valve cover hose HONDA CR-V 1997 RD1-RD3 / 1.G Workshop Manual

13. Remove the upper radiator hose, heater hose and
water bypass hose.
WATER BYPASS
UPPEBRADIATORHOSE
17
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
neclor
. Radiator fan switch connector
. Coolant temperature gauge sendlng unlt connec-
tor
. Throttle position sensor connector
. Manifold absolute pressure {MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
ldle air control (lAC) valve connector
Distributor connector
Remove the spark plug caps and distributor from the
cylinder head.
Remove the cruise control actuator (see section 4).
Support the engine with a jack, then remove the
upper bracket. Make sure to place a cushion
between the oil pan and the iack (see page 6-10).
a
18. Remove the cylinder head cover.
19. Inspect the timing belt (see page 6-9).
CYLINDER
(cont'd)
6-19
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Automatic Transmission
Special Tools . 14'2OescriptionGeneral Operation . .... 14 3Power Flow . . .. '14_6
Electronic Control System .. .. . . .. .14_15Hydraulic Control .. 14 24Hydraulic Flow....-....... .. . .... .. .. . 14_29Lock'up Syslem .. .'t4'39Electrical SystemComponenl Locdlrons 14 45
PCM Circuil Dragram (A/T Control Svstem)'97 Model ....................... . . .. - . ... .14-46'98Model ................. . ... .. .. .1450'99 00Models.... . .... . . . 1452
PCM Terminal Voltage/Measuring ConditionsA"/T Control System-'97Model ...... ..14'48A,/T Control System -'98 00 Models . . .. . . 14 54
Troubleshooting Procedures .. ..... ... - 14_56Svmotom to comoonent CharlEiectr,cal Syslem -'97 Model . . 14 60Electrical System -'98 - OO Models . .. . . 14_62Electrical Troubleshooting ('97 Model)Troubleshooting Flowaharts .... ..... . .. . . 14_64
Electrical Troubleshooting ('98 - 00 Models)Troubleshootinq Flowclt"n" .... . ....- . .14-93ElectricalTroublesliooting('99 00Models)Troubleshootino FlowchartO/D OFF Indicator Light Does Not Come On 14 131
O/D OFF Indicator Liaht On ConstantlY . . . .1!-132O/D OFF Indicator Light Does Not Come OnEven Though O/D Switch ls Pressed . .... - 14_133
Lock up Control Solenoid Valve A,/B AssemblyTest....................-......... . .14-135Replacement . .ll_135Shifr ControlSolenoid Valve Ay'B Assembl,Test .............................. . .. 14-136
Replacement..............- . .14'136Linear Solenoid AssemblYTest.............................................. .. .... . 14_137Replacement .. . 14138Marnshaftlcountershafl Speed SensorsReplacement ...-... 14_138A/T Gear Position SwitchTest ..........................-... . .. 14-139ReplacementA/T Gear Positionlndicator.................. 14-140
Valve Eodynepair ............................... ..... . . .. - . .. ... 14 192
Assembly .................... .. 1{_193
Valve CapsDesciiption....-........................ .. ...... 14194
tnspeition ................... .. 14' 195
N4ain Valve BodyDisassembly/lnspection/Reassemblv - ...... .. 14_196
Secondarv Valve BodYDisassemblv4nspectron/ReassemblY .. . 14 198
Reoulator Valve Bodvbisassembtv,lnspiction/Reassemblv . 14199
Servo EodvDisassembly/lnspection/Reassembly ... ....14'200
Lock'uo Valve BodYDis;ssembly/lnspection/Reassembly .... . 14_201
MainshaftDisassembly/lnspection/Reassembly .. .. .. ..14'202
Inspection ....-.............. ..11_203
Sealing RingsReilaceient ...... ..... . 14'204
CountershaftDisassembly/lnspection/Reassembly .. . . . . . 11-205
Disassembly/Reassemb|y . . ........ ...... . .. 14_206Inspedron ................ . .... . 14 207
One wav ClutchDisassembly/lnspection/ReassemblY ... 11_209
Sub-shaftDisassembly/lnspection/Reassembly ... . .. . 14-210
oisassembly/Re6ssembly . . ... .-...... . . ..14-211
Sub-shaft BearingsReplacement .......14'212
Clutchllfustrated Index .......... . . .14-213
Disassembly .... .. .....14-216Reassembfy .... . .. .. . 14'218
Differentialllfustrated Index " 14-222Backlash Inspection . .... . .14'223
Bearing Repiacement .. 11-223
Differe-ntial Carrier Replacement .. .. . . . .. ..11-2?4
OifSeal Replacement. . .. 14'225
Side Clearance lnspection . . - .. ... . - ...... . .. 11'226
Transmission Housing BearingsMainshaJVCountershaft EearingsRepfacement .......14221Sub'siralt Eearing Replacement . . . . . . . . . ..11'224
Toroue Converter Housing BearingsMainshattEearing/OilSe6lReplacement . .. l4229
Countershaft Bea;ing Replacement.. .... .. ..14-230
Input Test - '97 - 98 ModelsInput Test '99 - 00 Models
Symptom to-Component ChartHydraulic System ...............
