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

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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METRICITEMENGLISHNOTES
AIR CONDITIONINGCooling capacity3,520 Kcal/h j 14,000 BTU/h
Compressor Type/manutacturerNo. of cylinderCaPacityMax. speedLubricant capacityLubricant type
Scroll/KElHlN
85.7 mf/rev | 5.23 cu'in/rev10,000 rpm130mf 1 algIlozsP-10
Condenser TypeCorrugated fin
Evaporator TypeCorrugated fin
Blower TypeMotor inputSpeed controlMax. capacity
Sirocco fan200 w 112 v4-Speeo440 m3/h 15,500 cu fvh
Temperature control
Compressor clutch TypePower consumptionDry, single plate, poly-V-belt drive40 W max./12 VAt 68'F (20 C)
Befrigerant TypeOuantity
HFC-134a 1R-134a)zoo o' g 24j an oz
STEERING SYSTEMTypeOverall ratioTurns, lock to lockSteering wheel diameter
Power assisted, rack and pinion
SUSPENSIONType Front
Bear
Shock absorber Front and Rear
Independent double wishbone, coil springwith stabilizerIndependent double wishbone, coil springwith stabilizerTelescopic, hydraulic nitrogen gas tilled
WHEEL ALIGNMENTCamber
CasterTotaltoe
FronthearFrontFrontRear0inln 1/16 in0mmln2mm
0'- r"00'2.10'
BRAKE SYSTEMTvpe
Pad surface areaLining surface areaParking brake
Front
RearFrontRearTvpe
Power-assisted selt-ad,ustingventilated discPower assisted self-adiusting drum49 cm, x 2 7.6 sq-in x 273 cm, x2 11.3 sq-in x 2Mechanical actuating, rear two wheel brakes
Drum brake
TIRESize and pressureSee tire inlormation label.
ELECTRICALBafteryStarterAlternator
In under-dash fuse/relay boxIn under hood fuse/relay box
In underhood ABS fuse/relay boxHeadlightsFront turn signal lights
Front parking lightsFront side marker lightsRear side marker lightsRear turn signal lightsErake/parking lightsBack-up lightsCeiling lights {fronvrear)License plate lightSpotlightsHigh mount brake lightlgnition key lightAshtray lightGauge lightsIndicator lightslllLrmination and pilot IightsHeater illumination lights
12 V, 36 AH/s HR12V 1.0, 1.1 kW12V 100A
7.5 A, 10 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A'100 A7.5 4,20 A. 40 A12V 60/55 W12 V- 21 W ('97 model),12 V - 27 W ('98-00 models)12V 5 W {'97 model),3 CP ('98 - 00 models)12V-8W12 V,3 CP12V-21W12 V 2115 W12V 21 CP (18 W)12V-8W12V-8W12V-5W12V -21W
12 V- 1.4 W12V 1.4 W12 V 1.4 W,3 W,3.4 W12V-0.84W, 1.12 W, 1.4 W,3 W, LED12 V - 0.84 W, 1.4 W, LED12 V,1.4 W
2-13
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Engine Electrical
Speciaf Tools ............. 4-2
Starting System
Component Location Index ............ 4-3
Circuit Diagram ................................ 4-4
Starter Test ........... 4-5
Starter Solenoid Test ...................... 4'5
Starter Replacement ....................... 4-7
Field Winding Test ........................... 4-7
Starter Overhaul ............................,. 4-8
Brush Inspection ...........................,., 4-9
Overrunning Glutch Inspection ...... 4-9
Armature lnspection and Test ........4-10
Brush Holder Test ............................ 4-12
Starter Reassemb|y ......................... 4-1 2
Perf ormance Test ............................. 4- 1 3
lgnition System
Component Location Index ............ 4-14
Circuit Diagram ................................ 4-15
lgnition Timing Inspection and
Setting .......................................... 4-16
Distributor Replacement ........,........ 4-17
Distributor Overhaul .............,,......... 4-18
lgnition Control Module (lCM) Input
Test ..............................,................ 4-19
fgnition Coil Test .............................. 4-2O
lgnition Wire Inspection and
Test ............................................... 4-20
Spark Plug Inspection ..................... 4-21
-+
ENGINE
Charging System
Component Location Index ............ 4-22
Circuit Diagram ....................,........... 4-23
Troubleshooting .............................. 4-24
Alternator Replacement ..........,....... 4-30
Alternator Overhaul .......,,................ 4-31
Rectifier Test .........4-32
Alternator Brush Inspection ........... 4-32
Rotor Slip Ring Test ........................ 4-33
Stator Test ............. 4-33
Alternator Belt Inspection and
Adiustment ........4-34
Gruise Control
Component Location Index .,,,........ 4-36
Circuit Diagram ................................ 4-37
Control Unit Input Test ................... 4-38
Main Switch Test/Replacement ..... 4-40
Set/Resume Switch Test/
Replacement .......................,........ 4'40
Actuator Test ....,,., 4-41
Actuator Replacement ...............,.... 4-42
Actuator Cable Adiustment ............ 4-43
Clutch Switch Test .......................... 4-43
Brake Switch Test .................. .......... 4-44
Actuator Solenoid Test .............. ...,. 4-44
Actuator Disassembly ..................... 4-45
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Starting System
Starter Test
NOTE: The air temperature must be between 59 and'100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described.
