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

Fuel and Emissions
Special Tools ...................... 11-2
Component Locations
lndex ...................... ....,.... 11-3
Svstem Description
Vacuum Connections ...........,....,.,................. 1 1-9
Electrical Connections ................................... 1 1-15
System Connectors .,.,,.,............................,.,. 1 1-36
Troubleshooting
Troubleshooting Procedures,.,..................... 11-60
Engine Control Module/Powertrain ConttolModule Terminal Arrangement .............., 11-67
Diagnostic Trouble Code Chart .................... 1 t-75
How to Read Flowcharts .......,.....,.,............... I 1-79
PGM-Fl System
System Description .................,.,.,,,............... 1 1-80
Troubleshooting Flowcharts
Engine Control Module/PowertrainControl Module ........11-52
Manifold Absolute Pressure Sensor ............. 11-90
Intake Air Temperature Sensor .................... 1 1-95
Engine Coolant Temperature Sensor .,..,.,.... 1 1-99
Throttle Position Sensor ...........,.....,.,.,..,...... I 1'103
Primary Heated Orygen Sensor (Sensor 1) ... 11-110
Secondary Heated Oxygen Sensor{Sensor 2l .................. 1 1-117
Heated Oxygen Sensor Heater ..................... 11-121
Fuef Supply System ......11-124
Random Misfire ,....,.,..... 11-126
Mistire Detected in One Cylinder .....-........... 11-128
Knock Sensor ................ 11-130
CKP/TDC/CYP Sensor .................................... 1 1-131
Vehicle Speed Sensor ...............................,.... 1 1-135
Barometric Pressure Sensor .....,...,...,.,,........ 1 1-137
Electrical Load Detector ...,.,.......................... 1 1-138
CKF Sensor ................,.,, '11-112
ECM/PCM lnternaf Circuit ............................. 11'117
HO2S Replacement .,.,.,. 11-148
ldle Control System
System Description ............ 11-149
Troubleshooting Flowcharts
ldle Control System ...... 11-150
fdle Air Control Valve ......................,............. 11-152
Air Conditioning Signal ................................. I 1-155
Alternator FR Signal ...................................... 1 1-159
Starter Switch Si9na1 .................................... t l-161
Power Steering Pressure Switch Signal ...... 11-162
Brake Switch Si9na1 ...................................... 11-166
Fast ldle Thermo Valve .,.,.............................,.,.,. 11-168
ldle speed setting .............. 11-169
Fuel Supply System
Fuel Lines ............................ 11-171
Fuef Tube/Ouick-Conneci Fittings ..................... 11 -175
System Description ............ 11-178
Fuel Pressurg ...................... 11-178
Fuel Iniectors ................,..... 11-179
Fuel Pressure Re9u1ator .............................,.,...., f 1-181
Fuef Fifter ....,.,.,.,,,,.,............11-142
Fuel Pump ........................... 11-183
Fuel Gauge .......................... 11-184
Fuel Gauge Sending Unit ................................... I 1-185
Low Fuel Indicator System ...........,.,..,............... 1 1-185
PGM-FI Main Relay ............. 11-187
Fue|Tank................ ............. 11-191
Intake Air System
System Description ............ 11-193
Air Cleanel ,.,.,..................... 11-194
Throttle Cable ..................... 11-194
Throttle Body........ .............. 11-196
Emission Control System
System D$cription ...,....,.,. 11-199
Tailpipe Emission ............... 11-199
Three Way Catalytic Converter ..................,.,...,, 11-199
Positive Crankcase Ventilation System .,.,,,,.,.., 11-2O1
Evaporative Emission Controls .........,.,.,............ 11-203
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DATA LINK CONNECTOR {DLC) I16P}Troubleshooting Procedures, page 1 1'60PRIMARY HEATED OXYGEN SENSOR
{PRIMARY HO2SI {SENSOR 1)Troubleshooling, page 11 110
SECONDARY HEATED OXYGENSENSOR{SECONDARY HO2S) {SENSOR 2)Troubleshooting, page 1 1-1 17
'97 - 98 models:
AIR CLEANERReplacement, page 1 1'194
Troubleshooting, page 1 'l -200
THROTTLE BODY (TB)Inspection, page 11 196Removal, page 11-197Disassembly, page 1 1-'198
POWERTRAIN CONTROL MODULE(PCM) (A/TI
Troubleshooting Procedures, page 1 1-60Troubleshooting. page 1 1'82
THROTTLE CABLEInspection/Adjustment, page 1 1-1 94Installation, page 11- 195
VENTILATION (PCV) VALVEInspection, page 1 1-201FAST IDLEVALVE (A/T}
(cont'd)
1 1-5
PGM-FIMAIN RELAYRelay Testing, page 11-l87Troubleshooting. page 1'1 188
SERVICE CHECK CONNECTOR {2PITroubleshooting Procedures, page 1 1-60
,a'=_-_
WAY CATALYTIC
Inspection, page 1 1-168
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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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PGM-FI System
Powertrain Control Module {PCM} -'97 Model
NOTE: lf this symptom is intermiftent, check for a loose fuse No. 25 METER (7.5 A) in theunderdash f{rse/relay box, a poor connection at PCM terminal A18, or an intermittentopen in the GRN/ORN wire between the PCM (A18) and the gauge assembly.