Checking
Removal ...,lllustrated Index (4WD)
Interlock SystemInterlock ControlUnit lnputTest. -..... -.. .... . - 14 144* Key Interlock Solenoid Test .- .. . . . - . . . ..... 14_146* Shift Lock Solenoid Test ..............-.-. . .. . ... .... 14 147*Shift LockSolenoidReplacement...... .. . .. .. 14 148* park pin Switch Test ......... 14 119' Park Pin Switch Replacement- '97 - 98 Models ....... 14-150* Park Pin Swirch/Over Drive (O/Di SwitchReplacemenl '99-00Models . .. 14_151over-Drive (O/D) Switch {'99 00 [4odels]Test........_..................... .......14-152Hydr.ulic System
..............._............... t4 142.................................. 14-143
Control Lever AssemblyR6placement ......,.,Reverse ldler Gear
lllustrated lndex
.......... 14-230
14 231
11-231
1nsta1|ation ..................Park StopInspeclion/AdjustmenlTransfer AssemblY.......14.232
RoadTest.............-.... ........ .StallSpeedTest ....._........................ ....... 14-159Fluid Level......_................... 14'160
Disessembly .................... 14-235Transfer Drive Gear BearingReplacementTrans{er Driven Gesf Shaft BearingReplacementTransfer Housing Roller BearingReplacementTransfer Cov€r A Bearing Outer RaceReplacementTransfer Housing Bearing Outer RaceReplacement ......-..,,,,,.....ReassemblvTransmassaonBeassembly ... -.. .... .14 250
Torque Converier/Drive Plate . .-. .... .. . ... .....14_258
Transmissionlnstatlation .................. ....... 14'259
Cooler Flushing . . ......11-261ATF Cooler HosesConnection.................. ....... 14-266I Shift LeverRemoval/lnstallation . .. 14'261
Disassemblv/Reassemblv - '97 - 98 Models . . 14_264
Disassembli/Reassemblv -'99 - 00 Models . 14-269
Over'Orive (O/D) Switch WireClearanceAdjustment. - ... . . . .. .. . 14'270
Detent Spring Replscement . . -.. ... .14'271*Shift CableAdiustment ....... 14'272
Repfacement.............. . 11'273
14 15711-237
11-237
14-238
$-234
11-23914-240
Transmigrion
Inspeclron ....., ...........Transfer AssemblyRemova1,.,,,..............,lnstallalion ........... .. ...Transmission
14 164
14-16514,167
14-169
End Cover/Transmissio . 14'174Transmission Housing .... ... .. . . .... .. 14-176Torque Converter Housingly'alve Body.. - ... -. 14 178
lllustrated lndex (2WD)End Cover/Transmissio ....... 14 180Transmission Housing . . ... . .. .... ... 14'182Torque Convener Housing/r'alve Body ......- 14-184
End CovefRemovat ...................... ....... 14'186Transmission HousingRemoval ...................... .. 14_188Torque Convener HousingA/alve BodYRemovat ................-..... .-..... 14-190
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Description
General Operation
The Automatic transmission is a 3-element torque converter and triple-shaft electronically controlled unit which provides 4
speeds forward and 1 reverse speed The unit is positioned in line with the engine'
There are two tvoes of automatic transmission on CR-V; the four-wheel drive (4WD) model ('97 - 00)' and the front-wheel
drive (2WD) model ('98 - 00).
