors .,.,,.,............................,.,. 1 1-36
Troubleshooting
Troubleshooting Procedures,.,..................... 11-60
Engine Control Module/Powertrain ConttolModule Terminal Arrangement .............., 11-67
Diagnostic Trouble Code Chart .................... 1 t-75
How to Read Flowcharts .......,.....,.,............... I 1-79
PGM-Fl System
System Description .................,.,.,,,............... 1 1-80
Troubleshooting Flowcharts
Engine Control Module/PowertrainControl Module ........11-52
Manifold Absolute Pressure Sensor ............. 11-90
Intake Air Temperature Sensor .................... 1 1-95
Engine Coolant Temperature Sensor .,..,.,.... 1 1-99
Throttle Position Sensor ...........,.....,.,.,..,...... I 1'103
Primary Heated Orygen Sensor (Sensor 1) ... 11-110
Secondary Heated Oxygen Sensor{Sensor 2l .................. 1 1-117
Heated Oxygen Sensor Heater ..................... 11-121
Fuef Supply System ......11-124
Random Misfire ,....,.,..... 11-126
Mistire Detected in One Cylinder .....-........... 11-128
Knock Sensor ................ 11-130
CKP/TDC/CYP Sensor .................................... 1 1-131
Vehicle Speed Sensor ...............................,.... 1 1-135
Barometric Pressure Sensor .....,...,...,.,,........ 1 1-137
Electrical Load Detector ...,.,.......................... 1 1-138
CKF Sensor ................,.,, '11-112
ECM/PCM lnternaf Circuit ............................. 11'117
HO2S Replacement .,.,.,. 11-148
ldle Control System
System Description ............ 11-149
Troubleshooting Flowcharts
ldle Control System ...... 11-150
fdle Air Control Valve ......................,............. 11-152
Air Conditioning Signal ................................. I 1-155
Alternator FR Signal ...................................... 1 1-159
Starter Switch Si9na1 .................................... t l-161
Power Steering Pressure Switch Signal ...... 11-162
Brake Switch Si9na1 ...................................... 11-166
Fast ldle Thermo Valve .,.,.............................,.,.,. 11-168
ldle speed setting .............. 11-169
Fuel Supply System
Fuel Lines ............................ 11-171
Fuef Tube/Ouick-Conneci Fittings ..................... 11 -175
System Description ............ 11-178
Fuel Pressurg ...................... 11-178
Fuel Iniectors ................,..... 11-179
Fuel Pressure Re9u1ator .............................,.,...., f 1-181
Fuef Fifter ....,.,.,.,,,,.,............11-142
Fuel Pump ........................... 11-183
Fuel Gauge .......................... 11-184
Fuel Gauge Sending Unit ................................... I 1-185
Low Fuel Indicator System ...........,.,..,............... 1 1-185
PGM-FI Main Relay ............. 11-187
Fue|Tank................ ............. 11-191
Intake Air System
System Description ............ 11-193
Air Cleanel ,.,.,..................... 11-194
Throttle Cable ..................... 11-194
Throttle Body........ .............. 11-196
Emission Control System
System D$cription ...,....,.,. 11-199
Tailpipe Emission ............... 11-199
Three Way Catalytic Converter ..................,.,...,, 11-199
Positive Crankcase Ventilation System .,.,,,,.,.., 11-2O1
Evaporative Emission Controls .........,.,.,............ 11-203
