Brake HONDA CR-V 1998 RD1-RD3 / 1.G Service Manual

1?
4678
CavityWire
ColorTest CondhionTost: Desired RosultPossible Cause(lf result is not obtainedl
1WHT/BLU
lgnition switch turned
to ACC (l), ignition key
pushed all the way in
Check for voltage to ground:
There should be battery voltage.
Blown No. 48 {30 A} fuse in the
under-hood fuse/relay box
Blown No.33 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty steering lock assembly
{key interlock solenoid)
An open in the wire
YEL
lgnition switch ON (ll)Check for voltage to ground:
There should be battery voltage.
Blown No.25 (7.5 A) fuse in the
under-dash fuse/relay box
An open in the wire
YEUBLK
lgnition switch ON (ll)Check for voltage to ground:
There should be baftery voltage.
Blown No. 25 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty shift lock solenoid
An open in the wire
4BLKUnder all conditionsCheck for continuity to ground:
There should be continuity.
. Poor ground (G401)
. An open in the wire
5WHT
lgnition switch turned
to ACC (l), ignition key
pushed all the way in
Check for voltage to ground:
There should be battery voltage.
Blown No.48 (30 A) fuse in the
under-hood fuse/relay box
Blown No. 33 (7.5 A) fuse in the
under-dash fuse/relay box
Faulty steering lock assembly(key interlock switch)
An open in the wire
BLI(BLU
Shift lever in ECheck for continuity to ground:
There should be continuity,
Faulty Ay'T gear position switch
Poor ground (G101)
An open in the wire
8WHT/BLK
Shift lever in @ and
pulled toward steering
wneel
Check for continuity to ground:
There should be continuity.
Faulty park pin switch
Shon to ground
Shift lever in ECheck for continuity to ground:
There should be no continuity.
Wire side of female terminals
Reconnect the interlock control unit 8P connector.
14-145
7WHT/RED
lgnition switch ON (ll)
and brake pedal
presseo
Check for voltage to ground:
There should be 1 V or less.
Faulty brake switch
Faulty throttle position (TP)
sensor
Faulty PCM
An open in the wire
Faulty interlock control unit
lgnition switch ON (lll,
brake pedal and accel-
erator pedal pressed at
the same time
Check for voltage to ground:
There should be baftery voltage,
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Road Test
NOTE: Warm up the engine to normal operating temperature (the radiator tan comes on).
1. Before testing, check the transmission fluid level, see page 14-160.
2. Apply the parking brake and block the wheels. start the engine, then shift to E {'97 - 98) or E {'gg - 00) position
while pressing the brake pedal. Press the accelerator pedal and release it suddenly. The engine should not stall.
3. Repeat same test in E position ('97 - 98 models).
4. Test-drive the vehicle on a flat road in the E or E position. Check that the shift points occur at approximate speeds
shown on a flat road. Also check for abnormal noise and clutch slippage.
Throttle position sensor voltage represents the throttle opening. Monitor it with the Honda PGM Tester or as follows:
a. Unbolt the PCM for road testing; reJer to page 14-58.
b. Set the digital multimeter to check throttle position sensor voltage between these terminals on the PCM:
. '97 Model: Between terminals D'! (+) and A9 (-) or A22 {-}
. '98 - OO Models; Between terminals C27 (+) and 820 (-) or 822 {-)
BACKPROBE ADAPTER
BACKPROBE SETorsAz - 001moA(two roquircdl
STACKING PATCH
CORD
DIGiTAL MULTIMETER
{Comm€rcirllY .vailablc}KS-AHM-32-003,or equival.nt
'97 Model:PCM CONNECTORS
'98 - 0O Models:
A l32Pt
Wire side of female terminals
PCM CONNECTORS
B {25Pt c l31P}
(cont'd)
LGl (BRN/BLK)
'. //B 1 l'o ti , jl. to a 2r / / 11111t1.t nait la t1 t213tr / t6t, tl / / / / 1 3 / 10n v
t-'a:IM-&E -Llfiffi-fl)\"".'E
Wire side ot female termanals14-157
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Road Test
(cont'd)
lgrr or E Position:
Upshift
NOTE:
. Lock-upON:The lock-up control solenoid valve A turns ON.. Lock-up OFF: The lock-up control solenoid valve A turns OFF.
4. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th. then shift from E or E position to E position.The vehicle should immediately begin slowing down from engine braking.
5. Check for abnormal noise and clutch slippage in the following positions.
E {1st Gear) Position
Accelerate from a stop at full throttle, Make sure there is no abnormal noise or clutch slippage.Upshifts should not occur with the shift lever in this position.
E (2nd cear) Position
Accelerate from a stop at fuI throttre. Make sure there is no abnormar noise or crutch srippage.Upshifts and downshifts should not occur with the shift lever in this position.
E (Reverse) Position
Accelerate from a stop at full throttle. and check for abnormal noise and clutch slippage.
6. Test in E (Park) Position
Park the vehicle on slope (approx. 16"), apply the parking brake, and shift into E position. Release the brake; the vehi-cle should not move.
Throftle OpsningUnit of sps€dlsi + 2nd2nd * 3rd3rd + ilthLock-up ON
Throttle position sensor
voltage: 0.75 V
mph9-1220-2328-33
km/h15-1945-5334-40
Throttle position sensor
voltage; 2.25 V
mph22-2643-49oz - ott68-74
km/h35-4169-7999 - 108109 - 118
Fully-opened throttle,
Throttle position sensor
voltage: 4.5 V
mph37-43101 - 11190 - 101
k-/h60-69111 - 124163 - 179145 - 163
Downshift
Throttle OpeningUnit ot speedLock-up OFFi{th + 3rd3rd * 2ndznd + lst
Fully-closed throttle,
Throttle position sensor
voltage; 0.5 V
mpn19-231A - 2'l6 - 10 {3rd - 1st)
km/h5t-5D29-3410 - 15 (3rd * 1st)
Fully-opened throttle,
Throttle position sensor
voltage: 4,5 V
mph88-9986-9657 -6426-32
km/h142 - 't59138 - 15492 - 10342-51
14-158
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Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not te3t stall speed for mors than 10 s€€onds at a time'
. Do not shift the lever while raising th€ engine spsed.
. Be sure to remove tho pressuro gauge bofore testing stall speed,
1. Before testing, check the transmission fluid level, s€e page 14-160.
2. Engage the parking brake and block all four wheels
3. Connect the tachometer, and start the engane.
4. Make sure the Ay'C switch is OFF
5. After the engine haswarmed upto normal operating temperature (the radiator fan comes on),shiftinto@ position.
6. Fully press the brake pedal and accelerator for 6 to 8 seconds, and note engine speed '
j. A|ow 2 minutes for cooling, then repeat the test in E, E ('97 - 98). E {'99 - 00}, and E positions. Stall speed should
be the same in E, E, E, tr. and E positions
Stall Speed rpm:
Specitication: 2,550 rpm
S€rvice Limit: ?,400 - 2.700 rpm
TROUBLEPROBAELE CAUSE
Stall rpm high in El, E, E, E and E
positions
ATF pump output is low
Clogged ATF strainer
Pressure regulator valve stuck closed
Slipping clutch
Stall rpm high in E positionSlippage of 1st clutch, 1st-hold clutch, or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 2nd clutch
stall rpm high in E! or E positionSlippage of 1st clutch or 1st gear one-way clutch
Stall rpm high in E positionSlippage of 4th clutch
Stall rpm low in [dd, E. E, E, ana E
positions
. Engine output low
. Torque converter one-way clutch slipping
14-159
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Pressure Testing
Changing
NOTE: Keep all foreign particles out of the transmis-
sion.
1. Bring the transmission up to operating temperature
(the radiator fan comes on) by driving the vehicle.
