Oil HONDA CR-V 1998 RD1-RD3 / 1.G Workshop Manual

Clutch Inspection
Check the plated parts of the armature plate for color
changes, peeling or other damage. lf there is dam-
age, replace the clutch set.
Check the rotor pulley bearing play and drag by rotat-
ing the rotor pulley by hand. Replace the clutch set
with a new one if it is noisy or has excessive play/drag.
Measure the clearance between the rotor pulley and
the armature plate all the way around. lf the clear-
ance is not within specified limits, the armature plate
must be removed and shims added or removed as
required, following the procedure on page 22-66.
Cloarance: 0.5 t 0.15 mm {0.020 t 0.q)6 in)
NOTE: The shims are available in four thicknesses:
0.1 mm. 0.2 mm. 0.4 mm and 0.5 mm
ABMATUBE
ROTOR
. Release the field coil connector from the holder, then
disconnect it. Check the thermal protector for conti-
nuity, lf there is no continuity, replace the thermal
prorecror.
NOTE: The thermal protector will have no continuity
above 251.6 to 262.4"F 1122 to 128"C). When the tem-perature drops below 240.8 to 219.8"F (116 to 104'C),
the thermal protector will have continuity.
Check resistance of the field coil.
Field Coil Resistance: 3.2 i 0.15 ohms at 68"F {20'C)
lf resistance is not within specifications, replace the
field coil.
22-65
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l-
5. Remove the bolt and holder, and screw and clamp.
then disconnect the field coil connector. Remove
the snap ring A with snap ring pliers, then remove
the field coil. Be careful not to damage the field coil
and comoressor.
FIELD COIL
CLAMP
HOLDER
GROUNDTERMINAL
7,a N.m
10.75 kgt'm,5 tbt ftl
6. Position the rotor pulley squarely over the field coil.
Press the rotor pulley onto the compressor boss
with the special tool. lf the rotor pulley does not
press on straight, remove it, and check the rotor
pulley and compressor boss for burrs or damage.
CAUTION: Maximum pre3s load: 39,200 kPa
(400 kgf/cm,, 5,690 psi)
Press
+
HUB ASSEMBLYGUIDE ATTACHMENT07966 - 6920500
7.
ROTORPULLEY
Reassemble the comDressor clutch in the reverse
order of disassembly. Make note of the following
rrems.
Install the field coil with the wire side facing down,
and align the boss on the tield coil with the hole in
the compressor.
Clean the rotor pulley and compressor sliding
surfaces with non-oetroleum solvent.
lnstall new snap rings A and B.
Make sure the snap rings are fully seated in the
groove.
Make sure that the rotor pulley turns smoothly
after it's reassembled.
Route and clamp the wires properly or they can
be damaged by the rotor pulley.
a
a
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Compressor
Thermal Protector Replacement
1. Remove the bolt, the ground terminal and the hold-
er. Disconnect the field coil connector. then remove
the thermal Drotector.
7.4 N.m (0.75 kgrf.m,5lbf ftl
GROUNDTERMINAL
ReDlace the thermal protector with a new one, and
apply silicone sealant to the bottom of the thermal
orotector,
3. lnstall in the reverse order of removal.
SILICONE SEALANT
22-68
Relief Valve Replacement
l.Recover the refrigerant with a Recovery/Recycling/
Charging System (see page 22-59).
Remove the relief valve cover ('97 model), the relief
valve and the O-ring. Plug the opening to keep for-
eign matter from entering the system and the com-
pressor oil from running out.
O.RINGReplace.
RELIEFVALVE9.8 N.m {1.0 hgf.m,7.2 rbr.ftl
Put the cover on the relief valve so that the arrow
directs downwards as shown in the illustration
above ('97 model).
Clean the mating surfaces.
Replace the O-ring with a new one at the relief valve,
and apply a thin coat of refrigerant oil before
installing it.
Remove the plug. and install and tighten the relief
valve.
7. Charge the system (see page 22-61), and test its
performance (see page 22-561r.
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Gondenser
't.
Replacement
Recover the refrigerant with a recovery/recycling/
charging ststion (see page 22-59)
Remove the front grille (see section 20).
Remove the coolant reservoii, but do not discon-
nect the reservoir hose Jrom the coolant reservoir
and the radiator.
Remove the bolts and the suction line bracket as
shown. Remove the bolts and the upper mount
brsckets from the radiator.
UPPER MOUNTBRACKETS
Remove each bolt, then disconnect the discharge
and condenser lines from the condenser, Plug or
cap the lines immediately after disconnecting them
to avoid moisture and dust contamination.