Toroue Converter, G€ars, and Clutches
The torque converter consists of a pump. turbine. and stator assembly in a single unit. The torque converter is connected to
the engine crankshatt. These parts turn together as a unit as the engine turns. Around the outside of the torque converter is
a ring gear which meshes with the starter pinion when the engine is started. The torque converter assembly serves as a fly-
wheel while transmitting power to the transmission mainshaft.
The transmission has three parallel shafts: the mainshaft. the countershaft, and the sub-shaft. The mainshaft is in line with
the engine crankshaft. The mainshaft includes the 1st, 2nd. and 4th clutches, and gears lor 3rd,2nd,4th. reverse and 1st
(3rd gear is integral with the mainshaft, while reverse gear is integral with the 4th gear). The countershaft includes the 3rd
clutch and gears for 3rd,2nd, 4th, reverse, 1st, and park. Reverse and 4th gears can be locked to the countershaft at its cen-
ter, providing 4th gear or reverse, depending on which way the selector is moved. The sub-shaft includes the lst-hold
clutch and gears for lst and 4th.
The gears on the mainshaft are in constant mesh with those on the countershaft and sub-shaft. When certain combinations
of gears are engaged by the ctutches, power is transmitted from the mainshaft to the countershaft to provide E, D!, tr, tr,
and E position ('97 - 98 models). and E. E, E, and E position ('99 - 00 models)'
Electlonic Control
The electronic controt system consists of the Powenrain Control Module (PCM), sensors, a linear solenoid, and four
solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM is
located below the dashboard, under the kick panel on the passenger's side.
Hydraulic Control
The valve bodies include the main valve body, the secondary valve body, the regulator valve body, the servo body, and
the lock up valve body. They are bolted to the torque converter housing. The main valve body contains the manual valve,
the 1-2 shift valve, the 2nd orifice control valve. the CPB {Clutch Pressure Back-up) valve, the modulator valve, the servo
control valve. the relief valve, and ATF pump gears. The secondary valve body contains the 2-3 shift valve, the 3-4 shift
valve, the 3,4 orifice control valve. the 4th exhaust valve and the CPC (Clutch Pressure Control) valve. The regulator valve
bodv contains the pressure regulator valve, the torque converter check valve, the cooler relief valve, and the lock-up con-
trol valve. The servo body contains the servo valve which is integrated with the reverse shift tork, and the accumulators
The lock-up valve body contains the lock-up shift valve and the lock-up timing valve. The linear solenoid and the shift con-
trol solenoid valve Ay'B are bolted to the outside of the transmission housing, and the lock-up control solenoid valve Ay'B is
bolted to the outside of the torque converter housing. Fluid trom the regulator passes through the manual valve to the
various control valves. The clutches receive fluid from their respective feed pipes or internal hydraulic circuit
ShiftControl Mechanism
input from various sensors located throughout the vehicle determines which shift control solenoid valve the PCM will acti-
vate. Activating a shift control solenoid valve changes modulator pressure, causing a shift valve to move. This pressurizes
a line to one of the clutches. engaging that clutch and its corresponding gear. The shift control solenoid valves A and B are
controlled by the PCM.
Lock-up Mechanism
tn E! position (,97 - 98 modets) and in E position ('99 - O0 models), in 3rd and 4th, and in Del position in 3rd ('97 - 98
models) and in El position with Over,Drive (O/D) is OFF (by pressing rhe O/D switchl in 3rd ('99 - 00 models), pressurized
fluid is drained from the back of the torque converter through a fluid passage, causing the lock-up piston to be held
against the torque converter cover, As this takes place, the mainshaft rotates at the same speed as the engine crankshaft.
Together with hydraulic control, the PcM optimizes the timing of the lock-up mechanism The lock-up valves control the
range of lock-up according to lock-up control solenoid valves A and B, and the linear solenoid. When lock-up control
solenoid valves A and B activate, the modulator pressure changes. The lock-up control solenoid valves A and B and the
linear solenoid are controlled by the PCM.
{cont'd)
14-3
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Transmission
Removal
@
2.
'1.
Make sure lifts. iacks, and safety stands aro placed
properly, and hoist brackets are attached to the col-
rest position on the engine lsee section 11.