PCM OON ECTOR A {32P}
Wire side of female terminals
PCM CONNECTOR A {32PI
Wire side ot temale terminals
11-42
The Malfunction lndicator LamD(MlL) nev6r comes on {even lortwo seconds) after ignition isturned on (lll, or it's on dimlyand flickers.
Turn the ignition switch ON {ll}.
- Rep.ir short or opon in thowire batween No. 25 METER(7.5 Alfuso and gauge a$€m-bty.- R6pl.c€ No. 25 METER 17.5 Alfus€.
ls the charging system light on?
Try to stan the engine.
Does the engine start?
Chock tor.n open in th6 wire3{PG1, PG2linesl:1. Turn the ignition switch ON (ll).2. Measure voltage betweenbody ground and PCM con-nector terminals A10 and A23individually.
Check for an op€n in the wir6 orbulb (MlL lin€l:1. Turn the ignition switch OFF.2. Connect the PCM connectorterminal A18 to body groundwith a iumper wire.3. Turn the ignition switch ON {ll).
n€peir open in tho wirelslhwoon PCM and Glol (loc!t.d
at thc tha.mo3tat houling thrthtd moro th.n 1.0 V.
ls thore l€ss than 1.0 V?
Substituto . known-good PCMand r€check. ll symptom/indica-tion goss away, rcplaca the origi-nal PCM.
- R6pai. open in th. wileibelwoon rcM lAl8l dnd g.ugea3rombly.- Roolac€ the MIL bulb.
ls the MIL on?
Substitut6 a known-good PCMand rocheck. ll 3ymptom/indica-tion goes away, replace the o.igi-n.l PCM.
PGl IBLKI
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Powertrain Control Module (PCM) -'97 Model (cont'dl
(From page 11 83)
Check for a short in the wire (MlL
line):1. Turn the ignition switch OFF.2. Disconnect the PCM connectorA {32P).3. Turn the ignition switch ON (ll).
Repair short to body ground inthe wire between the PCM {418}and MlL.ls the MIL ON?
Substitute a known-good PCMand recheck. lf symptom/indica-tion goes away. replace the origi-nal PCM.
Inspect Fl E/M (15 A) fuse in theundeFhood fuse/relay box.
- Reoair shod in the wirebetween Fl E/M {15 A} fuseand PGM-FI main relav.- Replace FIE/M 115 A)fuse.
Inspect No. 13 FUEL PUMP (15 Aifuse in the underdash fuse/relay
- Repair short in lh€ wirebolween No. 13 FUEL PUMP
115 A) Iuse and PGM-FI main
- Replace No. 13 FUEL PUMP
115 A) fuse.
Check loJ a short in a sensor:1. Turn the ignit;on switch ON (ll).
2. Disconnect the 3P connectorof each sensor one at time:. MAP sensor
(To page 11-85)
11-84
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(From page 11-84)
Reolace the Sensor that causedthe lighl lo go out.Does the MIL go off.,
Check for a short in the wires
lvCC linesl:1. Turn the ignition switch oFF.2. Disconnect the PCM connector D (16P).
3. Check for continuity betweenbody ground and PCM connector terminals D4 and Dl0 individually.
Repair shorl lo body ground
in the wile between the PCM
{D4} and the MAP sensor.Repair short to body ground inth€ wire between the PCMlol0l and the TP sensor.
Check tor an open in the wires
llGP line3l:1. Disconnect the fuel injectorconnectors and IAC valve con
2. Turn the ignition switch ON (lli.
3. [,4easure voltage betweenbody ground and PCM con'nector terminals A'11 and A24individually.- Repair open in the wire(slboiween the PCM 1A11, A24)and the PGM-Fl main relav.- Ch€ck lor poor connectionsor loose wires at ihe PGM-FImain relay.- Tesi lhe PGM-FI main relav
{see p.g6 1l-1871.Check for an open in the wires
{LG linesl:1. Turn the ignition switch OFF.2, Reconnect all sensor connec-tors,3. Reconnect the PCM connectorD (16P).
