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

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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Troubleshooting
Engine/Powertrain Control Module Terminal Arrangement - '98 - 00 Models
(cont'd)
ECM/PCM CONNECTOR B {25PI
Wire side of female terminalsECM/PCM CONNECTOR B I25PI
*2t MlT*3: '98 model"4: '99 - 00 models
NOTE: Standard baftery voltage is l2
Ierminalnumb€tWire colorTerminsl nameDescriptionSignal
1YEUBLKIGPl (POWER SOURCE)Power source for the ECM/PClvlcontrol circuit.withagewith
ignition switch ON (ll): battery volt-
ignition switch OFF:0 V
BLKPG1 (POWER GROUND}Ground for the ECM/PClvl controlcircuit.Less than 1.0 V at all times
REDlNJ2 (No. 2 FUEL INJEC-roR)Drives No. 2 Iuel injector.With engine running: duty controlled
BLUlNJ3 1No. 3 FUEL INJEC-TOR)Drives No. 3Iuel jnjector.
YELlNJ4 {No.4 FUEL INJEC-TOR)Drives No. 4 fuel injector.
8*1WHTLS- (A"/T CLUTCH PRES.SURE CONTROL SOLE,NOID VALVE _ SIDE)
A,/T clutch pressure controlsolenoid valve power supplynegative terminal.
With ignition switch ON (ll): dutycontrolled
9YEUBLKIGP2 IPOWER SOURCE)Power source for the ECN,I/PCMcontrol circuit.With ignition switch ON (lll: bafteryvoltageWith ignition switch OFF:0 V
10BLKPG2 (POWER GROUND}Ground for the ECM/PCM controlcrrcurt.Less than '1.0 V at all times
' BRNlNJl (No. 1 FUEL INJECTOR)Drives No. l tuel injector.With engine running: duty controlled
YEUGRNrcM {rGNrTroN coN-TROL MODULE)Sends ignition pulse.With ignition switch ON (ll): batteryvoltageWith engine running: pulses
17*1REDLS+ (A,,IT CLUTCH PRESSURE CONTROL SOLE-NOID VALVE + SIDE)
A,/T clutch pressure controlsolenoid valve power supplypositive terminal
With ignition switch ON (ll): dutycontrolled
19*.PNK
ODIND (OVER-DRIVE
OFF INDICATOR}Drives OVER-DRIVE OFFindicator light.With OVER-DRIVE OFF indicator lightturned ON: 0 VWith OVER-DRIVE OFF indicator lightturned OFF: battery voltage
20BRN/BLKLG1 (LOGIC GROUND)Ground for the ECM/PCM controlcircuit.Less than 1.0 V at all times
WHT/BLUVBU (VOLTAGE BACKUP)Power source for the ECM/PCMcontrol circuit.Power source forthe DTC memory.
Battery voltage at all times
22BRN/BLKLG2 (LOGIC GROUND)Ground for the ECN4/PCM controlctrcutt,Less than 1.0 V at all times
23BLVBLUIACV {IDLE AIR CON.TROL VALVE)Drives IAC valve.With engine running: duty controlled
11-72
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PGM-FI System
System Description
INPUTS
CKP/TDC/CYP Sensor
CKF Sensor
MAP Sensor
ECT Sensor
IAT Sensor
TP Sensor
Primary HO2S
Secondary H02S
vss
KS*5
BARO Sensor
ELD*6
Starter Signal
ALT FR Signal
Air Conditioning Signal
Ay'T Gear Position Signal*1
Baftery Voltage (lGN.1)
Brake Switch Signal
PSP Switch Signal
Fuel Tank Pressuae Sensor*4. *5
Countershaft Speed Sensor*1
Mainshaft Speed Sensor*r
OVER-DRIVE Switch Signal*s
ENGINE CONTROL MODULE (ECM)/
POWERTRAIN CONTROL MODULE (PCM) OUTPUTS
|iuel 1"j""- Th,rhg ""d Drrafr";-l
Et*-.nt"tdt"cont.orl
to,r*,c;;trffi;]
l.----.---:. .Lrgnrnon |lmrng Lonrror I
Ecir/PcM B*k',p Fr""il]
m;"t-ll-r*'io*l
Fuel Injectors
PGM-Fl Main Relay (Fuel Pump)
MIL
IAC Valve
Ay'C Compressor Clutch Relay
Radiator Fan Relay
Condenser Fan Relay
ALT
tcM
EVAP Purge Control Solenoid
Valve
Primary HO2S Heater
Secondary H02S HeaterEVAP Bypass Solenoid Valve*a *5
EVAP Control Canister Vent Shut
DLC
Lock-up Control Solenoid Valve*l
Shift Control Solenoid Valve*1
Ay'T Clutch Pressure Control
Solenoid Valve*1
D4 Indicator Light'1 *3, *a
D Indicator Light,l *5
OVER-DRIVE OFF Indicator
Lighl*t *:
*1: A/T {3:'97 model'2: M/f +4:'98 model*5: '99 - 00 models"6: USA
PGM-Fl System
The PGM-Fl system on this model is a sequential multiport fuel injection system.