Park the vehicle on level ground. turn the engane
off. then remove the drain Plug.
NOTE: lf a cooler flusher is to be used, see page
14-264 and 14-265.
TRANSMISSIONEND COVER
DRAIN18 x 1.5 mmSEALING WASHEBReplace.49 N.m {5.0 kgt.m, 36 lbf.tl)
Reinstall the drain plug with a new sealing washer,
then refill the transmission with the recommended
fluid to the uDper mark on the dipstick. Always use
Genuine Honda Premium Formula Automatic
Transmission Fluid (ATF) Using a non-Honda ATF
can affect shift quality.
Automatic Transmission Fluid Capacity:
4WD;
2.9 { (3.1 US qt. 2.6 lmp qt) 8t change
5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul
2WD:
2.7 | l2.S US qt,2.1lmp qtl ai change
5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
2.
a
a
1.
Wlrile testing, be careful of the rotaling wheols.
Mako sure lifts, iacks, and safety stands ar€ placed
properly (see scction 11.
Before testing, be sure the transmission fluid is
filled to the proPer level.
4WD:
Raise the vehicle (see section 11.
2WD:
Raise the front of the vehicle, and make sure it is
securely supported. Set the parking brake, and block
both rear wheels securely.
Allow all four wheels {4WD) or front wheels (2wD}
to rotate freely.
Warm up the engine (the radiator fan comes on),
then stop it and connect the tachometer.
Connect the oil pressure gauges to each inspection
hole securely, and do not allow dust or other foreign
particles to enter the inspection holes.
TOROUE: 18 N'm ll.8 kgf'm, 13 lbf'ft)
5.
A/T PRESSURE HOS€,2210 mm07MAJ - PYiOllA
{4 Requircd}
,4'/"' ,a
W'
A/T PRESSURE HOSEADAPTER07MAJ - PYt0120(il Rcquiledl
6. Measure the following Pressure:. Line Pressure ..........,14-162
. 1st. 1st-hold Clutch Pressure .............'. 14-162
. 2nd,3rd and 4th Clutch Pressure .......... 14-163
7. Install new sealing washers and the sealing bolts in
the inspection holes, and tighten to the specified
toroue.
(cont'd)
A/T OIL PRESSUREGAUGE SET W/PANEL07{06 - 0020400
/4\\-J-- (
+..\.-.\-'-\
A/T LOW PBESSUREGAUGE w/PANEL07406 - 0070300
TOROUE: 18 N'm 11.8 kgf'm, 13 lbf'ft)
14-161
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Transfer
4.
Inspection
@E Mako suro lifts, jacks, and safety standsare placod properly lsoe section t).
1. Raise the front of the vehicle, and make sure it issupported securely.
2. Set the parking brake, and block both rear wheelssecurely.
Shift to E position.
Make a reference mark across the propeller shaftand the transfer assembly flanges.
Separate the propeller shaft from the transferassembly.
8 x 1.25 mm32 N.m 13.3 kgl,m,24 lbf.ftlReplace.
14-164
\
6. Set a dial indicator on the transfer assembly flange.then measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inl
7. lf the measurement is out of standard, remove thetransfer assembly and adjust transfer gear backlash{see page '14-232 thru 14-2491.
8. Check for fluid leaks between the mating faces oftransfer cover A and cover B.
9. lf there is a fluid leak, remove the cover, and reDlacethe O-ring.
'10. Check for fluid leaks between the mating face of thetransfer assembly and transmission.
11. lf there is a fluid l€ak, remove the transf€r assem-bly, and replace the O-ring,
12. Check the transfer oil seal for damage and fluidle8ks.
13, lf oil seal replacement is required. remove the trans-fer assembly, replace the oil seal, and adjust thetotal starting torque (see page 1+232 thtu ]'4-249||.
NOTE: Do not replace the oil seal with the transferassembly on the transmission.
