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

MEASUREMENTSTANDAFD INEWISERVICE LIMIT
lgnition coilRated voltage VPrimary winding resistance 0 at 68'F (20'C)120.63 0.77
lgnition wireBesistance at 68"F (20 C) ktl25 max.
Firing order1 3 4-2
Spark plugTypeGapSee Section 41.0 - 1.1 (0.039 - 0.043)
lgnition timingAt idle BTDC161 2 {Red)
Alternator belt*rDeflection with 98 N {10 kgf, 22 lbf)8.5 11.510.33 0.45)with used belt5.5 - 8.0 (0.22 - 0.31) with new belt
Belt tension N {kgf, lbt)Measured with bek tension gauge340 - 490 {35 - 50, 77 110) with used belt690 880 (70 90, 150 - 200i with new belt
AlternatorOutput A (at 13.5 V, hot and 6,000 alternator rpm AIIM/IBrush length
959010.5 (0.41)1.5 (0.06i
Staning motorOutput kW A/fMica depth MfiCommutator runoutCommutator O.D.Brush lengthBrush spring tension N (kgf, lbf)
1.11.00.5 - 0.8 {0.02 - 0.03)0,0.02 (0 0.0008)27.9 28.0 (1.0984 1.1024)14.0 14.5 (0.55 0.57)13.7 - 17.7 (1.40 - 1.80,3.09 - 3.97)
0.2 (0.008)
0.0s (0.002)
27.0 (1.06)
9.0 (0.35)
Standards and Service Limits
Engine Electrical - Section 4
'1 When using a new belt, ddiust deflection to new value. Run the engine for 5 minutes then turn it of{. Beadiust deflection to used belt value.
Cylinder Head/Valve Train - Section 6
MEASUREMENTSTANDARD {NEW} SERVICE LIMIT
Compression250 rpm and Nominalwide open throttle MinimumkPa (kgflcm', psi) Maximum variation
1 ,230 i'12 .5 , 11Al930 (9.s, 135)200 12.0,2al
Cylinder headWarpageHeight131.95 - 132.05 {5.195 - 5.199)0.05 {0.002)
CamshaftEnd playCamshaft to hoider oil clearanceTotal runoutCam lobe height '97,'98 models lNEX'99,'00 models lNEX
0.05 0.1s (0.002 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 {0.001)max.33.204 \1.3072133.528 {1.3200)33.1 16 \1 .321 4)33.528 {'1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
Valve clearance (Cold)* lNEXValve stem O.D. lNEXStem'to-guide clearance lNEX
0.08 - 0.12 (0.003 0.005)0.16 0.20 (0.006 - 0.008)6.580 - 6.590 (0.2591 0.2594)6.550 - 6.560 (0.2579 0.2s83)0.02 - 0.05 {0.00t 0.002)0.05 - 0.08 (0.002 0.003)
u* to.rutt6.52lO.257l0.08 {0.003i0.'1t (0.004)
width tNEXStem installed height lNEX
1.25 - 1.55 (0.049 - 0.061)1.25 1.55 (0.049 - 0.061)40.765 - 41.235 {1.6049 1.6234)42.765 - 43.235i'1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 {1.6333}43.485 {1.7120i
Valve springFree length lNEX42.36 (1.668i
44.32 t1 .1 451
Valve guideI,D, INEXInstalled height tNEX
6.61 6.63 10.260 - 0.261)6.61 6.63 {0.260 - 0.261i13.75 - 14.25 10.541 0.561i15.75 - 16.25 {0.620 0.640i
6.6510.26216.65 (0.262i
*: Measured between the camshaft and rocker arm,
2-2
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Design Specifications
ITEMMETRICENGLISHNOTES
DIMENSIONSOverall lengthOverallwidthOverall heightWheelbaseTrack FrontRearSeating capacity
4,510 mm1,750 mm1,608 mm2,622 mrn1,533 mm1,534 mm5lf
177.6 in68.9 in63.3 in103.2 in60.4 in60.4 in
WEIGHT (USA)Gross vehicle weight rating (GVWR)| 4,165 tbs
WEIGHT (CANADA)Gross vehicle weight rating (GVWR)1,900 kg
ENGINEType
Cylinder arrangementBore and strokeDisplacementCompression ratio '97,'98 mooers'99, '00 modelsValve train
Lubrication systemOil pump displacement at 6,000 engine rpmWater pump displacement at 7,600 engine rpmFuel required