Fuel iniecior Timing and Duration
The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold pressure. The
basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors
to obtain the final discharge duration.
ldle Air Control
ldle Air Control Valve (lAC Valve)
When the engine is cold, the Ay'C compressor is on, the transmission is in gear, the brake pedal is depressed, the P/S load
is high, or the alternator is charging, the ECM/PCM controls current to the IAC Valve to maintain the correct idle speed.
lgnition Timing Control
o The ECM/PCM contains memories for basic ionition timing at various engine speeds and manifold air flow rates.
lgnition timing is also adjusted for engine coolant temperature.
. A knock control system was adopted which sets the ideal ig nition timing for the octane rating of the gasoline used.*s
Other Control Funstions
1. Starting Control
When the engine is started. the ECM/PCM provides a rich mixture by increasing fuel injector duration.
2. Fuel Pump Control
. When the ignition switch is initially turned on (ll). the ECMiPCM suppli€s ground to the PGM-FI main relay that
supplies current to the fuel pump for two seconds to pressurize the fuel system.
. When the engine is running, the ECM/PCM supplies ground to the PGM-FI main relay that supplies current to the
fuel oumo.
. When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which
cuts current to the fuel pump.
1 1-80
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Fuel Cut-off Control
. During deceleration with the throttle valve closed, current to the fuel injectors iscutoffto improvefuel economyat
speeds over 970 rpm ('97 - 98 models), 920 rpm ('99 - 00 modelsl.
. Fuel cut-off action also takes place when engine speed exceeds 6,500 rpm ('97 - 98 models), 6900 rpm ('99 - 00
models), regardless of the position of the throttle valve, to protect the engine from over-rewing.
With Ay'T model. the PCM cuts the fuel at engine speeds over 5,000 rpm when the vehicle is not moving.*'
4,./C Comoressor Clutch Relav
When the ECM/PCM receives a demand for cooling from the air conditioning system, it delays the compressor from
being energized, and enriches the mixture to assure a smooth transition to the Ay'C mode.
Evaporative Emission (EVAP) Purge Control Solenoid Valve
When the engine coolant temperature is above 154"F (68'C), the ECM/PCM controls the EVAP purge control solenoid
valve which controls vacuum to the EVAP purge control canister,
Alternator Control
The system controls the voltage generated at the alternator in accordance with the electrical load and driving mode.
which reduces the engine load to improve the fuel economy.
PCM Fail-saf e/Back-up Functions
1. Fail-safe Function
When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-pre
grammed value for that sensor that allows the engine to continue to run.
2. Back-up Function
When an abnormality occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independent
of the system in order to permit minimal driving.
3. Self-diagnosis Function IMalfunction Indicator Lamp (MlL)l
When an abnormality occurs in a signal from a sensor, the ECM/PCM supplies ground for the MIL and stores the DTC
in erasable memory. When the ignition is initially turned on {ll), the ECM/PCM supplies ground for the MIL for two
seconds to check the MIL bulb condition.
4. Two Trio Detection Method
To prevent false indications, the Two Trip Detection Method is used for the HO2S*1, fuel metering-related. idle control
system, ECT sensor and EVAP control system self-diagnostic functions. When an abnormality occurs, the ECM/PCM
stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON (ll) again,
the ECM/PCM informs the driver by lighting the MlL. However, to ease troubleshooting, this function is cancelled
when you jump the service check connector, The MIL will then blink immediately when an abnormality occurs.
