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

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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Emission Control System
Evaporative Emission (EVAP) Controls (cont,dl
Evaporative Emission (EVAP) Two Way Valve Testing
'97 model:
1. Remove the fuelfill cap.
2. Remove the vapor Iine from the EVAP two wayvalve on the fuel tank, and connect it to a T_fittingfrom a vacuum gauge and a vacuum pump asshown.
VACUUM,/PRESSURE GAUGEotJAz - 001 rDoBT-FITTINGVACUUMPUMP/GAUGE,0 - 30 in.HgA973X-041-XXXXX
3. Apply vacuum slowly and continuouslv whilewatching the gauge. The vacuum should stabilizemomentarily at 0.7 - 2.0 kpa (5 - 1S mmHg, 0.2 _ 0.6in.Hg).
lf the vacuum stabilizes (valve opens) below0.7 kPa (5 mmHg,0.2 in,Hg) or above 2.0 kpa(15 mmHg, 0.6 in.Hg), install a new valve and retest.
4.Move the vacuum pump hose from the vacuum fit_ting to the pressure fitting, and move the vacuumgauge hose from the vacuum side to the pressureside as shown.
PiESSURESIDE
5. Slowly pressurize the vapor line while watching thegauge. The pressure should stabilize at 1.3 - 4.7 kpa(0 - 35 mmHg, 0.4 - 1.4 in.Hg).. lf the pressure momentarily stabilizes (valve
opens) at 1.3 - 4.7 kpa (10 - 35 mmHg, 0.4 _ 1.4in. Hg), the valve is OK.. lf th6 pressure stabilizes below 1.3 kpa fio mmHg,0.4 inrHg) or above 4.7 kpa (35 mmHg, 1.4 in.Hg),install a new valve and retest.
T-FITTING
11-224
.98 - 0O models:
1. Remove the fuel fill cap.2. Remove the vapor line from the EVAP two wayvalve {located above the EVAP control canister). andconnect it to a T-fitting from vacuum gauge andvacuum pump as shown.
VACUUM/PRESSUFE
VACUUM PUMP/GAUGE,0 - 30 in.HgA973X - 041 -
xxxxx
5.
Apply vacuum slowly and continuously whilewatching the gauge.
The vacuum should stabilize momentarily at O.g _
2.1 kPa (6 - 16 mmHg, 0.2 - 0.6 in.Hg).lf the vacuum stabilizes (valve opens) below0.8 kPa (6 mmHg, 0.2 in.Hg) or above 2.1 kpa(16 mmHg, 0.6 in.Hg), install a new valve and retest.Move the vacuum pump hose from the vacuum fit-ting to the pressure fitting. and move the vacuumgauge hose from the vacuum side to the pressure
side as shown.
Slowly pressurize the vapor line while watching thegauge.
The pressure should stabilize momentarilv above1.0 kPa (8 mmHg, 0.3 in.Hg).a lf the pressure momentarily stabilizes (valve
opens) above 1.0 kPa (8 mmHg. 0.3 in.Hg), thevalve is OK.. lf the pressure stabilizes below ,|.0 kpa {g mmHg.0.3 in.Hg), install a new valve and retest.
T-FITTING
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lllustrated Index
NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
.lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage1\
2-6).
. Inspect the hoses for damage. leaks. interference, and twisting.
LOCK PIN
*CLUTCH LINE19 N.m (1.9 kgj.m,14 tbtft)
8 x 1.25 mm13 N.m {1.3 kgf m,9.4lbtft)
PEDAL PIN.RESEFVOIR
HOSE
*RESERVOIR TANK
CLUTCH PEDALAdjustment, page 12-4*CI-UTCH MASTER CYLINDERFemoval/lnstallation, page 12-5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
*CLUTCH LINE15 N.m (1.5 kgt m,11 tbr.ft)
*CLUTCH LINE24 N.m {2.4 kgf.m,17 tbf.ft)
CLUTCH DISCRemoval/lnspection, page 1 2-8Installation, page 12,13
8 x 1.25 mm25 N.m {2.6 kgt m,19 rbf.ftt
I x 1.25 mm22 N.m 12.2 kgl'm, 16lbfft)
.o-.9r
WM\,".0--
ffi-P"8Nmlloks{m'
FLYWHEELInspection, page 12IRepiacement, page 12-9
12 x 1.0 mm103 N.m (10.5 kgtm,75.9 lbf ftl
PRESSURE PLATERemoval/lnspection, page'12-7
Installation, page'12 13
RELEASE BEARINGRemoval/lnspection, page 12-1'!Installation, page 12-12
*CLUTCH LINE15 N.m (1.5 kgt m,11 tbf.ft)
12-3
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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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Glutch Master Cylinder
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake tluid does contact the paint. wash
it off immediately with water.
. Plug the end ol the clutch line and leservoir hose
with a shop towel to prevent brake tluid trom coming
out.
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syringe.
Disconnect the clutch line and reservoir hose from
the clutch master cylinder,
't.