Water-cooled, 4-stroke DOHCgasoline engineInline 4-cylinder, transverse84.0 x 89.0 mm.1,973 cm3 (m{)
9.2
3.31 x 3.50 in120 cu-in
9.6Belt driven, DOHC4 valves per cylinderForced and wet sump, trochoid pump501 (53 US qt,44 lmp qt)/minute1401 (148 US qt, 123 lmp qt)/minuteUNLEADED gasoljne with 86Pump Octane Number or Higher
STARTERTypeNormal output
NominalvohageHour ratingDirection of rotationWeight
Planetary gear reductionA/T: 1.1 kWM/T: 1.0 kW12V30 secondsClockwise as viewed from gear end3.7 kg 8.2 lbsApprox.
CLUTCHClutch type
Clutch lacing area
MIT
MIT
Single plate dry, diaphragm springTorque converter203 cm, 31.5 sq-in
TRANSMISSIONTransmission type
Primary redLrction
MITSynchronized s-speed torward, 1 reverseElectronically controlled4-speed automatic, 1 reverseDirect I : 1
TypeManualtransmission
Gear ratio 1st2nd3rd4th5thReverse
3.5001.9561.3441.0710.8123.000*,. 3.461*'
*1: '97 - 99 models*2: '00 model
Final reduction Gear typeGear rataoSingle helical gear4.562
Transfer0.434
Rear differential2.533
TypeAutomatic transmission
Gear ratio 1st2nd3rd4thReverse
2.722
1.0790.7111.955
Final reduction Gear typeGear ratioSingle helical gear4.357
Transfer0.393
2-12
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Engine
Engine RemovaUlnstallation ................ 5-1
Cylinder Head/Valve Train ................... 6-1
Engine Bfock .......... ...........7-1
Engine Lubrication ...........8-1
Intake Manifold/Exhaust System ........ 9-1
Cooling ......... 10-1
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6. Disconnect the engine control module (ECM)/power-
train control module (PCM) connectors from the ECM/
PCM.
7. Disconnect the main wire harness connector.
Remove the grommet and wire harness clamps, then
pull out the EcM/Pclvl connectors.
6x1.0mm11 N.m 11.1 kgl.m,8lbf.ftl
CONNECTOR
GROMMET
L Disconnect the engine wire harness connectors on
the left side of the engine compartment.
ENGINE WIREHARNESS CONNECTORS
(cont'd)
5-3
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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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Troubleshooting
Troubleshooting Procedures
How To Begin Troubleshooting
When the Malfunction indicator Lamp (MlLl has been reported on, or there is a driveability problem, use the appropri-ate procedure below to diagnose and repair the problem.
A. When the MIL has come on:
1. Connect the Honda PGM Tester or an OBD Il scan tool to the 16P Data Link Connector (DLC) located behind theright side of the center console.
Turn the ignition switch ON (ll).
Check the DTC and note it. Also check and note
the freeze frame data.
Refer to the Diagnostic Trouble Code Chart and
begin troubleshooting.
NOTE:
. SeetheOBDll scan tool or Honda PGM Tester user's manuals for specific operating instructions.. The scan tool or tester can read the Diagnostic Trouble Codes (DTC), freeze frame data, current data, and otherEngine Control Module (ECM}/Powertrain Control Module (PCM) data.. Freeze frame data indicates the engine conditions when the first malfunction, misfire or fuel trim malfunction wasdetected. lt can be useful information when troubleshootino.