5. Two (or Three) Driving Cycle Detection Method {'97 model)
A "Driving Cycle" consists of starting the engine, beginning closed loop operation, and stopping the engine. lf misfir-
ing that increases emissions or EVAP control system malfunction is detected during two consecutive driving cycles.
or TWC deterioration is detected during three consecutive driving cycles, the ECM/PCM turns the MIL on. However, to
ease troubleshooting, this function is cancelled when you jump the service check connector. The MIL will then blink
immediately when an abnormality occurs.
*1: '97 - 98 models*2: '99 - 00 models
5.
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Fuel Supply System
System Description
The fuel supply system consists of a fuel tank, in-tank
high-pressure fuel pump. PGM-Fl main relay, fuel filter,
fuel pressure regulator, fuel injectors, and fuel delivery
and return lines. This system delivers pressure-regulat-
ed fuel to the fuel injectors and cuts the fuel delivery
when the engine is not running.
Fuel Pressure
Relieving
Before disconnecting fuel pipes or hoses, release pres-
sure from the system by loosening the 12 mm banjo
bolt on the too of the fuel filter.
Do not smoke while working on the fuel system.
Ke€p open flames or sparks away from your work
area,
Be sure to relieve fuel pressure while the ignition
switch is off.
Write down the frequencies for the radio's preset
buttons.
Disconnect the battery negative cable from the bat-
tery negative terminal.
Remove the fuel fill cap.
Use a box end wrench on the 12 mm banjo bolt at
the fuel filter while holding the fuel filter with anoth-
er wrench.
Place a rag or shop towel over the '12 mm banjo bolt.
Slowly loosen the 12 mm banjo bolt one complete
rurn 12 mm BANJoBOLT
1.
SHOP TOWEL
NOTE: Replace the washers whenever the 12 mm
banio bolt is loosened or removed.
11-178
Inspection
1, Relieve fuel pressure.
2. Remove the 12 mm banjo bolt on the fuel filter while
holding the fuel filter with another wrench. Attach
the 12 mm fuel pressure adapter bolt and the special
tool.
FUEL PRESSUREREGULATON
FUELPRESSUREGAUGE07406 - 0040001
The illustration shows'97 - 98 models,'99 - 00 models are similar.
Start the engine. Measure the fuel pressure with the
engine idling and the vacuum hose of the fuel pres-
sure regulator disconnected from the fuel pressure
regulator and pinched. lf the engine will not start,
turn the ignition switch on (ll), wait for two seconds,
turn it off, then back on again and read the fuel
pressure.
Pressure should be:'97 - 98 mod€ls:
260 -31O kPa 12.7 - 3.2 kgf/cm,, 38 - 46 psil'99 - 0O models:
270 - 32O kPa Q.A - 3.2 kgf/cm', ifo - /U psil
Reconnect vacuum hose to the fuel pressure regulator.
Prgs3ure should be:'97 - 98 models:
210 - 25O kPa 12.1- 2.6 kgf/cm', 30 - 37 psi)'99 - 00 models:
22O -26iJ kPa 12.2 - 2.7 kgt/cm', 31 - 38 psi)
lf the fuel pressure is not as specified, first check the
fuel pump (see page 11- 183). lf the fuel pump is OK,
check the following:
. lf the fuel pressure is higher than specified,
inspect for:- Pinched or clogged fuel return hose or line.- Faulty fuel pressure regulator (see page 11-
181).
. lf the fuel pressure is lower than specified. inspect
for:- Clogged fuel filter.- Faulty fuel pressure regulator (see page 11-
1811.- Fuel line leakage.
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Interlock System
Park Pin Switch Replacement -'97 - 98 Models
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.
1. Remove the instrument Danel lower cover (see section 20).
2. Remove the upper and lower steering column covers (see section li,.
3. Remove the flange nuts and bolts securing the steering column. then lower the steering column.4. Disconnect the shift lock solenoid and the park pin switch connectors.
