Ect switch HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Emission Control System
Evaporative Emission (EVAPI Controls (cont,dl
1T1456I (conro)
€VAPBYPASSSoLENOtOVALVEECM/PCM CONNECTOR A I32P)
Wire side of female terminals
VACUUMPUMP/GAUGE.0 -30 in.HgA373X -
041 -
xxxxx
EVAP BYPASS SOLENOIDVALVE 2P CONNECTOR lcorlTl
2WBS(BLU}
II
Wire side offemaletermrnats
tGlIBLK/WHT}
EVAP bypa3s solenoid valve test.(The continuation ot DTC P1456troubleshooting.l
Check the EVAP bypass sotenoid
1. Disconnect the vacuum hosefrom the EVAP two way valve,and connect a vscuum pumpto the hose,2. Connect the ECM/PCM con-nector terminal 43 to the bodyground with a jurnper wire.3. Turn the ignition switch ON 0t).4. Apply vacuum to the hose.
EVAP bypass solenoid valve/EVAP two way valve is OK. Doth6 EVAP control crnister ventshut vafve le3t lso€ page 11-2'111.
Does the valve hold vacuurn?
Check for an op€n in the wir€(2WBS line):1. Turn the ignition switch OFF.2. Disconnect the EVAP bypasssolenoid valve 2P connector.3. Check for continuity betweenthe EVAP bypass so teno idvalve 2P connector terminalNo. 2 and body ground.
Repair open in the wire betweenthe EVAP bypass solenoid valv.and ECM/PCM lA3).
Chack tor an op6n in the wirellcl line):1. Turn the ignition switch ON l).2. Measure voltage between theEVAP bypass solenoid valve2P connector terminal No. land body ground.
Replace the EVAP byps.,s solonoidvatus and O-ring3.
Ropair o,pen in the wire botwoenth6 EVAP bypa$ sotenoid vatvoand No. 15 ALTERNATOR SpSENSOR (7.5 Altuso.
2WBS (BLU}
/3
7,x
4l6o/to -/
,/ 16 1718't920 211/z3
26 272A29solT32
JUMPER WIRE
11-216
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EVAP control canister vent shut
valve l€st,lThe conlinualion ot DTC P1456
troubleshooting.)
Check the EVAP control cankter
vent 3hut valve:1. Disconnect the vacuum hose
from the EVAPthree way valve,
and connect a vacuum PUmPto the hose.2. Turn the ignition switch ON (ll).
3. Apply vacuum to the hose
EVAP control crnisier vent lhul
valve is OK. Do the v.cuum
hoses and connections te3l lseepage 11-218).
Does the valve hold vacuum?
Chock the EVAP control canbtel
vent shul valvo:1. Turn the ignition sw;tch OFF.
2. Disconnect the EVAP controlcanister vent shut valve 2P
connector.3. Check for continuity betlveen
the EVAP control canister vent
shut valve 2P connector termi-nal No. 1 snd body ground.
Roplac€ the EVAP contlol canbt€]venl shut valve and O-ring.
Chock lor a short in the wire(VSV lino)r1. Disco n nect the EcM/PCN4connoctor A (32P).
2. Check for continuity betweenthe EVAP control canister vent
shut valve 2P connector termi-
nal No. 1 and body ground.
Reorir 3hort in tho wiro bgtweonthe EC1I/I/PCM lAal .nd the EVAP
codrol canbtor vent shut valv6.
Substitute a known.good ECM/
PCM and recheck. lf symptom/indicrtion goes awaY, replace
the original ECM/PCM.
VACUUMPUMP/GAUGE,0 - 30 in.Hg
A973X - 041 -
XXXXX
EVAPTHREE
VALVEEVAPCONTROLCANISTER
EVAP CONTROLCANISTER VENT SHUTVALVE 2P CONNECTOR IC361)
r+l1t2l
f1 VSV
(o) tLT cnrulwxrt
1
Wire side of female terminals
EVAPCONTROLCANISTERVENTSHUTVALVE
O.RINGReplace.
ILT GRN/WHT)
(cont'd)
-21711
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Emission Control System
Evaporative Emission (EVAP) Controls (cont,dl
iTl457l ("ont'or
APCONTROLCANISTER
Ropair op€n in th6 wire betweenthe EVAP purge control 3olenoidvelve and ths ECM/PCM (A61.