Apply th€ parking brake and block the r€ar wheels,
so vehicls will noi roll off the stands and fall on you
while working under it.
NOTE: Use fender covers to avoid damaging painted
surfaces.
Disconnect the negative terminal, then disconnect
the positive terminal from the battery.
Remove the intake air duct and the air cleaner hous-
ing assembly,
Remove the starter cables. Remove the harness
clamp from the clamp bracket.
5.
STARTERCABLES
Remove the transmission ground cable terminal
and the radiator hose clamp lrom the transmission
hanger.
Disconnect the lock-up control solenoid valve con-
nector, then remove the harness clamp from the
clamp bracket.HARNESS CLAMP
RADIATOR HOSECLAMP
CONTROLSOLENOID VALVECONNECTOR
CLAMP
6. Disconnect the vehicle speed sensor (VSS), the coun-
tershaft speed sensor, and the A/T gear position
switch connectors.
A/T GEAR POSITIONSWITCH CONNECTOR
VEHICLE SPEEDSENSOR |VSS'
CONNECTORBfiACKET
SPEED SENSORCONNECTOR
7. Remove the transmission housing mounting bolts.
MOUNTING BOLTS
(cont'd)
14-169
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Power Steering Pump
Disassembly (cont'dl
1.
7.
9.
10.
Drain the fluid from the pump.
Hold the steering pump in a vise with soft jaws.
hold the pulley with the special tool, and remove
the pulley nut and pulley. Be careful not to damagethe pump housing with the jaws of the vise.
UNIVERSAL HOLDER07725 - 0030000
Loosen the flow control valve cap with a hexwrench, and remove it.
Remove the O,ring, flow control valve and spring.
Remove the inlet joint and O-ring.
Remove the pump cover and pump cover seal.
Remove the outer side plate, pump cam ring, pump
rotor, pump vanes, side plate and O-rings.
Remove the snap ring, then remove the sub-valvefrom the pump housing.
Remove the circlip, then remove the pump driveshaft by tapping the shaft end with the ptastic ham-mer.
Remove the pump seal spacer and pump seal.
17-26
Inspection
Flow Control Valve
1. Check the flow control valve for wear, burrs, and
other damage to the edges of the grooves in thevalve.
'97 model:
FLOWCONTROL VALVE
Check fordamage to edges.
'98 - 0O mod€ls:
FLOW CONTBOL VALVE
Check for damageto edges.
Insp€d the bore of the flow control valve tor scratchesor wear.
Slip the valve back in the pump, and check that itmoves in and out smoothly. lf OK, go to step 4; ifnot, replace the pump as an assembly. The flowcontrolvalve is not available separately.
CONTROL VALVE
4. Attach a hose to the end of the valve as shown.
FLOW CONTROL VALVE HOSE
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Power Steering Gearbox
AN'USTABLE HOSE CLAMP
Removal (cont'dl
14. Loosen the 14 mm flare
pump outlet hose.
nut, and disconnect the
14 mm FLARE NUT
15. Loosen the adjustable hose clamp and disconnect
the return hose,
16. Loosen the 16 mm flare nut, and remove the return
hose joint.
17. After disconnecting the hoses and lines, plug or seal
them with a piece of tape or equivalent to prevent
foreign maisrials from entering the valve body unit.
NOTE:
. Do not loosen the cylinder line A and B between
the valve body unit and cylinder.
. With 2WD, continue to step 23.
17 -32
STOP BOLT
10 x 1.25 mm
4WD: Stepr 18-22
18. Removethe right tront mount, then apply vinyl tape
to the side frame to protect it from the transmission
cover and stop bolt.
12 x 1.25 fiiAReplace.
RIGHT FRONT MOUNT
x 1,25 mm
SIDE FRAME
'19. Remove the left front mount, then apply vinyl tape
to the side frame to protect it from the stop bolt.
Vinyltape orequivalgnt material.
Vinyltap€ orequival€nt m6terial.
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Master Cylinder/Brake Booster
Removal/lnstallation
1, Disconnect the brake fluid level switch connectors.
2. Remove the reservoir cap from the master cylinder.
3. Remove the brake fluid from the master cvlinder
reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder.
To prevent spills, cover the line joints with rags or
shop towels.
5. Remove the master cylinder mounting nuts and
wasners.