B. When the MIL has not come on, but there is a driveability problem, refer to the Symptom Chart on page 11-64.
C. DTCs will be indicated by the blinking of the Malfunction Indicator Lamp {MlL) with the SCS service connector con-nected.
Connect the SCS service connector to Service Check Connector as shown. {The 2P Service Check Connecror rslocated behind the right side of the center console.) Turn the ignition switch ON 0l).
DATA LINK CONNECTOR I16PI
1 1-60
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ll. Engine Controt Module (EcM)/Powertrain Control Module {PCM) Reset Procedure
Either of the following actions will reset the ECM/PCM.
. use the oBD ll scan tool or Honda PGM Tester to clear the ECM's/PCM's memory. (see the oBD ll scan tool or
Honda PGM Tester user's manuals for specific operating instructions )
. Turn the ignition switch oFF. Remove the BACK UP (RADIO) (7.5 A) fuse from the under-hood fuse/relay box for 10
seconos.
lll. Final Procedure {this procedure must be done after any troubleshooting)
1. Remove the SCS Service Connector if it is connected. lf the SCS service connector is connected. and there are no
DTCS stored in the ECM/PCM, the MIL will stay on when the ignition switch is turnsd oN (ll).
2. Do the ECM/PCM Reset Procedure.
3. Turn the ignition switch OFF
4. Disconnect the OBD ll scan tool orHonda PGM Tester from the Data Link Connector ( 16P)'
(cont'd)
1 1-61
BACK UP {RADIOI I7,5 AI FUSE
FUSE/RELAY BOX
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Powertrain Control Module Terminal Arrangement -'97 Model
FCM CONNECTOR A (32P)NOTE: Standard battery voltage is 12 V.
Wire side of lemale terminals
f€rminalnumlreJWirecolor
Telminalnama
DescriptionSignal
YELlNJ4 (No.4 FUELINJECTOR)Drives No. 4 {uel injector.With engine running: duty controlled
2BLUlNJ3 (No.3 FUELINJECTOR)Drives No. 3luel injector.
REDlNJ2 {No.2 FUELINJECTOR)Drives No.2 tuel injector.
BRNlNJl (No. l FUELINJECTOR)Drives No. 1 fuel injector.
5BLK WHTSO2SHIC (SECONDARY
HEATED OXYGEN SENSOR HEATER CONTROL)
D ves secondary heated oxygensensor heater.With ignition switch ON {ll): battery voltageWith fully warmed up engino running: dutycontrolled
6BLKAr'YHT
PO2SHTC (PRIMARY
HEATED OXYGENSENSOR HEATERCONTROL}
Drives primary heated oxygensensor heater,With ignition switch ON lll): battery voltagewith fully warmed up engine running: dutycontroll6d
I8RN/BLKLGl (LOGIC GROUND}Ground forthe PCM control circuit.Less than 1.0 V at all times
10BLKPG1 lPOWER GROUND}Ground for the PCM power circuit.
l1YEUELKIGPl lPOWER SOURCE}Power source for the PCM controlcircuit.
With ignition switch ON (ll): battery voltageWith ignition switch OFF: 0 V
12BLI(BLUIACV {IDLE AIRCONTROL VALVE}Drives IACV.With €ngine running: duty controlled
REDryEL
PCS (EVAP PURGECONTFOL SOLENOIDVALVE)
Drives EVAP purge controlsolenoid valve.