VACUUMPUMP/GAUGE, O-30 iN.HgA973X - 0rl -
xxxxx
'\)
Wire side of lemale terminals
EVAP PURGE CONTROL SOI.ENOIDVALVE 2P CONNECTOR (Cl08)
PCSIRED/YELI
femaletermanals
ECM/PCM CONNECTOR A {32P}
PCS (RED/YELI
,/3 458/'t0
,,/ 14 ,/'t61718l92024
,/ 262930
JUMPERWIRE
- The MIL has been reported on.- DTC P1457 is stored.{EVAP purge control solenoidvalve test.l*
Check the EVAP purge conrrol30lenoid velve:L Disconnect the vacuum hosefrom the EVAP conlrol canis,ter, and connect a vacuumpump to the hose.2. Connect the ECM/PCM connector terminal A6 to the bodyground with a jumper wire.3. Turn the ignition switch ON (tl).4. Apply vacuum to the hose.
EVAP purge control solenoidvalve is OK. Oo the EVAP bypasssolenoid valve t€3t {see psge 1l-221t.
Does the valve hold vacuum?
Check for an open in the wire(PCS line):1. Turn the ignition switch OFF.2. Disconnect the EVAP purgecontrol solenoid valve 2P connector,3. Check for continuity betweenthe EVAP pu rge controlsolenoid valve 2P connectorterminal No.2 and bodygrouno,
ls there continuity?
Check for an open in the wire(lGl line):1. Turn the ignition switch ON t).2. Measure voltage between theEVAP bypass solenoid valve 2pcoonector terminal No. 1 andbody ground.
ls there battery voltage?
Repah open in lhe wir6 betwoenthe EVAP pu.ge cont.ol solonoidvdlvo and No. 15 ALTERNATORSP SENSOR {7.5 Al fu!€.
*: Continued frr '98 model
1-220
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EVAP bypass solenoid valv€ test.
{The continuation of DTC P1457
troubleshooting.l
Check the EVAP bypass 3olenoid
1. Disconnect the vacuLlm hose
from the EVAP two way valve,
and conned a vacuum PUmPto the hose.2. Turn the ignition switch ON (ll).
3. Apply vacuum to the hose
EVAP bvpas3 30lsnoid vrlvo/
EVAP two way v.lve is OK. Do
the EVAP control canisler vent
3hut v.lve te3l (see Psge11'2221.
Does the valve hold vacuum?
Ch6ck the EVAP byp.ss solenoid
'1. Turn the ignition switch OFF
2. Disconnect the EVAP bypass
solenoid valve 2P connector.
3. Check {or continuity between
the EVAP bypass soleno id
valve 2P connector termlnal
No. 2 and body ground
ReDlace the EVAP bypass 3olenoid
valve and O-rings.
Check for a short in lhe wire
{2WBS linel:1. Disconnect ECM/PCM connec
tor A (32P).
2. Check lor continuity betlveenthe EVAP bypass soleno id
valve 2P connector termrnalNo. 2 and body ground.
Rcpsir short in th. wire bgtwoen
the EcM/PCtrl lA3l lnd the EVAP
bypa$ solenoid valvo.ls there continuitY?
Sub3tiiute . known'good ECM/
PCM End recheck. lI sYmptom/
indication goe3 away, tePlace
the original ECM/PCM.
EVAPBYPASSFUELTANKPRESSUBE SENSORSOLENOIDVALVEEVAP TWO WAY
VALVE
VACUUMPUMP/GAUGE,0-30 in.HgA973X -
041 -
xxxxx
EVAP AYPASS SOLENOID
VALVE 2P CONNECTOR (C647}
q
@)
T
t.'-+lt1t?l
| 2wBs
(d1 terul
Y-L
Wire side offemaleterminals
2WBS(BLU}
(cont'd)
11-221
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Emission Control System
Evaporative Emission (EVAP) Controls (cont,dl
lT145il ("ont'o)
EVAPTHREE
VATVE \'t
VACUUMPUMP/GAUGE,0 - 30 in.HsA973X - 041 -
xxxxx
WIRE
ECM/PCM CONNECTOR A {32PI
vsv
Wire side of female terminals
EVAPCONTROLCANISTER
EVAP CONTROLCANISTER VENT SHUTVALVE 2P CONNECTOR {C361}
riErr+J
I vsv
/A {Lr GRN/WHT|
YI
Wire side of female terminals
CANISTEFVENTSHUTVALVE
EVAPCONTROL
(}BING
Replace.
ffilrcr
e
(BLK/wHr)
I
11-222
EVAP control canistor vent shutvalve t6t.(The continuation of DTC p1457
troubl€ahooting.)
Chcck the EVAP control c.nirt6lvent ahut vrlve:1. Disconnect the vacuum hosetrom the EVAP thre€ way valve,and connect a vacuum pumpto the hose.2. Connect the ECM,PCM conn6c,tor terminal A4 to the bodyground with a jumper wire.3. Turn the ignition switch ON fil).4. Applyvacuum to the hose.
EVAP control crni3ter v6nt shutvelve b OK. Do the canistsr sys-lern loak test {3ee page 11-2231.
Does the valve hold vacuum?