Alte.nate Procedure:
. Use the following equipment:- Ammeter, 0 - 400 A- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
Tachometer,0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section 1 1).
Check the Starter Engagement:
'1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box.
2. Turn the ignition switch to START (lll) with the shift
lever in E or E position (A/T) or with the clutch
pedal depressed {M/T). The starter should crank the
eng ine.
. lf the starter does not crank the engine, go to
step 3.
. lf it cranks the engine erratically or too slowly, go
to "Check for Wear and Damage" on the next
page.
NEGATIVE TERMINAL
4.
5.
6.
7.
8.
Check the battery, battery positive cable, ground.
staner cut relay, and the wire connections for loose-
ness and corrosion. Test again.
lf the staner still does not crank the engine, go to
step 4.
Unplug the connector (BLK /VHT wire and solenoid
terminal) from the starter.
Connect a jumper wire from the baftery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem.
. lf the starter cranks the engine, go to step 6.
Check the ignition switch (see section 23).
Check the starter cut relay {see section 23}.
Check the IVT gear position switch (A/T) or the clutch
interlock switch (M[).
Check for an open in the wire between the ignition
switch and starter.
(cont'd)
4-5
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Starting System
Starter Test (cont'dl
Check lor Wear and D8mage
The starter should crank the engine smoothly and
steadily. lf the staner engages, but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter ring gear or flywheel ring gear for
oamage.
Check the drive gear overrunning clutch for binding or
slipping when the armature is rotated with the drive
gear held. lf damaged, replace the gears.
Check Cranking Voltage and Current Draw
Cranking voltage should be no less than 8.7 volts on Ay'T
models, and 8.0 volts on M/T moders.
Current draw should be no more than 230 amperes on
A,/T models, and 200 amperes on M/T models.
lf cranking voltage is too low, or current draw too high,
check for:
. dead or low battery.
a open circuit in starter armature commutator seg,
ments.
. starter armature dragging.
. shorted armature winding.
. excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
lf speed is too low, check for:
a loose baftery or starter terminals.
. excesslvely worn staner brushes
. open circuit in commutator segments.
. dirty or damaged helical splines or drive gear.
a defective drive gear overrunning clutch.
Check Starter Disengagement
With the shift lever in @ or @ position (A,iT) or with the
clutch pedal depressed {M/T). turn the ignition switch to
START (lll). and release to ON (ll).
The starter drive gear should disengage from the torque
converter ring gear or flywheel ring gear when you
release the key.
lf the drive gear hangs up on the torque converter ring
gear or flywheel ring gear, check for
. solenoid plunger and switch malfunction.
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuity between the S
terminal and lhe armature housing (ground). The
coil is OK if there is continuity.
STARTER
B TERMINALMOUNTING NUT9 N.m 10.9 kgtm,7 tbtftl
TERMINAL
ARMATUREHOUSING(GROUND}
BLK/WHTWIRE
Check the pull in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.
2.
4-6
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RE
Starter Replacement
1.
B TERMINALMOUNNNG NUTI N.m (0.9 kgl.m,7 rbt ftl
Remove the two bolts holding the starter. then
remove the starter.
