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

4. Disconnect the heater hoses from the heater unit.
Engine coolant will run out when the hoses are dis-
connected; drain in into a clean drip pan.
CAUTION: Engino coolant will damage p8int. Ouickly
rinse any spill€d engine coolant Itom painted sur-
faces.
HEATER HOSEIOUTLET SIDE)
Remove the mounting nut from the heater unit.
Take care not to damage or bend the fuel lines, the
brake lines. etc.
CLAMPS
13 N.m 11.3 kg{.m,9.4 lbtftl
22-51
7.
ll.
Remove the dashboard (see section 20).
Remove the evaporator (see page 22-48).
Disconnect the connectors from the mode control
motor and the air mix control motor, and remove the
wire harness clips and wire harness from the heater
unit. Remove the clip from the heater duct, then
remove the mounting nuts and the heater unit
6x1.0mm9,8 N.m (1.0 kgt m,7.2lblft)
qInstall in the reverse order of removal. Make note of
the following items.
a
a
a
a
Apply sealant to the grommets.
Do not interchange the inlet and outlet heater
hoses. Make sure that the clamps are secure.
Refill the cooling system with engine coolant
{see section 10).
Adiust the heater valve cable (see page 22-53).
Make sure that there is no air leakage.
HEATER UNIT
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Temperature Control
Adjustment
l. From under the hood, open the cable clamp, then
disconnect the heater valve cable from the heater
vatve arm.
From under the dash, disconnect the heater valve
cable housing from the cable clamp. and disconnect
the heater valve cable from the air mix contlol arm
Set the temperature control dial on MAX COOL with
the ignition switch ON (ll).
Attach the heater valve cable to the air mix control
arm as shown above. Hold the end of the heater
valve cable housing against the stop, then snap the
heater valve cable housing into the cable clamp.
HEATER VALVE ARM
HEATER VALVE CABLE
5. From under the hood. turn the heater valve arm to
the fullv closed position as shown, and hold it.
Attach the heater valve cable to the heater valve
arm, and gently pull on the heater valve cable hous-
ing to take up any slack, then install the heate. valve
cable housing into the cable clamp.
HEATER VALVE ARM
HEATER VALVE CABLE
22-53
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A/C System Service
Pressure Test Chart
NOTE: Performance Test is on page 22-56.
Test resultsRelatad symptomsPrcbable caus€Remody
Discharge (high)pressure 6bnormallyhagh
After stopping compressor, pressuredrops to about 200 kPa 12.0 kgtlcm,,28 psi) quickly, and then lalls gradualty.
Air in systemDischarge, evacuate, and rechargewith specified amount.Evacuation: see page 22-60Charging: see page 22-61No bubbles in sight glass whencondenser is cooled by waterExcessive refrigerant in systemDischarge, evacuate, and rechargewith specilied amount.Reduced or no air flow throughcondenser. Clogged condenser or radia-tor fins. Condenser or radiator fannot wo.king properly
CleanCheck voltage and fan rpm.Check fan direction.
Line to condensor is excossivelv hot.Restricted flow of relrigerant insy$emFestricted lines
Discharge pressureabnormally lowExcessive bubbles in sight glass;condenser is not hot.Insufficient retrigerant inCheck for leak.Charge system.High and low pressures are balancedsoon after stopping compressor. Lowside is higher than normal.
. Faulty compressor discharge
. Faulty compressor seal
Replace the comprossor.
Outlet ot expansion valve is notfrosted, low-pressure gauge indicates
' Faulty expansion valve. Moisture in system. Replace. Discharge, evacuate, andrecharge with specified amount.Suction {low) pros,sure abnormallyExcessive bubbles in sight glass;condenser is not hot.Insufficiont relrigerant inRepair the leaks.Discharge, evacuate, andrecharge with specified amount.Charge as r€quired.Expansion valve is not frosted, andlow-pressure line is not cold. Low-pressure gauge indicates vacuum.
' Frozen expansion valvelMoisture in system). Faulty expansion valve
. Discharge, evacuate, andrecharge with specitied amount.. Replace th€ expansion valve.Discharge temperature is low, and theair llow trom vents is restricted.Frozen evaporatorRun the fan with compressor off,then check evaporator tempera,ture sensor.Expansion valve is frosted.Clogged expansion valveClean or replace.Feceiver/dryer outlet is cool, and inlotrs w6rm (should be warm duringoperation).