9.8 N.m 11.0 kst m,7.2 tbf.ftl
CLUTCH LINE
19 N'm 11 9 kgJ m'
14 lbf.frl
Remove the reservoir from the engine compartment
bulkhead.
13 N.m t1.3 kgt.m,g.il lbtft)
4. Prv out the lock pin, and pull the pedal pin out of
the voke. Remove the nuts.
NUTSI x 1.25 mm
5, Remove the clutch master cylinder.
CLUTCH MASTERCYLINDEF
Install the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system {see page
12-61.
12-5
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Slave Cylinder
RemovaUlnstallation
CAUTION:
. Do nol spill brake tluid on the vehicle; itmaydamage
the paint; if brake fluid do€s contast the paint, wash
it off immediately with water.. Plug the end of the clutch line with a shop towel toprevcnt brake tluid from coming out.
.6|l,Super High Temp Urea crease (p/N 08798 -
9002).
: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch line from the slave cvlinder.
2. Remove the slave cylinder from the clutch housing.
12-6
3. Install the slave cylinder in the reverse order ot
removal.
NOTEr Make sure the boot is installed on the slave
cylinder.
CLUTCH LINE15 N.m (i.S kgf.m, lt tbf.ftl
SLAVE CYLINDER
.-lG(P/N 08798 - 90021
E x 1.25 mm22 N.m (2.2 kgt.m,16 tbtft)
(Brake AssemblyLube)
Bleed the clutch hydraulic system.
Attach a hose to the bleeder screw, and suspend
the hose in a container of brake fluid.
Make sure there is an adequate supply of fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
Refill the clutch master cylinder with fluid whenqone.
Always use Genuine Honda DOT3 Brake Fluid.
Using a non Honda brake fluid can cause corro-
sion and decrease the life of the system.
Confirm clutch operation, and check for leaking
fluid.
7.8 N.m (0.8 kgf.m. 5.8 lbt.ft)BLEEDER SCREW
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Pressure Plate
Removal/lnspection
1.Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard lNewl: 0.6 mm {0.02 in) max.
Service Limit: 0.8 mm (0.03 in)
HANDLE07936 - 3710100
CLUTCH ALIGNMENT DISCOTJAF - PM7O11A
CI.UTCH ALIGNMENT SHAFT07NAF - PR30100
FEELER GAUGE
lf the height is more than
the pressure Plate.
the service limit, replace
2. lnstall the sDeciallools as shown.
RING GEAR HOLDER ADJUSTER NUT
ENGINE BLOCKADJUSTER BOLT
BOLT
NUT WASHER
To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps. then remove the pressure plate.
4. Inspect the pressure plate surface for wear, cracks,
and burning.
5. Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Inspect for warpage using a straight edge and feeler
gauge. Measure across the pressure plate.
Standard lNew): 0.03 mm 10.001 in) max.
Service Limit: 0.15 mm (0.006 inl
6.
FEELER GAUGE
lf the warpage is more than the service limit,
replace the pressure plate.
PRESSURE PLATE
PRESSURE PLATE
12-7
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Glutch Disc
Removal/lnspection
'1. Remove the clutch disc and specialtools.
CLUTCH DISC
Inspect the lining of the clutch disc for signs of slip-ping or oil. lf the clutch disc is burned black or oil
soaked, replace it.
Measure the clutch disc thickness.
Standard (New): 8.,1- 9.1 mm (0.33 - 0.36 in)
Service Limh: 6.0 mm (0.2,1 in)
CLUTCH DISC
lf the thickness is less than the service limit, reDlace
the clutch disc.
12-8
4. Measure the rivet depth from the lining surface to
the rivets, on both sides.
Standard (New): 1.2 - 1.7 mm 10.05 - 0.07 in) min.
Service Limit: 0.2 mm {0.008 inl
lf the rivet depth is less than
replace the clutch disc.
the service limit,
LINI G SURFACE
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Flywheel
Inspection
2.
3.
Llnspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the fly-
wheel for wear, cracks, and burning
Measure the flywheel runout using a dial indicator
through at least two full turns. Push against the fly-
wheel each time you turn it to take up the crank-
shaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (Newl: 0.05 mm (0.002 in) max.
Service Limit: 0.15 mm {0.006 inl
lf the runout is more than the service limit, replace
the flywheel and recheck the runout
Turn the inner race ot the flywheel bearing with your
finger. The bearing should turn smoothly and qui-
etly. Check that the bearing outer race fits tightly in
the tlywheel. lf the race does not turn smoothly, qui-
etly, or fit tight in the flywheel, replace the bearing.
FLYWHEEL
RING GEAR
FLYWHEEL
L
2.
Replacement
Installthe special tool as shown.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, and remove the flywheel.
MOUNNNGBOLTS
FLYWHEEL
(cont'd)
12-9
RING GEAR HOLDER07LAB - PV00r00ol07924 - PD20003
3. Remove the ball bearing from the flywheel.
BALL BEARING
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