Overhaul HONDA CR-V 1999 RD1-RD3 / 1.G Owner's Manual

Symptom-to-Com ponent Chart
Hydraulic System (cont'd)
NOTES
See flushing procedure, page l4-264 and 265,
BSet idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in enginesection of this manual.
clf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
Dlf the clutch pack is seized or is excessively worn. inspect the other clutches fot wear, and check the orificecontrol valves, CPC valve, and linear solenoid for free movement.
lf the linear solenoid is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed. the transmission will not upshift. lf stuck open, the transmission hasno lst gear.
Hlf the 2nd orifice control valve is stuck, inspect the 2nd and 3rd clutch Dacks for wear.
lf the 3-4 orifice control valve is stuck, inspect the 3rd and 4th clutch packs for wear.
Jlf the clutch pressure control valve is stuck closed. the transmission will not shift out of lst gear.
Klmproper alignment of main valve body and torque converter housing may cause ATF pump seizure. Thesymptoms are mostly an rpm-related ticking noise or a high-pitched squeak.
Llf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differentialpinion shaft. lf both are OK and no cause for the contamination is found, replace the torque converter.
Mlf the lst clutch feed pipe guide in the end cover is scored by the mainshaft. inspect the ball bearing forexcessive movement in the transmission housing. lf oK, replace the end cover as it is dented. The o-rinounder the guide is probably worn.
N' Replace the mainshaft if the bushing for the 4th feed pipe is loose or damaged, lf the 4th feed pipe is darrFaged or out of round. replace the end cover.' Replace the mainshaft if the bushing for the l st feed pipe is loose or damaged. lf the 1st feed pipe is dam-aged or out of round, replace it.
oA worn or damaged sprag clutch is mostly a result of shifting the transmission in E!. E, or E positionwhile the wheels rotate in reverse. such as rocking the vehicle in snow.
PInspect the frame for collision damage.
lnspect for damage and wear:
l. Reverse selector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shift fork for scuff marks in center.
4. Differential pinion shaft for wear under pinion gears.
5. Bottom of 3rd clutch for swirl marks.
Replace items 1, 2, 3. and 4 if worn or damaged. lf transmission makes a clicking, grinding, or whirring noise,also replace mainshaft 4th gear, reverse idler gear, and countershaft 4th gear in addition to 1,2, 3, or 4.lf differential pinion shaft is worn, overhaul differential assembly, replace ATF strainer, and thoroughly cjeantransmission, flush torque converter. cooler, and lines,lf bottom of 3rd clutch is swirled and transmission makes gear noise. replace the countershaft and final drivenoear,
Be very careful not to damage the torque converter housing when replacing the main ball bearing. you
may also damage the ATF pump when you torque down the main valve body. This will result in ATF pumpseizure if not detected. Use the Drooer tools.
SInstall the main seal flush with the torque converter housing. lf you push it into the torque converterhousing until it bottoms out, it will block the fluid return passage and result in damage.
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Component Locations
lndex
Note these items during disassembly:' lf an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur-ing transit, storage or service. it should be deployed (see section 24),a Before removing the gearbox, remove the driver.s airbag assembly and steering wheel.. After installing the gearbox, check the wheel alignment and adjust if necessary.
SRS components are located in this area. Review the SRS component locations, precautions, and procedures an the SRssection (24) before performing repairs or servrce.
STEERING WHEELRemoval, page 17,18Disassembly/Reassembly, page 1?,18Installation, page 17-19DRIVER'S AIRBAG ASSEMBLYRemoval/lnstallation, see section 24
STEERING GEARBOXRack Guide Adjustment, page 17-15Removal, page 17-31Disassembly, page 17-34Reassembly, page 17,40Installation, page 17,51VALVE BODY UNITOverhaul, page 17-38
STEERING COLUMNRemoval/lnstallation. page 17-20Inspection, page l7 21Steering Lock Replacement, page 17 22CABLE REELRemoval/lnstallation, see section 24tcNrnoN swtTcHSee s€ction 23
STEERING HOSES, LINESReplacement. page l7-23
Pump Belt Inspection andAdjustment, pag€ t7-14Pump Pressure Check, page 17-16 ot 17-1jReplacemont, page 17-24Disassembly, pa96 17,25Inspection, page 17-26Reassembly. page17-28
RESERVOIRFluid R6placement. page 17 15Fluid Leakage lnspection, page 17-23
END BALL JOINTBallJoint Boot Replacement, page 17-50
17-3
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Air Conditioning
Heater Control Panel
Reofacement ,.,...,,.,..,.,.,,22-46
Blower Unit
Replacement .................. 22-46
Overhaul ...........,,,., .......-.22-17
Evaporalor
ReDlacement ...,.,.,..,......,22-4A
Overhaul ................ .........22-19
A/C Filter
Replacement ..................22-50*Heater Unit
ReDfacement ..................22-50
Overhaul ..,.,..,.,...,.. .........22-52
Temperature Control
Adiustment ....................22-53
A/C Service Tips and Precauiions............-....-.... 22-54
A/C System Torque Specifications .................... 22-55
A/C System Service
Performance Test ......,...22-56
Pressure Test Chart .-.....22-5a
Recovery ..............,. ...-.-...22-59
Evacuation -...........-........22-60
Charging ................ .......-.22-61
Leak Test ........................22-61
Compressor
Repfacement ..........-.......22-62
flfustrated Index .....,.......22-64
Cfutch fnspection .........,.22-65
Cfutch Overhaul ............- 22-66
Thermaf Protector Rep|acement ................... 22-68
Refief Valve Replacement .............................. 22-68
A/C Comoressor Belt
Adiustment .................... 22-69
Condenser
Repfacement .,.....,,.,..,.,..22-70
'Read SRS precautions betore working in this area.