Clogged receiver/dryerReplace
Suction pressureabnormally highLow-pressure hose and check joint arecooler than tho temperature aroundevaporator.
. Expansion valve open too long. Loose expansion capillarytube
Repair or roplace.
Suction pressure is lowored whencondenser is cooled by water.Excessive refrigerant in systemDischarge, evacuate, and rechargewath specified amount.High and low-pressure are equalizedas soon as tho compressor is stopped,and both gauges tluctuate whilerunning.
Faulty gasketFaulty high-pressure valveForeign panicle stuck in high-
Replace the compressor.
Slction and dis,charge pressutesabnormally high
Reduced air flow through condens€r,. Clogged condenser orradiator tins. Condenser or radiator fannot working properly
CleanCheck voltage and fan rpm.Check Ian direction.
No bubbles in sight glass whencondenser is cooled by walerExcessive refrigerant jn systemDischarge, evacuate, and rechargewith specified amount.Suction and dis-charge pressureabnormally low
Low-pressure hose and motalendareas are cooterlhan evaporator.Clogged or kinked low-pressure hose pansRepair or replace.
Temperature around expansion valvers too low compared with that aroundClogged high-pressure lineRepair or replace.
Refrigerant leaksCompressor clutch is diny.Compressor shaft seal leakingReplace the compressor.Compressor boltls) are dirty.Leaking around bolt(s)Tighton bolt{s) or replacecompressor.Compressor gasket is wet with oil.Gasket leakingReplace the compressor,
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Charging
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritate eyes, nose and
throat. Avoid breathing th€ air conditioner refrigerant
and lubricant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming service. Additional health and
safety information may be obtained from the relrigerant
and lubricant manufacturers.
Connect a R-'134a refrigerant recovery/recycling/charging
station to the vehicle, as shown. following the equipment
manufacturer's instructions.
R€covery/Recycling/Charging Station
HIGH-PRESSURESIDE
Add the same amount of new refrigerant oil to system
that was removed during recovery. Use only SP-'10
refrigerant oil.
Charge the system with Required amount of R-134a
refrigerant. Do not overcharge the system; the compres-
sor will be damaged.
Select the appropriate unit of measure for your
charging station.
Refrigerant capacity: 700 to 750 g
0.70 to 0.?5 k9
1.5 to 1.6 lbs.
21.7 to 26.5 oz.
ll-
22-61
Leak Test
Use only service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposure to air conditionor refrigerant and
lubricant vapor or mist can irritate eyes, nose and throat.
Avoid breathing the air conditioner retrigerant and lubri-
cant vapor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle ajr conditioner sys-
tems should not be pressure tested or leak tested with
compressed arr.
!@ some mixturos of air and R-1348 have
been shown to be combustible at olovatod pres3uras
and can result in fire or explosion causing iniury or
property damage. Never use comprelised air to pressure
test R-13ila service equipment or vehicle air conditioner
systems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
2.
1.Connect a R-134a refrigerant recove rylrecycling/
charging station to the vehicle, as shown in the pre-
vious column, following the equipment manufactur-
er's instructions.
Open the high-pressure valve to charge the system
to the specified capacity, then close the supply
valve, and remove the charging system couplers.
Select the appropriate unit of measure for your
charging station.
Refrigerant capacity: 700 to 750 g
0.70 to 0.75 kg
1.5 to 1.6 lbs.
21.7 to 26.5 oz.
Check the system for leaks using a R-134a refriger-
ant leak detector with an accuracy of 14 g (0.5 ozl
per year or better.
lf you find leaks that require the system to be opened
(to repair or replace hoses, fittings, etc.), recover the
system according to the Recovery Procedure on page
22-59.
After checking and repairing leaks, the system must
be evacuated (see System Evacuation on page 22-601.
5.
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Gompressor
lllustrated Index
CENTER NUTReplace.
ARMATURE PLATEInspection, page 22-65
sHtM{s)Replace.
SNAP RING BReplace.
ROTOR PULLEYInspection. page 22-65
SNAP RING AReplace.
FIELD COILInspection, page 22-65
THERMAL PROTECTORReplace.Inspection, page 22-55Replacement, page 22-68
coMPRESSOR ----------------(Do not disassemble.)
O.RINGRoplace.
RELIEF VALVEReplacement, page 22-68
RELIEF VALVE COVER('97 modelonly.)