With engine running, engine coolantbelow 154'F (68"C): battery voltageWith engine running, engine coolantabove 154"F (68"C): duty controlled
16GRN/VELFLR (FUEL PUMP RELAY)Drives Iuel pump relay.0 V for two seconds after turning ignition
switch ON lll), then battery voltage
118LI(REDACC (A,/C CLUTCHRELAY}Drives Ay'C clutch relay.With comoressor ON: 0 VWith compressor OFF: baftery voltage
18GRN/ORNMIL (MALFUNCTION
INDICATOR LAMP}Drives MlL.With MIL turned ON: 0 VWith MIL turned OFF: baftery voltage
19*WHT/GRNALTC (ALTERNATOR
CONTROL}Sends alternator control signal.With tully warmed-up engine running:
battery voltageDuring driving with smallelectrical load:0 '
20YEUGRNICM (IGNITION CONTROLMODULE)Sends ignition pulse.With ignition switch ON (ll): baftery voltageWith engine running: pulses
22BRN/BLKLG2 (LOGIC GROUND}Ground tor the PCM control circuit.Less than 1.0 V at alltimes
23BLKPG2 {POWER GROUND}Ground lor the PCM power circuit.
24YEUBLKIGP2 {POWER SOURCE}Power source for the PCM controlcircuit.
With ignition switch ON (ll): battery voltage
With engine switch OFF: 0 V
27GRNFANC (RADIATOR FANCONTROL)Drives radiator {an relay.With radiator fan running: 0 VWith radiator fan stopped: baftery voltage
*: USA
{cont'd)
11-67
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Troubleshooting
PCM CONNECTOR B I25PI
Powertrain Control Module Terminal Arrangement -'97 Model (cont'dl
Wire side of female terminalsPCM CONNECTOR B I25P}NOTE: Standard battery voltage is l2 V.
1 1-68L
TerminelnumbercolorTerminalnameOescriptionSignal
1LS 1A/T CLUTCHPRESSURE CONTROLSOLENOID VALVE -)
Drives A,/T clutch pressure controlsolenoid valveWith ignition switch ON (ll): duty con-trolled
2REDLS + (A"/T CLUTCHPRESSURE CONTROLSOLENOID VALVE +)
Drives A,/T clutch pressure controlsolenoid valveWith ignition switch ON (ll)r duty controlled
38LU//EL
SHA (SHIFT CONTROLSOLENOID VALVE A)Drives shift control solenoid valve A.In 2nd, R position. in 2nd and 3rd gear inD4, D3 position: Battery voltageIn lst gear in D4, D3 position, in 4th gear
in D4 position: 0 V
4GRN/BLKLC B (LOCK-UP CONTFOLSOLENOID VALVE B)Drives lock-up control solenoidvalve B,With full lock-up; Baftery voltageWith half lock-up: duty controlled
5YELLC A (LOCK.UP CONTROLSOLENOID VALVE A)Drives lock-up control solenoidWith lock'up ON: battery voltageWith lock-up OFF:0 V
IPNKATPD3 (Ay'T GEARPOSITION SWITCH}Detects A/T gear position switchsignal. _
In D3 position:0 Vln any other position: battery voltage
11GRN/VVHT
SHB (SHIFT CONTROLSOLENOID VALVE 8}Drives shift control solenoid valve B.In 1st, 2nd position, in 1st and 2nd gear inD4, D3 position: Battery voltageIn R position, ;n 3rd gear in 04, D3, in 4thgear in D4 position: 0 V
12WHT/BEDILU (INTERLOCK
CONTROL UNITiDetects interlock control unh signal.With ignition switch ON (ll)and brakepedal depressed: battery voltage
GRN/BLKD4IND (04 INDICATORLIGHT}Drives Dl indicator light.With D4 indicator light turned ON: batteryvoltageWith D4 indicator light turned OFF: 0 V
14NMSG (MAINSHAFT
SPEED SENSOR GROUND}Ground tor mainshaft speed sensor.
