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

G: FRONT SEAT PASSENGER AIRBAG MODULE DANGEN
A DANGEREXPLOSIVE/FLAMMABLECONTACT WITH ACID, WATER. OR I{EAVY METALS SUCH
AS COPPER. T.EAD. OR MERCURY MAY PRODUCE HARMFUL
AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.
STORAGE TEMPERATURES MUST NOT EXCEED 2OO"F
IlOO'C). FOR PROPER HANDLING, STORAGE, AND
DISPOSAL PROCEDURES REFER TO THE SERVICE MANUAL,
SRS SUPPLEMENT.POTSONCONTAINS POTSONOUS SODIUM AZIDE ANO POTASSIUM
NITRATE.FIRST AIDIF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR 15
MINUTES. IF GASES (FROM ACID OR WATEN CONTACT)
ARE INHALEO. SEEK FRESH AIR. IN EVERY CASE, GET
PROMPT MEDICAL ATTENTION.KEEP OUT OF REACH OF CHILDREN.
A WARNINGTHE AIRBAG INFLATOR IS EXPLOSIVE AND, IF
ACCIDENTALLY DEPLOYED, CAN SERIOUSLY HURT OR
KILL YOU.. DO NOT USE ELECTRICAL TEST EOUIPMENT OR
PROBING DEVICES,THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.. NO SERVICEABI-E PARTS lNSlDE. DO NOT DISASSEMBII.
. PLACE AIRBAG UPRIGHT WHEN REMOVEO.
. FOLLOW SERVIC€ MANUAL INSTRUCTIONS CAREFULLY
H: PASSENGER INFORMATION lU S.A. modell
{U.S.A.'97 model}
AIEBAG SEE OTHER SIDE,
{U.S.A.'98 - 00 modelsl
AIRBAG WARNINGFLIP VISOR OVER.
l: SRS INFORMATION
lU.s.A.'97 model ilcanada '97 - 00 mod€ls I
CAUTIONTO AVOID SERIOUS INJURY:. FOR MAXIMUM SAFEW PROTECTION lN ALL TYPES OF
CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
8ELT.o OO NOT INSTALL REARWARD-FACING CHILO SEATS lN
ANY FRONT PASSENGER SEAT POSITION.. DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE
AIRBAG.. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRBAG AND YOURSELF.. SEE THE OWNER'S MANUAL FOR FURTHER
INFORMATION AND EXPLANATIONS. THE SRS MUST BE INSPECTED TEN YEARS AFTER lT lS
INSTALLED.. THE DATE OF INSTALLATION lS SHOWN ON THE
DRIVER'S DOORJAMB.
lU.S.A.'98 - 00 models)
WARNINGDEATH OR SERIOUS INJURY CAN OCCUR'
. CHILDREN 12 ANO UNDER CAN BE KILLED BY THE
AIRBAG.. THE BACK SEAT lS THE SAFEST PLACE FOR CHILDREN.
. NEVER PUT A REAR-FACING CHILD SEAT lN THE
FRONT.o SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG
. ALWAYS USE SEAT BELTS AND CHll-D RESTRAINTS.
. THE SRS MUST BE TNSPECTED TEN YEAnS AFTER lT lS
INSTALLED.. THE OATE OF INSTALLATION lS SHOWN ON THE
DRIVER'S DOORJAMB.
J: FRONT PASSENGER AIRBAG WARNING
lU.S.A.'98 - 00 models)
WARNINGCHILDREN CAN BE KILLED OR INJURED 8Y THE
PASSENGER AIRBAG.THE BACK SEAT IS THE SAFEST PLACE FOR CI{ILDREN 12
AND UNDER.MAKE SURE ALL CHILDREN USE SEAT BELTS OR CHILD
SEATS.
K: FRONT SEATBELT TENSIONER WARNING
WABNINGEXPLOSIVE MATERIAL INSIDEYOU CAN BE SERIOUSLY HURT OR BURNED,
. DO NOT TAMPER OR DISASSEMBLENO SERVICEABLE PARTS INSIDE.. REFER TO SERVICE MANUAL FOR COMPLETE
INSTRUCTIONS.
(cont'd)
1-13
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-?E
handling a metal gasket. take care not to fold it or damage the contact surface.
Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts.
CYLINDER HEAD BOLT11 x 1.5 mm85 N.m {8.7 kgf.m,6:} lbf.ft)Tightening, page 6'30.Apply engine oilto the threads.VALVEKEEPERS
\
END PIVOT BOLT63 N.m 16.4 kgl m, 46 lbf.ft)
EXHAUSY VALVESEALReplace.
EXHAUST VALVEGUIDEInspection, page 6-25Replacem6nt, page 6-25Reaming, page 6-27
10 x 1.25 mm4,0 N.m {i1.5 kgf.m.33 rbf.ft)
GASKETReplace.
OIL CONTROLORIFICEClean.
EXHAUST VALVESPRING
SPRING BETAINER
INTAKE VALVESPRING
INTAKE VALVE SEALReplace.