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Component Location
lndex
EVAPORATORReplacement, page 22-48Overhaul, page 22-49
SERVICE VALVEILOW-PRESSURE SIDE}
CONDENSERReplacement, page 22-70
A/C PRESSURE SWTTCHWhen the refrigorant pressure is below 200 kPa 12.0 kglc.r|r,28 psi) or abov€ 3,200 kPa (32 kgflcmr, 455 psi), the AJC pressureswitch opens the circuit to the Ay'C switch and stops the airconditioning to protect the compressor.
Replacement, page 22-62Clutch Inspection, page 22-65Clutch Overhaul, pago 22-66Thermal Protector Replacement, page 22-68Relief Valve Replacem€nt. page 22-68
SERVICE VALVEIHIGH-PRESSURE SIDEI
,
[\,
-il
(cont'd)
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Component Location
lndex (cont'dl
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.
BLOWER UNITReplacement, page 22-46Ovethaul, page 22 47
/alowen ruoronl
\Test, page 22-16 /
EVAPORATORFeplacement, page 22-48Overhaul, page 22,49
RECIRCULATIONCONTROL MOTORReplacement, page 22 42
HEATER UNITReplacement, page 22 50Overhaul, page 22 52
lest, pag.e 22 42
A/C FILIERReplacement. page 22-50VALVE CABLEAdjustment, page 22-53
RECIRCULATIONCONTROL SWITCH
a/c swtTcH
MODEMOTOR
REAR WINDOWDEFOGGERSwlTCHSee section 23Replacement, page 22-41Test, page 22-41MODE CONTROLDIAL
HEATER CONTROLPANELReplacement, page 22 46
swtTcH
22-4
CONTROL
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Overhaul
Note these items when overhauling the blower unit.
. The recirculation contfol motor. the power transistor, the blower motor high relay, and the blower motor can be
replaced without removing the blower unit.
. Betore reassembly, makesurethatthe recirculation control doorand linkage move smoothly without binding.
o After reassembly, make sure the recirculation control motor runs smoothly (se€ page 22-42).
o Make sure that there is no air leakage.
RECIBCULATION CONTBOL MOTORReplacement. page 22-42
BLOWER
m
Tost, page 22-45
POWEB TMNSISTORTest. page 22'44
22-47
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}-Overhaul
1. Remove the filter lid. then pull out the A/C filter
assembly.
Pull out the evaporator temperature sensor from
the evaporator fins.
Remove the self-tapping screws and the clamps
from the housings.
Carefully separate the housings, then remove the
evaporator.
lf necessary, remove the expansion valve When
loosening the nuts of the expansion valve, use a sec-
ond wrench to hold the expansion valve or the evapo-
rator line. Otherwise, they can be damaged.
6. Reassemble the evaporator in the reverse order of
disassembly. Make note of these items.
. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the right O-rings
for HFC-'134a (R-134a) to avoid leakage.
. Install the expansion valve capillary tube with
the capillary tube in contact with the outlet line
directly, and wrap it with electricaltape.
. Reinstall the evaporator temperature sensor to
its original location.
. Make sure that there is no air leakage.
ELECTRICAL TAPEReplace.Make sure there is no foreign matter stuck between
the capillary tube and outlet line.
CAPILLARY TUAE
EXPANSION VALVE
4.
TEMPERATURESENSORlest, page 22-41
,m
\!{
YFILTER LID
;
I-OWER HOUSINGA/C FILTER ASSEMBLY
22-49
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Heater Unit
Overhaul
1. Remove the self-tapping screws and the heater corecover.
Pull out the grommet from the heater core pipes.
Remove the self-tapping screw and the pipe clamp.
HEATER CORE COVER
Pull out the heate. core. Be careful not to bend the
inlet and outlet pipes during heater core removal.
Reassemble the heater unit in the reverse order of
disassemblv.
HEATER CORE
22-52
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Compressor
Glutch Overhaul
1. Remove the center nut while holding the armature
plate with the tool.
A,/C CLUTCH HOLOERlCommerciallY .vailable)Robinair: P/N 1020,0Ked-Mooro: P/N J37872
CENTER NUT17.6 N.m ('1.8 kgf.m, 13lbfft)Reolace. \
i
2. Remove the armature plate by pulling it up by hand.
ARMATURE PLATE
sHtMls)Replace.
za:s
(i@,
22-66
3. Remove the snap ring B with snap ring pliers. Be
careful not to d8mage the rotor pulley and com-
pressor.
SNAP RING BR6place.
Remove the rotor pulley from the shaft with the
tools. Be sure the claws ot the puller are on the back
of the rotor pulley, not on the belt area; otherwise
the rotor pulley can be damaged.
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