22-64
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Compressor
Thermal Protector Replacement
1. Remove the bolt, the ground terminal and the hold-
er. Disconnect the field coil connector. then remove
the thermal Drotector.
7.4 N.m (0.75 kgrf.m,5lbf ftl
GROUNDTERMINAL
ReDlace the thermal protector with a new one, and
apply silicone sealant to the bottom of the thermal
orotector,
3. lnstall in the reverse order of removal.
SILICONE SEALANT
22-68
Relief Valve Replacement
l.Recover the refrigerant with a Recovery/Recycling/
Charging System (see page 22-59).
Remove the relief valve cover ('97 model), the relief
valve and the O-ring. Plug the opening to keep for-
eign matter from entering the system and the com-
pressor oil from running out.
O.RINGReplace.
RELIEFVALVE9.8 N.m {1.0 hgf.m,7.2 rbr.ftl
Put the cover on the relief valve so that the arrow
directs downwards as shown in the illustration
above ('97 model).
Clean the mating surfaces.
Replace the O-ring with a new one at the relief valve,
and apply a thin coat of refrigerant oil before
installing it.
Remove the plug. and install and tighten the relief
valve.
7. Charge the system (see page 22-61), and test its
performance (see page 22-561r.
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Connector ldentification and Wire Harness Routing
Engino Wire Harness
Connecto; or
Terminal
Number of
CavitiesLocationConneqts toNotos
c101
c102
c103
c 104
c105
c105
c106
c 107
c 108
c 109
c]10
c1l'l
c112
c113
c't 14
cl16
cl16
c117
c118
c119
c120
c121
c't22
c't23
c't25
cl26
cl27
cr 28
cl29
c130
c131
c132
c 133
c134
c134
c135
c 136
10
6
1
2
1
2
1
10
20
31
16
22
l0
l0'14
14
1
Left side of engine compartment
Left side of engine compartment
Middle of engine
Middle of engine
Left side of engine compartment
Left side of engine compartment
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Right side of engine
Middle of engine
Behind right kick panel
Under right side of dash
Under right side of dash
Under right side of dash
Under right side of dash
Under right side of dash
Right side of engine
Right side of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Left side of engine compartment
Middle of engine
Middle of engine
Main wire harness (C304)
Main wire harness (C305):'97 - 98 models
No. 1 fuel injector
Crankshaft speed fluctuation (CKF) sensor
Alternator
Alternator
Engine oil pressure switch
No.2 fuel injector
Evaporative emission (EVAP) purge
control solenoid valve
No. 3 fuel injector
No. 4 fuel injector
Primary heated oxygen sensor(Primary HO2S) (sensor 1)
Radiator fan switch
Coolant temperature sending unit
Engine coolant temperature (ECT) sensor
Mainshaft speed sensor
Lock-up control solenoid valve
Back-up light switch
Shift control solenoid valve
Linear solenoid valve
Countershaft speed sesnsor
Starter solenoid
Distributor
Junction connector
PCM
ECIWPCM
ECM/PCM
ECM/PCM
Main wire harness (C,|:}1)
IVT gear position switch
Vehicle speed sensor (VSS)
Throttle position (TP) sensor
MAP sensor
ldle air control (lAC)valve
lntake air temperature (lAT) sensor
Junction connector
Junction connector
Power steering pressure (PSP) switch
Junction connector
Knock sensor (KS)
A/r
USA
Canada
Alr
AlT
M/'r
Afi
'97mooel
'97 model'98 - 00
mooets
'99 - 00
models
T101
r102
Left side of en0ine companment
Right side of engine compartment
Alternator
Under-hood fuse/relay box
G101Middle of engineEngine ground, via engine wire harness
23-14
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Gonnector ldentification and WireHarness Routing
Main Wire Harness lEngine compartmont left and right branches)
Connectot ol
Terminal
Number ot
CavitiesLocationConneqts toNot€s
c301
c303
c304
c305
c306
c307
c308
c309
c352
c354
c356
c357
c358
c359
c360
LJO I
5
2
10
'14
1
1
t1
3
10
8
10
2
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Left side of engine companment
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Windshield wiper motor
Daytime running lights resistor
Test techometer connector
Engine wire harness (C10])