6x1.0mm9.8 N.m 11,0 kgf.m, 7.2 lbfttl
t\,l/
ait- -:
i..
6x1.0mm
6xl.0mm9,8 N.m 11.0 kgf'm' 7.2lbf'ft)
22-70
DISCHARGE LINE
CONDENS€R LINE
6. Remove the mounting bolts, then remove the con-
denser by lifting it up as shown. Be careful not to
damage the radiator and condenser fins when
removing the condenser.
Install in the reverse order of removal. Make note of
the following items.
. lf you're installing a new condenser, add refriger-
ant oil (sP-10) (see page 22-54]..
o Replace the O-rings with new ones at each fit-
ting, and apply a thin coat of refrigerant oil
before installing them. Be sure to use the right
O-rings for HFC-134a (R-134a) to avoid leakage.
. Be careful not to damage the radiator and con-
denser fins when installing the condenser.
. Be sure to install the lower mount cushions of
condenser securely into the holes,
. Charge the system (see page 22-61), and test its
performance (see page 22-56).
7.
1,0 mm
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Connector ldentification and Wire Harness Routing
Engino Wire Harness
Connecto; or
Terminal
Number of
CavitiesLocationConneqts toNotos
c101
c102
c103
c 104
c105
c105
c106
c 107
c 108
c 109
c]10
c1l'l
c112
c113
c't 14
cl16
cl16
c117
c118
c119
c120
c121
c't22
c't23
c't25
cl26
cl27
cr 28
cl29
c130
c131
c132
c 133
c134
c134
c135
c 136
10
6
1
2
1
2
1
10
20
31
16
22
l0
l0'14
14
1
Left side of engine compartment
Left side of engine compartment
Middle of engine
Middle of engine
Left side of engine compartment
Left side of engine compartment
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Right side of engine
Middle of engine
Behind right kick panel
Under right side of dash
Under right side of dash
Under right side of dash
Under right side of dash
Under right side of dash
Right side of engine
Right side of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Left side of engine compartment
Middle of engine
Middle of engine
Main wire harness (C304)
Main wire harness (C305):'97 - 98 models
No. 1 fuel injector
Crankshaft speed fluctuation (CKF) sensor
Alternator
Alternator
Engine oil pressure switch
No.2 fuel injector
Evaporative emission (EVAP) purge
control solenoid valve
No. 3 fuel injector
No. 4 fuel injector
Primary heated oxygen sensor(Primary HO2S) (sensor 1)
Radiator fan switch
Coolant temperature sending unit
Engine coolant temperature (ECT) sensor
Mainshaft speed sensor
Lock-up control solenoid valve
Back-up light switch
Shift control solenoid valve
Linear solenoid valve
Countershaft speed sesnsor
Starter solenoid
Distributor
Junction connector
PCM
ECIWPCM
ECM/PCM
ECM/PCM
Main wire harness (C,|:}1)
IVT gear position switch
Vehicle speed sensor (VSS)
Throttle position (TP) sensor
MAP sensor
ldle air control (lAC)valve
lntake air temperature (lAT) sensor
Junction connector
Junction connector
Power steering pressure (PSP) switch
Junction connector
Knock sensor (KS)
A/r
USA
Canada
Alr
AlT
M/'r
Afi
'97mooel
'97 model'98 - 00
mooets
'99 - 00
models
T101
r102
Left side of en0ine companment
Right side of engine compartment
Alternator
Under-hood fuse/relay box
G101Middle of engineEngine ground, via engine wire harness
23-14
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Gauge Assembly
Component Location Index
SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS
section {24} before performing repairs or service.
I x 1.25 mm24 N.m {2.4
VEHICLE SPEED SENSOF {VSS'Troubleshooting, page 23-62
GAUGE ASSEMBLYGau ge/lndicator/TerminalLocation Index, page 23-56Bulb Locations, page 23-57Removal, page 23-61
J-
FUEL GAUGE SENDING UNITSee section 1 l
PARKING BRAKE SWITCH
COOLANT TEMPERATURE GAUGESENDING UNITBRAKE FLUID LEVEL SWITCH
ENGINE OIL PRESSURE SWITCH
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l-
Bulb Locations
TAILGATE INDICATORLIGHT (,I.4 W) CHARGING SYSTEM LIGHT (1.4 WI
GAUGE LIGHT {1.4 WIGAUGE LIGHT I1,4 WIBRAKE SYSTEMLTGHT 11.4 WlLOW ENGINE OIL PRESSUREINDICATOR LIGHT {1./r W}SEAT BELTREMINDER LIGHT {1.' W'HIGH BEAMINDICATOR LIGHT
LOW FUEL INOICATOBLIGHT 13 WI
MALFUNCTIONINOICATORLAMP {MIL)BULB I1.4 WI
{1.4 Wl
RIGHT TURN SIGNALINDICATOR LIGHT I1.' WI
GAUGE LIGHTS 13 WI
LEFT TURN SIGNALINDICATOR LIGHT {1,4 W}
GAUGE LIGHT
t3 wl
SRS INDICATOR ('1./t W)(On the printed circuit board)
1,.