6. Remove the master cylinder from the brake booster.
CAUTION: Be careful not to bend or damage the
brake lines when removing the master cylinder.
Do not spill brake fluid on the vehicle; it may dam.
age the paint; it brake fluid does cont.ct the paint,
wash it oft immediately with water.
7. Disconnect the vacuum hose from the brake booster.
8. Remove the cotter pin and clevis pin from the clevis.
Do not disconnect the clevis by removing it from
the operating rod of the brake booster. lf the clevis
is loosened, adjust the pushrod length before
installing the brake booster (see page 19-15).
To Front Caliper (Without ABS)
\\
15 N.m {1.5 kgtm, vAcuuM HosE
r r rbf.ft) |
/ | BRAKE FLUTD LEvEL
/l /
swrrcHcoNNEcroRs
/ I I I COTTER PIN
I I / neotace
l,/-- ro Rear wheet cylinders / | I
h ./-''' /. I I IYli //*s (.S
I /r:
9. Remove the four booster mounting nuts.'10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the enqine com-
panment.
12. Install the brake booster and master cylinder in the
reverse order of removal, and note these items:
. When connecting the brake lines, make sure that
there is no interference between the brake lines
and other parts.
. Be careful not to bend or damage the brake lines
when installing the master cylinder.
. lf replacing the master cylinder or brake booster,
check and adjust the pushrod clearance before
installing the master cylinder (see page 19-14).
Fill the master cylinder reservoir, and bleed the
brake system (see page 19-7).
After installation, check the brake pedal height and
brake pedal free play (see page 19-5), and adjust if
necessary.
13 N.m 11.3 kg{.m,I rbf.ft)
13.
14.
To Master Cylinder(Without ABS)To Modulator Unit(with ABs)@-\
\
^ To Front Caliper
9i\.
-#qCLEVIS PIN
):-,/
PROPORTIONING CONTROL VALVE
MASTER CYLINDER
15 N.m (1.5 kgf.m, 11 lbl.ftl
BRAXE BOOSTER
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Charging
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritate eyes, nose and
throat. Avoid breathing th€ air conditioner refrigerant
and lubricant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming service. Additional health and
safety information may be obtained from the relrigerant
and lubricant manufacturers.
Connect a R-'134a refrigerant recovery/recycling/charging
station to the vehicle, as shown. following the equipment
manufacturer's instructions.
R€covery/Recycling/Charging Station
HIGH-PRESSURESIDE
Add the same amount of new refrigerant oil to system
that was removed during recovery. Use only SP-'10
refrigerant oil.
Charge the system with Required amount of R-134a
refrigerant. Do not overcharge the system; the compres-
sor will be damaged.
Select the appropriate unit of measure for your
charging station.
Refrigerant capacity: 700 to 750 g
0.70 to 0.?5 k9
1.5 to 1.6 lbs.
21.7 to 26.5 oz.
ll-
22-61
Leak Test
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditionor refrigerant and
lubricant vapor or mist can irritate eyes, nose and throat.
Avoid breathing the air conditioner retrigerant and lubri-
cant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle ajr conditioner sys-
tems should not be pressure tested or leak tested with
compressed arr.
!@ some mixturos of air and R-1348 have
been shown to be combustible at olovatod pres3uras
and can result in fire or explosion causing iniury or
property damage. Never use comprelised air to pressure
test R-13ila service equipment or vehicle air conditioner
systems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
2.
1.Connect a R-134a refrigerant recove rylrecycling/
charging station to the vehicle, as shown in the pre-
vious column, following the equipment manufactur-
er's instructions.
Open the high-pressure valve to charge the system
to the specified capacity, then close the supply
valve, and remove the charging system couplers.
Select the appropriate unit of measure for your
charging station.
Refrigerant capacity: 700 to 750 g
0.70 to 0.75 kg
1.5 to 1.6 lbs.
21.7 to 26.5 oz.
Check the system for leaks using a R-134a refriger-
ant leak detector with an accuracy of 14 g (0.5 ozl
per year or better.
lf you find leaks that require the system to be opened
(to repair or replace hoses, fittings, etc.), recover the
system according to the Recovery Procedure on page
22-59.
After checking and repairing leaks, the system must
be evacuated (see System Evacuation on page 22-601.
5.
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