4. Turn the ignition switch ON (ll).
5, M easu re voltage betweenbody ground and PCM connector terminals Ag a^d 422individually.
R6pair open in the wire{slbetween the PCM {A9. A22l andG101 {located at the thetmostathousing) that had more than 1.0 V.
ls there less than 1.0 V?
Substituto a known-good PCMand rech€ck. It symptom/indica-tion goos away, replace the origi-nal PCM.
PCM CONNECTOR D (16PI
VCCl NEL/RED}
Wire side of female terminals
PCM CONNECTOR A (32PI
Wire side of lemale terminals
1 1-85
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PGM-FI System
Tho Maltunction Indicator Lamo(MlL) n6Yor como3 on leven lortwo laconds) rft6r tho ignhion isturnod ON {lll.
Turn th6 ignition switch ON (ll).
- Repair lhort or opcn in thowire between the No. 25METER 17.5 Al fu3e snd thegauge assembly.- Repl.co the No. 25 METER17.5 Al fus€.
ls the low oil pressure light on?
Try to start the engine.
Chock for an opsn in th€ wiro orbulb {MlL line,:1. Turn the ignition switch OFF.2. Connect the ECM/PCM con-nector terminal A18 to bodyground with a iumper wire.3. Turn the ignition switch ON (ll).
Rep.ir open in the wi.osbotween the ECM/FCM lA18land the gaugo rasombly.Roplece the MIL bulb.
ls th6 MIL on?
Substitute a known-good ECM/PCM and rochock. lf rymptom/indication goes eway, replacetho o gind ECM/PCM.
Turn the ignition switch OFF.Inspect the Fl E/M 115 A) tusein the undeFhood fuse/relaybox.
- Repair short in the wirebetween lhe Fl E/M (15 AlfusG and the PGM-Fl m.in.slay.- Roplsce th€ Fl E/M (15 Alfu3€.
Inspect the No. 13 FUEL PUMP(15 A) fuse in the under-dashfuse/relay box.
- Repair short in th6 wirebetween tho No. 13 FUELPUMP 115 A) luse and thePGM-FI main .elay.- ReDlace tho No. 13 FUELPUMP 115 Al tuse.
Engine Gontrol Module/Powertrain Control Module (ECM/PCM) -'98 - 00 Models
NOTE:. lf this symptom is intermittent, check tor:- A loose Fl E/M {15 A) fuse in the under-hood fuse/relay box- A loose No. 25 METER {7.5 A) fuse in the under-dash fuse/relay box- A loose No. 13 FUEL PUMP (15 Alfuse in the underdash fuse/rolay box- An intermiftent short in the wire between the ECM/PCM (A18) and the gauge assem-
- An int€rmiftent short in the wire between the ECM/PCM (C19) and the MAP sensor- An intermiftent short in the wire between rhe ECM/PCM (C28), the TP sensor, theEGR valve lift sensor and/or {uel tank Dressure sensor- A laulty PGM-FI main relay
ECM/PCM CONNECTOR A (32P}
Wire side of female terminals
(To page 11-871
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Ch€ck tor rn opon in tha wiioa(lGP lino.):1. Disconnectthe fuel inj€ctor andIAC valve connectors.2. Turn the ignition switch ON {ll}.3. Measure voltage betweenbody ground and ECM/PCMconn€ctor terminals B'l and89 individually.
- Repaii opon in th6 wirc{3lbetw.6n tho ECM/PCM (B1.
Bgl lnd tho PGM-FI mainroby.- Chock for poor connactionsor loo3€ wiJo3 at the PGM-FImain ralry.- T.st the PGM-FI mtin r.lay(soo p.ge 11-1871.
ls there battery voltage?
Chack for an opon in tho wire3
{PG, LG lino3l:1. Reconnect the luel iniectorand IAC valve connectors.2. Measure voltage betweenbody ground and ECM/PCMconnector terminals 82, 810,820 and 822 individually.
B.pair open in the wiroltlb.twocn tho ECM/PCM .ndG101 lloc.t6d rt th. thormoiathouingl that had mo.e than 1 .0 V.
lsthere lessthan 1.0 V?
Chock for a shon in the wira3
{VCCI, VCC2 lin..l:Measure voltage between bodyground and ECM/PCN4 connectorterminals C19 and C28 individuallv.Chock lor a short in r s€nsor:While measuring voltagebetwoen body ground and ECM/PCM connector terminals C19and C28 individually, disconneclthe 3P connector ol each sensorone at time:
. TP sensor. Fueltank pressure sensor
ls there approx.5 V?