A/T GEAR POSITIONINDICATOR {1.12 x 7}(On the printed
circuit board)GAUGE LIGHT {3.' W}
ABS INDICATOR (1,4 W)
lOn the printed circuit board)cRutsE tNDtcAToR 11.r2 w)(On the printed circuit board)
f-= F -
J
23-57
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Precautions/Procedures
)General Precautions
Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being drop-
ped or improperly handled, such as dents, cracks or
deformation:
- Airbags- Cable reel- SRS unit- Seat belt tensioners
N
)-
Use only a digital multimeter to check the system, lf
it's not a Honda multimeter, make sure its output is
10 mA (0,01 A) or less when switched to the smallest
value in the ohmmeter range. A tester with a higher
output could damage the airbag circuit or cause acci-
dental deployment and possible injury.
Do not install used SRS Dans from another vehicle,
When making SRS repairs, use only new pans.
Except when performing electrical inspections,
always disconnect both the negative cable and posi-
tive cable from the batterv. and wait at least three
minutes before beginning work.
Replacement of the combination light and wiper/
washer switches and cruise control switch can be
done without removing the steering wheel:
- Combination light and wiper/washer switch replace-
ment {see section 231.- Cruise control sevresume switch replacement (see
section 41.
Whenever the ignition switch is ON {ll}, or has been
turned OFF for less than three minutes, be careful not
to bump the SRS unit; the airbags could accidentally
deploy and cause damage or injuries.
Whenever the airbag has been activated, replace the
SRS unit.
The original radio has a coded theft protection circuit.
Be sure to get the customer's code number before dis-
connecting the battery cables.
)
Airbag/Seat Belt Tensioner
Handling and Storage
Do not try to disassemble an airbag or a seat belt ten-
sioner. They have no serviceable parts. Once an airbag
or a seat belt tensioner have been deployed. they cannot
be repaired or reused.
For temporary storage of an airbag or a seat belt ten-
sioner during service, please observe the following pre-
cautons:
. Store the removed airbag with the pad surface up.
The driver's/front passenger's airbag connectors and
seat belt tensioner connectors have a built-in short
contact (see page 24-211.
@ r th€ airb.g is impropcrty stor€d face down,
accidental deployment could propel the unit with enough
forc€ to caus6 serious iniury,
Store the removed on a secure flat surface awav from
any high heat source (exceeding 212"F/100'C) and
free of any oil, grease. detergent or water.
lmproper handling or storage can internally damage
the airbag and seat belt tensioner. making them inop-
erative.
lf you suspect the airbag and seat belt tensioner have
been damaged, install new units and refer to the
Deploymenvoisposal Procedures for disposing of the
damaoed units.
AIRBAG CONNECTORS
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Precautions/Procedures
SRS Unit Precautions
Take extra care when painting or doing body work in
the area below the dashboard. Avoid direct exposure
of the SRS unit or wiring to heat guns, welding, or
spraying equipment.
Disconnect the driver's/front passenger's airbag con-
nectors and seat belt tensioner connectors before
working below the dashboard near the SRS unit.
After any degree of frontal body damage, or after a
collision without airbag deployment, inspect the SRS
unit for physical damage. lf it is dented, cracked, or
detormed, reolace it,
Be sure the SRS unit is installed securelv.
Do not disassemble the SRS unit.
Store the SRS unit in a cool {less than about
104"F/40"C) and dry {less than 80o/o humidity. no
moisture) place. Do not spill water or oil on the SRS
unit, and keep it awav from dust.
During installation or replacement, be careful not to
bump (impact wrench, hammer, etc.) the area a[ound
the SRS unit, The airbags could accidentally deploy
and cause damage or injury.
24-20
,..4
Inspection After Deployment
After a collision in which the airbags were deployed.
replace the SRS unit, and inspect the following:
1. Inspect all the SRS wire harnesses. Replace, don't
repair, any damaged harnesses
2. Inspect the cable reel for heat damage, lf there is any
damage. replace the cable reel.
3. After the vehicle is completely repaired, turn the
ignition switch on. lf the SRS indicator light comes
on for about six seconds and then goes off, the SRS
system is OK. lf the indicator light does not function
properly, go to SRS Troubleshooting.
rD
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