5. Remove the harness clamp bracket.
6. Remove the bolts secu ring the shift lever assembly, then removetheshift lever assembly.
7. Remove the screws securing the shift lock solenoid. then remove the shift lock solenoid,
8. Remove the parkpin switch connector from the shift lever control bracket.
9. Remove the control checker from the shift lever control bracket.
10. Remove the park Din switch from the control checker.
PARK PIN SWITCH
PARK PINSWITCH CONNECTOR
scnEw2.5 N m 10.25 kgt.m, 1.8 lbtftl
9.3 N.m 10.95 kgf.m, 6.9 lbl.ft)
BRACKETCONTROL CHECKER
11. Install the new Dark Din switch on the control checker.
12. lnstall the control checker on the shift lever control bracket.
13. Routethe park pin switch harness through thecutoutofthe shift lever control bracket, then install the park pin switchconnector on the bracket.
14. Install the sh ift lock solenoid by a ligning the joint of the sh ift lock solenoid plu nger with the tip of the shift lock exten-sion.
15. Secure the shift lock solenoid with the screws.
15. Install the shift lever assembly in the reverse order of the removal.'17. Check the operation of the shift lever and the shift lock.
14-150
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Park Pin Switch - Over-Drive (O/Dl Switch Replacement -'99 - 00 Models
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.
NOTE: lf replacement of the park pin switch or the O/D switch is required. replace them as a set.
1. Remove the instrument panel lowercover(see section 20).
2. Remove the upper and lower steering column covers (see section 17).
3. Remove the flange nuts securing the steering column. then lower the steering column.
4. Disconnect the shift lock solenoid and the park pin switch - O/D switch connectors
5. Remove the harness clamp bracket.
6. Remove the bolts securing the shift lever assembly, then remove the shift lever assembly.
7. Remove the screws securing the shift lock solenoid, then remove the shift lock solenoid.
8. Cut the O/D switch wires (REDand BLK),then remove the con nector from the shift lever control bracket
9. Remove the control checker from theshift lever control bracket
10. Remove the oark oin switch from the control checker.
11. Remove the shift lever knob from the shift lever, then remove the O/D switch from the shift lever knob.
SCREW2.5 N.m 10.25 kgtm, 1.8lbf,ft)SHIFT LEVER CONTROLBRACKET
PARK PIN SWITCH -
o/D swlTcHCONNECTOR
2.5 N.m (0.25 kgt m,1.8 tbf.fr)
HABNESS CLAMP BRACKET
9.3 N.m 10.95 kgl.m.6.9 tbf ft)
SHIFT LEVER KNOB6-12N,m{0.6 - 1.2 kgt.m.4 - 8.7 lbf ftl
SHIFT LEVERo/o swlTcH
12. Route the new O/D switch wires through the shift lever knob, shift lever, and shift lever control bracket, then install
the knob on the shift lever, and install the switch in the knob.
13. Install the new park pin switch on the control checker, then install the control checker on the shift lever control brack-
et.
14. Routethe parkpin switch harnessthroughthecutoutoftheshift lever control bracket.
15. Install the O/D switch wire terminals in the connector cavities securely. The wire terminals can be installed in cavity
No. 1 or No.2.
16, Install the connector and the harness clamp on the bracket.
17. tnstall the shift lock solenoid by aligning the joint ot the shift lock solenoid plu nger with the tip of the shift lock exten-
sion, then secure the shift lock solenoid with the screws,
18. lnstall the shift lever assemblv inthe reverse order of removal.
19. Adjust the clearance between the O/D switch wires and the edge of the sh ift lever control bracket (see page 14-270).
20. Check the shift lever operation and shift lock operation.
14-151
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1. Remove the A/T gear position switch harness
cramp.
Remove the y'VT gear position switch cover.
Remove the bolt securing the ly'T gear position switch
harness clamp on the end cover, then remove the A/T
gear position switch.
Remove the 12 bolts securing the end cover. then
remove the cover.
Slip the special tool onto the mainshaft as shown.
6. Engage the park pawl with the park gear.
7. Cut the locktabs of each shaft locknut using a chisel as
shown. Keep all chiseled particles out of the transmis-
ston.