Engine wire harness (C102): '97 - 98models
Left front ABS wheel sensor
Engine compartment wire harness (C201)
Brake fluid level switch {-)Brake fluid level switch (+)
Under-hood fuse/relay box (C908)
Under-hood fuse/relay box (C906)
Under-hood fuse/relay box (C905)
Under-hood fuse/relay box (C907)
ABS modulator unit
ABS pump motor
Engine compartment wire harness (C218)
Engine compartment wire harness (C218)
Right front ABS wheel sensor
Under-hood ABS fuse/retay box (C931)
Under-hood ABS fuse/relay box (C9321
Evaporative emission (EVAP) controcanister vent shut valve
Canada
ABS
USA
ABS
ABS'97 - 98
models'99 - 00
mooets
ABS
ABS
ABS'98 - 00
mooets
G35lRight side of engine compartmentBody ground, via main wire harnessABS
23-18
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Gonnector ldentification and Wire Harness Routing
Right Side Wire Harness
Connec{or or
Tsrminal
Number of
CavitiesLocationConnests toNotes
c601
c602
c603
c604
6'1
2
2
Behind right kick panel
Right B-piller
Right rear door
Under middle of dash
Right B-piller
Main wire harness (C428)
Front passenger's door switch
Right rear door wire harness (C691)
SRS main harness {C808)
Front passenger's seat belt tensioner
'98 - 00
mooets'98 - 00
models
Rear Bumper Wire Harness
Connector ol
Terminal
Number ot
CavitiesLocationConnocts toNotes
c641
c642
c643
4
2
2
Left quarter panel
Behind rear bumper
Behind rear bumper
Left side wire harness (C566)
Left rear side marker light
Right rear side marker light
Fuel Tank Pressure Sensor Sub-harness - '98 Model
Connector or
Terminal
Number ot
CavitiesLocationConnects toNot63
c645
c646
c647
?
2
Fueltank
Left side of fuel tank
Left side of fuel tank
Left side wire harness (C580)
Fuel tank pressure sensor
Evaporative emission (EVAP) bypass
solenoid valve
High Mount Brake Light Sub-harnoss
Conneslor or
Terminal
Number of
CavitiesLocationConnec-ts toNotes
c651
c652
c653
2
1
1
Top of hatch glass
Top of hatch glass
Top of hatch glass
High mount brake light
Rear wire harness (C617)
Rear wire harness (C618)
23-28
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Power Distribution
Fuse
1
3
5
6
7
I
9
10
11
12
13
14
"^
RED/B LU
RED/GRN
WHT/BLK
RED/VVHT
YEUBLK
RED
GRN/BLK
BLU/BLK
YEVBLK
YEUGRN
RED
BLK/YE L
BLK/VVHT
17
7.5 A
7.5 A
BLVBLU
BLKA/EL
18
19
20
22
7.54
7.54
l0 A
10 A
YEUBLK
YEVRED
BLKAr'YHT
RED /VHT
RED/YE L
Fuse-to-Component(sl Index (numerical sequencel (cont'dl
Under-dash Fuse/Relay Box:
Capacity
10 A
10 A
10 A
10 A
20A
204
15A
204
204
7.5 A'15 A
7.5 A
7.5 A
Wire ColorCircuit{s) Protected
Not used
Not used
Rear window washer motor (via switch)
Rear window wiper control unit ('97 model)
Rear window wiper motor
Daytime running rights resister {Canada)
Right headlight {High beam}
Daytime running rights resister (Canada)
High beam indjcator light
Left headlight (High beam)
Rear accessory socket (via relay)
Left rear power window motor (via switch)
Right rear power window motor (via switch)
Distributor (ignition control module)
Front passenger's power window motor (via switch)
Driver's power window motor {via switch)
Power window master switch (power window control unit)
Turn signal/hazard relay (via switch)
PGM-FI main relay
SRS unit (VA)
Cruise control unit (via switch)
Cruise main switch indicator light
Alternator
Charging system light
ELD unit (USA)
EVAP bypass solenoid valve ('98 - 00 models)
EVAP control canister vent shut valve ('98 - 00 models)
EVAP purge control solenoid valve
Primary HO2S
Secondary H02S
VSS
ABS control unit
Option connector (lG2)
Ay'C compressor clutch relay
Blower motor high relay
Blower motor relay
Condenser fan relay
Heater control panel
Left power mirror actuators (via switch)
Mode control motor
Radiator fan relay
Recirculation control motor
Right power mirror actuators (via switch)
Daytime running lights control unit (Canada)
Back-up lights
Reverse relay (A"/T)
Daytime running lights control unit (Canada)
Right headlight (Low beam)
Left headlight (Low beam)
23-44
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