Check for an open in the wireIVSV linGll1. Turn the ignition swjtch OFF.2. Disconnect the EVAP controlcanister vent shut valve 2pconnector.3. Check for continuity betweenthe EVAP control canister ventshul valve 2P connector termi-nal No. l and body ground.
Ropril op6n in tho wire botweonthe EVAP control canister v6ntshut v.lve and the ECM/PCM(A41.
Check tor an open in the wire(lGl line):1. Turn the ignition switch ON l).2. Measure voltage between theEVAP control canister vent shutvalve 2P connector terrninalNo. 1 and body ground.
Roplace thG EVAP cont.ol canis-ter Yent shut velve and O-ring.
Repai. opon in the wire betwoenth6 EVAP control canister vontshut valve .nd No. 15 ALTERNA-TOB SP SENSOR t?.5 Alfus6.
{LT GRN/WHT)
36a10
l4/1617l8't9202l232426 272a2930
JUMPER
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Canbter system leak test
{The continuation of DTC P1457
trouble3hootin9.)
Chock the EVAP control canistervent shut valve line and connoc'
tonS:1. Turn the ignition switch OFF
2. Connect to three'way tee fit_
tings into the hose from the
EVAP control canister to the
EVAP two way valve. Connect
the fuel tank pressure sensor
to one of the tee fittings and
the vacuum PumP to the other'
3. Remove the vent hose from
the EVAP control canister vent
shut valve and cap the Pon to
seal the fresh air vent Ior the
EVAP control canister.4. Turn the ignition switch ON (ll).
5. While monitoring the FTP
Sensor voltage with the Honda
PGM Tester, or measurangvoltage between ECM/PCM
connector terminals A29 and
C18 slowly PumP the vacuumpump using a stroke every 1 -
2 seconds.6. Continue to PumP vacuum
until that voltage droPs to
approx. 1.5 V.NOTE: Make sure that the
engine coolant temPeraturestillabove 95'F (35'Cland Yourvacuum PumP has no leak
7. Monitor that voltage for 20
seconds.
Check the EVAP Pu.ge control
solenoid valve line and connec-
tions:1. Turn the ignition switch OFF.
2. Disconnect the Purge lane
hose from the EVAP control
canister and Plug the Port3. Turn the ignition switch ON (lli.
4. While monitoring the FTP
Sensor voltage with the Honda
PGM Tester, or measuringvoltage between ECM/PCM
connector terminals A29 and
Cl8 slowly PumP the vacuumpump using a stroke every 1 -
2 seconds.5. Continue to pump vacuum
until that voltage droPs to
approx. 1-5 V.NOTE: Make sure that the
engine coolant temPeraturestill above 95'F (35"C) and Yourvacuum pump has no leak-
6. Monitor that voltage tor 20
seconds.
Doesthe voltage drop to 1.5 V
and holds at least 20 seconds?
lGp€ct the EVAP control cani3tel
vent 3hut valvo line and connec_
tion5.
Inlpect tho EVAP Putge control
solenoid valvo line and connec'
tion3. It th6y lro OK, do the EVAP
two way valve te3t (seo page 11-
2211.
Does the voltage drop to 1.5 V
and holds at least 20 seconds?
Reolace the EVAP conirol canister.
EVAPBYPASSSOLENOIDVALVE
FUEL TANK
EVAPCONTROL
VENTSHUTVALVE
EVAPCONTROLCANISTER
SENSOR
EVAP TWO WAYVALVE
EVAPTHREE
VALVE
ttrrL
ta
VACUUMPUMP/GAUGE,0 - 30 in.HgA973X -
041 -
XXXXX
FITTINGS
ECM/PCM CONNECTORS
A {32P)
PTANK ILT GRN)
c (31Pt
SG2 {GRN/BLK)
Wire side of female terminals
{cont'd)
11-223
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Clutch Pedal
Adiustment
NOTE:
. To check the clutch interlock switch and clutch
switch, see section 23.
. The clutch is self-adjusting to compensate for wear.
CAUTION: lf there is no clearance bstwa€n the mas-
ter cylinder piston and push rod, ths roloase bearingis held againsi the diaphragm spring, which canresuh in clutch slippage or other clutch probloms.
1. Loosen locknut A, and back off the clutch switch (or
sdjusting bolt) until it no longer touches the clutchpeoar.
2. Loosen locknut C, and turn the push rod in or out toget the specified stroke (@) and height (@) at theclutch oedal.
3. Tighten locknut C.
4. Thread in the clutch swirch (or adjusting bolt) untilit contacts the clutch oedal.
7.
5.
8.
q
Turn the clutch switch {or adjusting bolt} in an addi-
tional 3/4 to 1 full turn.
Tighten locknut A.
Loosen locknut B on the clutch interlock switch.