COMPANION FLANGE
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Transfer Assembly
Removal
@ Make sure the lifts, iacks, and safety
stands are placed properly (see section 11.
1. Raise the front of the vehicle, and make sure it is
supported securely.
2. Set the parking brake, and block both rear wheels
securelv.
3 Drain the automatic transmission fluid (ATF).
Reinstall the drain plug with a new sealing washer'
DRAIN PLUG'18 x'1.5 rnm49 N.m 15.0 kgf.m, 36 lbl.ftl
4. Remove the guard bar and the splash shield.
GUARD 8AR
14-165
5.Disconnect the primary heated oxygen sensor
{Primary HO2S) connector.
Remove exhaust pipe A.
SELF-LOCKINGNUTBeplace.
7.
SEI-F.LOCKINGNUTReplace.
NUTReplace
Remove the shift cable cover.
Remove the snap pin and control pin, then separate
the shift cable from the control lever. Do not bend
the shift cable excessively.
(cont'd)
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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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26. Connect the vehicle speed sensor (VSS). the coun-
tershaft speed sensor. and the A,/T gear position
switch connectors,
VEHICLE SPEEO
SPEED SENSOACO'{NECTOR
Connect the lock-up control solenoid valve connec-
tor, then install the harness clamp on the clamp
bracket.
HARNESS CI-AMP
27.
RADIATOR HOSECLAMP
TRANSMISSIONGROUND CAB1ITERMINAL
LOCK-UP OONTROLSOLENOID VALVECONNECTOR
6x1.0mm12 N'm (1.2 kgi.m,8.? tbtftl
28.
29.
Instail the transmission ground cable terminal on
the transmission hanger, and install the radiator
hose clamp on the transmission hanger,
Connect the starter cables to the starter, and install
the harness clamD on the clamD bracket. Make sure
the crimped side of the starter cable ring terminal is
facing out.
STARTEBCABLE
STARTER CAAtf,
Install the air cleaner housing assembly and the
intake air duct.
Refill the transmission with ATF (see page 14-161).
Connect the battery positive terminal and negative
terminal.
Set the parking brake, Start the engine, and shift the
transmission through all gears three times.
Check the shift cable adjustment (see page 14-271]-.
Check the tront wheel alignment and adjust it if
needed (see section 18).
Let the engine reach normal operating temperature
(the radiator fan comes on) with the transmission in
E or N position, then turn it off and check the ATF
level {see page 14-160).
Perform a road test (see page 14-157 and 14-158).
30.
31.
34.
CLAMP BRACKET
37.
14-263
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Real-time 4WD-Dual Pump System
Troubleshooting (Automatic Transmissionl
When starting and accelerating in forward gesrs {4WDmodel
1. Lift up the vehicle so all four wheels are off theground (see section 1).
2. Make a mark on either No.
shaft.
'I or No.2 propeller
PROPELLER SHAFT
Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
With the engine at idle. shift to the E position.
Apply the parking brake firmly. and measure thetime it takes the propeller shaft to rotate 10 times.. lf the measured time is more than 10 seconds,
the 4WD system is normal.
. lf the time is less than 10 seconds, there is aproblem in 4WD system. Check the differential
fluid. lf the differential fluid is normal, replace
the torque control differential case kit.
15-10
When starting and accelerating in revGrsg gear {4WDmodel
1. Lift up the vehicle so all four wheels are off theground (see section 1).
Make a mark on either No.
shaft.
1 or No. 2 propeller
PROPELLER SHAFT
Start the engine. and let it run until it warms up (the
radiator fan comes on at least twicei.
With the engine at idle, shift to the E position.
Apply the parking brake firmly, and measure the
time it takes the proDeller shaft to rotate 10 times,. lf the measured time is more than 10 seconds,
the 4WD system js normal.. lf the time is less than 10 seconds, there is aproblem in 4WD system. Check the differential
fluid. lf the differential fluid is normal, reolace
the torque control differential case kit.
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