Rooair ahort in tho wire b€twoentho MAP sen3or. TP sensor, Fuel
tank Dreaaure Sonsor and theECM/PCM tC19, C28).
ls there approx. 5 V?
Sub3lhuio . known-good ECM/PCM .nd rcch6ck. lf tymptom/indic.tion go.3 away, rapl.ceth. original ECM/PCM.Replece the ronsor thtt hadapprox. 5 V.
(From page 11-86)
lcont'd)
r
28
I1011't317
19202123
vXv) iiP2rELlBLK)
IGPl(YEL/BLK)
ECM/FCM CONNECTOR A {25PI
Wire side of lemale terminals
(YEL/RED)
Wire side oflemale terminals
ECM/PCM CONNECTOR C {3'IP}
| 2i37Es/'t61718 192021\22
26272elE30 31
vcc2(YEL/BLUIktvccl
11-47
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PGM-FI System
Engine Control Module/Poweftrain Control Module (ECM/PCM) -'98 - 00 Models (cont'dl
NOTE:. When there is no Diagnostic Trouble Code IDTC) stored, the MIL will stay on iI the SCSservice connector is connected and the ignition switch is ON (ll).. lf this symptom is intermittent, check for:- An intermittent short in the wire between the ECM/PCM (A10) and the service checkconnoctor- An intermittent short in the wire between the ECM/PCM (At8l and the gaugeassemDty. See the OgD ll scan tool or Honda PGM Tester user's manuals for specific operatingrnstructions.
ECM/FCM CONNECTOF A {32P)
Wire side of femsle t6rminals
The Malfunction lndicator LamolMlll 3lays on or comes on aftertwo 3econds.
Check the Dirgnostic TroubloCod€ (DTCI:'1. Connect a scan tool or HondaPGM Tester.2. Turn the ignition switch ON (ll).3. Read the DTC with the scantool or Honda PGM Tester.
Go to troublGhooting procadura.(3€c prg€ l lS0l
check tho DTc by MIL indication:1. Turn the ignition switch OFF.2. Connect the SCS service con-nector to the service checkconnector,3. Turn the ignition switch ON (ll).
Ropair op.n ol Bhort in wirob.twe.n thc ECM/FCtrl (A21)
and D.i. Link Connoctor.Go to troublo3hootlng proc€-dur6. lt o pag. 11.6lrl
Does the MIL indicate any DTC?
Try to start the engine.
Sub3titute r known"good ECM/PCM .nd roch.ck. lt .ymptom/indic.tion gooa awsy, repl.cothe origin.l ECM/PCM.
Does the engine stan?
Check tor a 3hort in the wireISCS linel:1. Turn the ignition switch OFFand turn the ignition switchoN { ).2- Measure voltage betweenbody ground and the ECM/PCi, conneclor terminal A10.
Ropria ahort to body ground intho wi.c Mwe.n tho ECM/PCMlA10l and aarvic. check connsc-tor.
lTo page 1l-89)
11-88
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PGM-FI System
Manifold Absolute Pressure (MAPI Sensor
The scan tool indicates Diagnostic Trouble Code (DTC) POl07: A low input (high vacuum) problem in theManifold Absolute Pressure (MAP) sensor,
The MAP sensor convens manifold absolute pressure into electrical signals and inputs the ECM/pCM.
OUTPUIVOLTAGE
tvl3.s
3.0
2.5
2.O
1.5
1.0
0.5
o .5 ro- 15^ 1olin.H9) GAUGEREADIT{G
lmmHgl
3025
100 200 300 a00 5oo 6fi, 7d)
MAP SENSOR 3P CONNECTOR IC131I
vccl(YEL/RED}
Th6 MIL has b€en reoorted on.DTC P0107 is 3tored.
Problom verification:1. Turn the ignition switch ON lll).2. Check the lvlAP with the scanroot.
lrtormittem tailu.e, lystam b OKat thb timo. Check tor poor con-noctions or loosa wird at C131(MAP rensor) and rt the ECM/PCM.
ls approx. 101 kPa (760 mmHg,30 in.Hg),2.9 V indicated?
Check for an op6n in wi.o IVCC1linel:1. Turn the ignition switch OFF.2. Disconnect the MAP sensorconnector,3. Turn the ignition switch ON {ll}.4. Measure voltage between theMAP sensor connector No. 1termanal and No. 2 terminal.
Roprir op€n in the wir6 bstweentho ECM/PCM (D4, C19*l and theMAP sensor.
ls there approx. 5 V?
(To page 11-91)
11-90
Wiro side ol temale terminals
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