4. Install in the reverse order of removal. When
installing the starter cable, make sure that the
crimped side ofthe ring terminal is facing out,
Crimped side of ringterminal
TERMINAL
Connect the battery positive cable and negative cable
to the batterv.
Disconnect the battery negative cable.
Disconnect the starter cable from the B terminal on
the solenoid. then disconnect the BLK/WHT wire
from the S terminal.
STARTER
l0 x 1.25 mm4,1 N.m {4.5 kgf.m,33 tbt.ftl
5.
o
Field Winding Test
Check for continuity between the brushes. lf there's
no continuity, replace the armature housing,
Check for continuity between each brush and the
armature housing {ground). lf there is continuity.
replace the armature housing.
t.
ERUSHES
4-7
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Starting System
Starter Overhaul
STARTER SOLENOID
STARTER SOLENOIDTest, page 4 6
OVEBRUNNINGCLUTCH
w
-6^lMOLYBDENUMDISULFIDE
SPRING CLIPReplace.
BBUSH HOLDERTest, page 4-12
ARMATURE HOUSING
ARMATUREInspection and Test. page 4-10
..'...:|@{MOLYBDENUMDISULFIDEBAUSHInsPeclon, page 4-9
ARUSH
GEAR HOUSING
4-A
END COVER
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Brush Inspection
Measure the brush length. lf it is not within the service
limit, replace the brush (or brush holder assembly).
Brush Lsngth
Standard {Newl: 14.0 - I'1.5 mm (0.55 - 0.57 inl
Servico Limit: 9.0 mm (0.35 in)
NOTE: To seat new brushes after installing them in their
holders. slip a strip of #500 or #600 sandpaper, with the
grit side up, over the commutator and smoothly rotate
the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.
BRUSH
4-9
2.
1.
Overrunning Clutch Inspection
Slide the overrunning clutch along the shaft. Does it
move freely? lf not, replace it.
Rotate the overrunning clutch both ways. Does it
lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, reDlace it.
3.lf the starter drive gear is worn or damaged, replace
the overrunning clutch assembly; the gear is not
available separately.
Check the condition of the torque converter ring gear
or the flywheel ring gear if the starter drive gear
teeth are damaged.
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Starting System
Brush Holder Test
1. Check that there is no continuity between the O and
O brush holders. lf there is continuitv, replace the
brush holder assembly.
O BRUSH HOLDER@ BRUSH HOLDER
Insert the brush into the brush holder, and bring the
brush into contact with the commutator, then attach
a spring scale to the spring. Measure the spring ten-
sion at the moment the spring lifts off the brush.
SPRING SCALE
Spring Tension: 13.7 - 17.7 N
(1.40 - 1.80 kgf, 3.09 - 4.00 lbf)
4-12
Starter Reassembly
NOTE: Use the illustration on page 4I as reference for
reassemDty.
1. Pry back each brush spring with a screwdriver, then
position the brush about halfway out ol its holder,
and release the spring to hold it there.
2. Install the armature in the housing. Next, pry back
each brush spring again, and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
- E^
F*4#-@
6t taal la
tlll
3. Install the endon the brush holder.
ft
cover
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,r1.?
Performance Test
Disconnect the wire from terminal N4.
Make a connection as described below using as
heavy a wire as possible (preferably equivalent to
the wire used for the vehicle).
Connect the battery as shown. lf the starter pinion
pops out. it is working properly. To avoid damaging
the starter, do not leave the battery connected for
more than 10 seconds.
3.
ie
Disconnect the battery from the M terminal. lf the
pinion does not retract, the hold-in coil is working
properly. To avoid damaging the starter, do not
leave the battery connected for more than 10 sec
onds.
@o12VBATTERY
4-13
5. Disconnect the battery also from the body. lf the
pinion retracts immediately, it is working properly,
To avoid damaging the starter, do not leave the bat-
terv connected for more than 10 seconds.
6.
7.
Clamp the starter firmly in a vise.
Connect the starter to the battery as described in
the diagram below, and confirm that the motor
starts and keeps rotating.
8, lf the electric current and motor soeed meet the
specifications when the battery voltage is at 11.5 V,
the starter is working properly.
Specifications:
MakerElectric currentMotor speed
DENSO90 A or less3,000 rpm or
more
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