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System Description
Vacuum Connections (cont'dl
'97 model:
ENGINECOOLANT
ITr|ll
O PRIMARY HEATED oxYGEN sENsoR {PRIMARY Ho2s,SENSOR lt
O SECONDARY HEATED oxYGEN sENsoR {SECoNDARYHO2S. SENSOR 2l€) MANIFOLD ABSOLUTE PRESSURE (MAPI SENSOR@ ENGINE cooLANT TEMPERATURE {EcT} sENsoRO INTAKE AIR TEMPERATURE (IAI} sENsoR@ CRANKSHAFT SPEED FLUCTUATION ICKFI SENSORO |DLE ArR coNTRoL {tAc)vALvE@ FAST IDLE THERMo vALvEO THRoTTLE EoDY ITB)@ FUEL INJEcTonO FUEL PULSATIoN oAMPER@ FUEL FILTEn(} FUEL PRESSURE REGULATOR
FUEL PUMPFUEL TANKFUEL TANK EVAPORATIVE EMISSION (EVAPIVALVEAIR CLEANERRESONATORPOSITIVE CRANKCASE VENTILATION {PCVI VALVEEVAPORATIVE EMISSION {EVAP} PURGE CONTROLSOI.'ENOID VALVEEVAPORATIVE EMISSION {EVAP) CONTROL CANISTEREVAPORATIVE EMISSION {EVAPI TWO WAY VALVETHREE WAY CATALYTIC CONVERTER (TWC)
@(D(D
o@(}
@
@@@
1 1-10
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System Description
I
I
I
Vacuum Connections (cont'dl
'98 model:
C PRIMARY HEATEO OXYGEN SENSOR (PRIMARY HO2S,
SENSOR 1)(, SECONDARY HEATEO OXYGEN SENSOR ISECONDARYHO2S, SENSOR 2)(!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR
G) ENGINE COOLANT TEMPERATUBE (ECT) SENSOR
O INTAKE AIR TEMPERATURE {IAT} SENSOR
@ CRANKSHAFT SPEED FLUCTUATION (CKFI SENSOR
O IDLE AIR CONTROL (IAC) VALVE
@ FAST IDLE THERMO VALVE (A/T)
O THROTTLE BODY (TBI(0) FUEL INJECTOR.1' FUEL PULSATION DAMPER.14 FUEL FILTER(i FUEL PRESSURE REGULATOR14 FUEL PUMP(D FUEL TANK@ FUEL TANK EVAPORATIVE EMISSION {EVAPI VALVE
C] AIR CLEANER(O RESONATOR1iC POSITIVE CRANKCASE VENTILATION (PCV) VALVE
6 \$REE$IN gN NL$\C CON\ER\ER (TNC\
ti q rpos,xr E qN
ssros \E aP cqN\RoLcaNtsr€R
@ EVAPORATIVE EMISSION IEVAP) PURGE CONTROL
SOLENOID VALVEq3 EVAPORATIVE EMISSTON IEVAP} CONTROL CANISTER
VENT SHUT VALVE
@ EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE
€i EVAPORATIVE EMISSION {EVAP) BYPASS SOLENOID
VALVE
€9 FUEL TANK PRESSURE SENSOROi EVAPORATIVE EMISSION {EVAP) THREE WAY VALVE
Qd PURGE JOINT
G/T only)
f
-i*'";-t
COOLANT Jt
U
11-12
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System Description
Vacuum Connections (cont'dl
'99 - q) models:
ENGINECOOLANT
t
o
o
o@
o@@@@@@@@@(t
PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S,SENSOR 1lSECONDARY HEATED OXYGEN SENSOR {SECONDARYHO2S. SENSOR 2lMANIFOLD ABSOLUTE PRESSURE (MAPI SENSORENGINE COOLANT TEMPERATURE IECN SENSORINTAKE AIR TEMPERATURE IIATI SENSORCRANKSHAFT SPEED FLUCTUATION {CKF) SENSORKNOCK SENSOR (KS}
IDLE AIR CONTROL IIACI VALVEFAST IDLE THERMO VALVE {A/T}THROTTLE BODY (TB}
FUEL INJECTORFUEL PULSATION DAMPERFUEL FILTERFUEL PRESSURE REGULATORFUEL PUMPFUEL TANKFUEL TANK EVAPORATIVE EMISSION (EVAPI VALVE
AIR CLEANERRESONATORPOSITIVE CRANKCASE VENTILATION (PCV} VALVETHREE WAY CATALYTIC CONVERTER ITWCIEVAPORATIVE EMISSION {EVAPI CONTROL CANISTEREVAPORATIVE EMISSION IEVAPI PURGE CONTROLSOLENOID VALVEEVAPORATIVE EMISSION {EVAPI CONTROL CANISTEFVENT SHUT VALVEEVAPORATIVE EMISSION IEVAPI TWO WAY VALVEEVAPONANVE EMISSION {EVAPI AYPASS SOLENOIDVALVEFUEL TANK PRESSURE SENSOBEVAPORATIVE EMISSION IEVAPI THREE WAY VALVEPURGE JOINT
@@@@@@
@
@@
@@@
11-14
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