M=tt"
Align the hole of the sub-shaft 1st gear with the hole
of the transmission housing. then insert a pin to lock
the sub-shaft while removing the sub-shaft locknut.
Remove the locknuts and conical spring washers from
each shaft.
NOTE:
Mainshaft and countershaft locknuts have left-
hand threads.
Clean the old countershaft locknut. lt is used to
install the press fit park gear on the countershaft.
MAINSHAFT
PIN8 mm pin,
commercially
SUB-SHAFTLOCKNUTReplace.COUNTERSHAFTLOCKNUTReplace.
CONICAL SPNING WASHERSReplace.
9. Remove the lock pin that was installed to hold the
sub-shaft.
10. Remove the special tool from the mainshaft.
11. Remove the 1st clutch, mainshaft 1st gear assembly,
and mainshaft 1st gear collar.'12. Remove the sub-shaft 1st gear.
13. Remove the park pawl, pawl spring, pawl shaft. and
pawl stoP.
14. Remove the park lever from the control shaft.
15. Using a universal two jaw puller, remove the park
gear, one-way clutch, and countershaft 1st geal
assemblv.
{Commercially available)
1SY GEAR
Remove the needle bearing and countershaft 1st gear
co ar.
Remove the ATF cooler lines,
LOCKNUTReplace.
2\
Irot)
PULLER
11.
14-187
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Brake Pedal
Pedal Hoight
1. Disconnect the brake switch connector, loosen the
brake switch locknut, and back off the brake switch
until it is no longer touching the brake pedal.
2. Lift up the carpet, At the insulator cutout, measure
the pedal height from the middle of the right side of
the oedal pad.
BRAKE SWITCH
ERAKE SWITCH
Standard Pedal Height (with floor m8i removed):
A/T: 161 mm (5 5/16 in)
M/T: 155 mm {6 U8 in}
Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. Do not adjust the pedal
height with the pushrod pressed. After adiustment,
tighten the locknut firmly.
PUSHROD LOCKNUT
15 N.m11.5 kgj m, 11 lbf ftl
4. Screw in the brake switch until its plunger is fully
pressed (threaded end touching the pad on the
pedal arm), Then back otf the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearance between the
threaded end and pad. Tighten the locknut firmly.
Connect the brake switch connecto.. Make sure that
the brake lights 90 off when the pedal is released
5. Checkthe brake pedalfree play as described below
Pedal Free Play
1. With the engine off. inspect the free play on the
pedal pad by pushing the pedal by hand-
Free Play: 1 - 5 mm (1/16 - 3/16 in)
2. lf the pedal free play is out of specification, adiust
the brake switch. lf the pedal free play is insuffi-
cient, it may result in brake drag.
swtTcH
PEOAL PAD
PEDAL FREE PLAY
19-5
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Diagnostic Trouble Code (DTC)
Diagnostic Trouble Gode IDTCI Indication
NOTE: This operation can also be done with the Honda pGM Tester.
1. Connect the SCS service connector to the service check connector (2P) located on the passenger's side of the centerconsote.
2. Turn the ignition switch ON (ll).
NOTE; Do not press the brake pedal whenturningthe ignition switch.
3 Record the blinking frequency of the ABS indicator. The brinking frequency indicates the DTc.
4. Turn the ignition switch OFF. and remove the SCS service connector.NOTE: The Malfunction Indicator Lamp (MlL) will stay on after the engine is startsd if the SCS seryica connecror rsconnected.
5. Erase the DTC.
Conditions for DTC indication. The vehicle is stopped.. The SCS service connector is connected before the ignition switch is turned ON flt).. The brake pedal is released.. The SCS service connector remains connected during this procedure.
The DTC indication stops and the ABS control unit axecutos tha softwaro lunction if at least one of tho following condi-tions i3 satisfiod:
. The vehicle is not stoooed.. The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda pGM Tesrer.. The SCS service connector is disconnectod during this procedure.
NQTE: The illustration of gauge assembly shows the '97 - 98 models. The '99 - oo models are similar.
SEFVICE CHECKCONNESTOR I2P}
GAUGE ASSEMBLY
A8S II{DEATOR
u.s.A.
@
CANADA
@
19-38
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