REDNM (MAINSHAFT SPEEDSENSOR)Detects mainshaft speed sensorsrgnal,With engine running: pulses
16ATPR (A"/T GEARPOSITION SWITCH)Detects A/T gear position switchsrgnal.InRposition:0VIn any other position: battery voltage
1'lBLUATP2 (A./T GEARPOSITION SWITCH)Detects A/T gear position switchsrg nal,In 2nd position: 0 VIn any other position: battery voltage
18BRNATP1 (4,,/T GEARPOSTTTON SWTTCH)Detects A/T gear position switchsrg nal,ln lst position: 0 VIn any other position: battery voltage
22GBNNCSG (COUNTERSHAFT
SPEED SENSOR GROUND)Ground tor countershaft speedsensor,
23BLUNC (COUNTERSHAFT
SPEED SENSOR)Detects countershaft speed sensorsrgnal.With agnition switch ON (ll), and lrontwheels rotating: pulses
24YELATPD4 (M GEARPOSITION SWITCH)Detects A,/T gear position switchsrgnal.In D4 positionr 0 VIn any other position: battery voltage
25LT GRNATPNP {A/T GEARPOSITION SWITCH)Detects A/T gear position switchsignal.In park or neutral:0 VIn any other position: about 5 V
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Troubleshooting
Powertrain Gontrol Module Terminal Arrangement -'97 Model (cont'd)
PCM CONNECTOR O {16PI
PCM CONNECTOR D (I6P)Wire side of f6male terminals
NOTE: Standard battery voltage is 12 V.
f.rminal
numbcrWir! colorT€rminal nam6DescriptionSignal
1RED/BLKTPS ffHROTTLE
POSITION SENSOR}
Detects TP sensor signal.With throttle fullv oDen: about 4.8 V
With throttle fullv closed: about 0.5 V
RE D,4/VHT
ECT (ENGINE COOLANT
TEMPERATURE
SENSOR
Detects ECT sensor signal.With ignition switch ON {ll): about
0.1 - 4.8 V (depending on engine
coolant temperature)
RED/GRN
MAP (MANIFOLD
ABSOLUTE PRESSURE
SENSOR)
Detects MAP sensor signal.With ignition switch ON (ll): about 3 V
At idle; about 1.0 V(depending on engine speed)
YEUREDVCCl (SENSOR
VOLTAGE)
Pow€r source for MAP sensor.With ignition switch ON (ll): about 5 V
With ignition switch OFF: 0 V
EG R N/WHT
BKSW (BRAKE
SWITCH)
Detects brake switch signal.With brake pedal released:0 V
With brake pedal depressed: battery
voltage
7WHT
PHO2S (PRIMARY
HEATED OXYGEN
SENSOR SENSOR 1)
Detects heated primary oxygen
sensor (sensor 1) signal.
With throttle fully opened from idle with
fully warmed up engine: above 0.6 V
With throttle quickly closed: below
0.4 v
8RED//E L
IAT (INTAKE AIR TEM.
PERATURE SENSOR)
Detects IAT sensor signal.With ignition switch ON lll): about
0.1 - 4.8 V (depending on intake air
temperaturel
10YEUBLUVCC2 (SENSOR VOLT-
AGEI
Provides sensor voltage.With ignition switch ON (ll): about 5 V
With ignition switch OFF: 0 V
11GRN/BLKSG2 (SENSOR
GROUND)
Sensor ground.Less than 1.0 V at all times
12GRN/WHTSGl (SENSOR
GROUND)
Ground for MAP sensor.Less than 1.0 V at all times
13RED/YE L
SHO2S SG(SECONDARY HEATED
OXYGEN SENSOR,
SENSOR 2 GROUND)
Ground for secondary heated
orygen sensor (sensor 2).
14WHT/RED
SHO2S (SECONDARY
HEATED OXYGEN
SENSOR, SENSOR 2)
Detects secondary heated
orygen sensor (sensor 2)
signal,
With throttle fully opened from idle with
fully warmed up engine; above 0.6 V
With throttle quickly closed: below
0.4 v
16*GRN/RED
EL (ELD)Detects ELD signal.With parking lights turned on at idle
about 2.5 - 3.5 V
With low beam headlights turned on
at idle: about 1.5 - 2.5V
1-70
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