Measure the clearance between the floor board and
clutch pedalwith the clutch pedal fully depressed.
Release the clutch pedal 15 - 20 mm (0.59 - 0.79 in)
from the fully depressed position and hold it there,Adjust the position of the clutch interlock switch sothat the engine will start with the clutch pedal in
this position.
Tighten locknut B.10.
LOCKNUT B9.8 N.m 11.0 kgf.m, 7.2 lbf.ftl
CLUTCH INTERLOCK SWITCH
CLUTCH SWTTCH{or ADJUSTING BOLTI
L(rcKNUT A9.8 N.m {1.0 kg{.m,7.2 lbf.ftl
CLUTCH MASTER CYLINDER
PUSH ROD
Pedal in contact with swhch
LOCKNUT C18 N.m (1.8 kgf.m, 13lbtftl
@ {STROKE at PEDAL): 135 - 1its mm (5.31 - 5.71 in}
@ (TOTAL CLUTCH PEDAL FREE PLAY)i7 -22mm (0.28-0.87 in) inctude the pedat ptay 1 - 9 mm (0.0it- 0.35 inl@ (GLUTC,H PEDAL HE|GHTI: ltxt mm (7.20 inl ro rhe ftoor
o (CLUTCH PEDAL DTSENGAGEMENT HEtcHTl: 72 mm {2.txt inl minimum to the floor
\,/a_-_--/
12-4
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MaintenanceBack-up Light Switch
Transmission Fluid
NOTE: Check the fluid with the engine OFF and vehicle
on level ground.
1. Remove the filler plug. then check the level and
condition of the fluid.
FILLER PLUG44 N.m {4.5 kgf.m. 33 lbf ftl
ll
Ptopet Level
\--ril /
HllllllTl /
Hllllrlll /_rf-F{--rno."."
ll| | Replaco.
The fluid level must be up to the filler hole. lf it is
below the hole, add fluid until it runs out. then rein-
stall the tiller plug with a new washer.
lf the transmission fluid is diny, remove the drain
plug and drain the fluid.
FILLEB PLUGa,a N.m 14.5 kgf..n. 33 lbt'ftl
DRAIN PLUG39 N m (4.0 kgf.m, 29 lbf'ft)WASHERReplace.
Reinstall the drain plug with a new washer. and
refill the transmission fluid to the proper level.
NOTE: The drain plug washer should be replaced at
every fluid change.
Reinstall the filler plug with a new washer.
Fluid Capacity
1.7 / {1.8 US qt, 1.5 lmp qtl at oil change
2.1 ! 12.2 US qt, 1.A lmp qtl at overhaul
Alwavs use Genuine Honda Manual Transmission
Fluid (MTF). Using motor oil can cause stiffer shift-
ind because it does not contain the proper additives.
Test/Replacement
1. Disconnect the connectors from the switch.
Terminal side oImale lerminals
BACK.UP LIGHT SWTTCHr 25 N.m 12.5 kgt m, 18 lbf.ftl
WASHERReplace.
Check for continuity between the No. 1 and No. 2
terminals.
. There should be continuity when the shift lever
tnto reverse.
. There should be no continuity when the shift
lever in position except reverse,
lf necessary, replace the switch.
13-3
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Transmission AssemblY
Removal
@FMak. sw. iack" and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket'
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(cont'd)
13-7
WIRE HARNESS CLAMP
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C) TRANSMISSION HANGER
O INTERLOCK BOLT
O 32 mm SEALING BOLT
@ STEEL BALL {5/16 in.)
€) SPRING 26.1 mm {1.03 in.l
@ wasHER Replace.
O sET BALL scREw
@ WASHER Replace.
€) FLANGE BOLT
@ oll SEAL Replace.
@ DRAIN PLUG
@ WASHER Replace.
@ FILLER PLUG
@ WASHER Replace.
(9 10 x 12 mm DOWEL PIN(D SPRING 25.6 mm 11.01 in.l
€' THRUST WASHER
@} SHIFT ARM C(3 CONICAL SPRING WASHER
@ SPECTAL BOLT
8] SHIFT ARM COVER
@ OIL SEAL Replace.
€! SHIFT LEVER
@I BREATHER CAP(2! SHIFT ARM SHAFT ASSEMBLY
@ SPRING PIN Replace.O SELECT ARM
€!} THRUST WASHER
@ sTH/REVERSE SELECTRETURN SPRING
@ SELECT RETURN SPRING
€) OIL GUTTER PLATE
@ 78 mm SHIM
@ OIL GUIOE M PLATE
@ SELECT SPRING BOLT
@ OIL SEAL Replace.
@ SELECT LEVER
O BACK.UP LIGHT SWITCH
@ WASHER Replace.OO TRANSMISSION HOUSING
13-13
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