VALVE SPRINGSEAT
INTAKE VALVEGUIDE
Removal, page 6-16Warpage, page 6 27Valve seat reconditioning,page 6 28Installation, page 6-30
EXHAUSTVALVE
INTAKE VALVERemoval, page 6-23Installation, page 6-29
CYLINDER HEAO
HEAD
O.RINGReplace.
8 x 1.25 mm24 N.m (2.4 kgf.m,17 tbf.ft)
DOWEL PIN
6-15
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Valve Guides
Valve Movement
1. Measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust (wobble method),
lntake Valve Stem-to-Guide Clearance:
Standard (Newl: 0.04 - 0.10 mm
(0.002 - 0.004 in)
Service Limit 0.16 mm (0.006 in)
Exhaust Valve Stem-to-Guide Clearance:
Standard {Newl: 0.10 - 0.16 mm
(0.004 - 0.006 inl
Service Limit: 0,22 mm (0.009 inl
lf the measurement exceeds the service limit,
recheck using a new valve.
lf the measurement is now within the service limit,
reassemble using a new valve.
lf the measurement still exceeds the limit, subtract the
O.D. of the valve stem, measured with a micrometer,
from the l.D. of the valve guide, measured with an
inside micrometer or ball gauge.
Take the measurements in three places along the
valve stem and three places inside the valve guide
The difference between the largest guide measure-
ment and the smallest stem measurement should
not exceed the service limit.
lntake Valve Stem-to-Guide Clearance:
Standard (New): 0.02 - 0.05 mm
{0.001 - 0.002 in)
Service Limit: 0.08 mm (0.003 in)
Exhaust Valve Stem-to-Guide Clearance:
Standard (New): 0.05 - 0.08 mm
(0.002 - 0.003 in)
Service Limit: 0.11 mm (0.004 in)
2.
3.
Replacement
1. As illustrated below, use a commercially available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. In most
cases, the same procedure can be done using the
sDecial tool and a conventional hammer.
VALVE GUIDE DRIVER(Commerciallv available)
2.
3.
(0.25 inl I
_,1-r
,_T-_lrl
'11.3 mm(0.{,r in}
orVALVE GUIDE DRIVER, 6.6 mm0t9a:I - G5t01q)
Select the proper replacement guides. and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150"C). Monitor the temperature with
a cooking thermometer. Do not get the head hofter
than 300'F (150"C); excessive heat may loosen the
valve seaIs.
6.4 mm
CAUTION: To avoid burns, uss heavy gloves when
handling the heated cylinder head.
(cont'd)
6-25
*]-- sz mm' l2.21inl
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Transmission
Cooler Flushing
@@ To prevent in;ury to face and eyos, atwayswear safety glasses ot a face shield when using thetlansmission flusher.
This procedure should be performed before reinstallingthe transmission.
2.
LCheck equipment for wear and cracks before using.Replace any worn or cracked components.
Using the measuring cup. fill the tank with 21 ounces{approximately 213 lull) ol biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontaaner.
Secure the flusher filler cap, and pressurize theflusher with compressed air to 550 - 829 kpa (5.6 _
8.45 kgf/cm,, 80 - 120psi). The air line should beequipped with a water trap to ensure a dry air sys-tem.
Hang the flusher under the vehicle.
Attach the flusher discharge hose to the return lineof the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-mission cooler using a clamp.
IMPORTANT:
Securely clamp the opposite end ofthe drain hose to abucket or floor drain.
DISCHARGEHOSE
tAirlp Water
TnAI{SrfiSStoN coot"€RFLUSHER{Comm.rcidly.v.il.bt.lK.r -Moor. J38,t{15.Aor aquival.nt
5.
14-264
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
10.
8.
1'I.
Turn on the water valve for 1O seconds. lf waterdoes not flow through the cooler, it is completelyplugged, cannot be flushed, and must be replaced.
Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
While flushing with the water and flushing fluid fortwo minutes, turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgf/cmr, t20 psi)
Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
Release the trigger, and rinse the cooler with wate.for one minute.
Turn the water valve off, and the water supply off.
Turn the air valve on for two minutes, or until nomoisture is visible leaving the drain hose. Residualmoisture in the cooler or lines can damage thetransmission.
Remove the flusher from the cooler line. Attach thedrain hose to a container.
Install the transmission, and leave the drain hoseattached to the cooler line.
12.
13.
14.
to.
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A/C Service Tips and Precautions
The air conditioner system uses HFC-'134a (R-134a) refrigerant and polyalkyleneglycol {PAG) refrigerant oil*, which are not
compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do
not attempt to use R-12 servicing equipmenu damage to the air conditioner system or your servicing equipment will
resutr.
*KEIHIN SP-10:
. P/N 38897 - Pl3 - A01AH: 120 m{ (4 fl.oz, il.2 lmp.oz)
. P/N 38899 - Pl3 - A01: 40 mf 11113tl.oz,1.4 lmp.oz)
Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove R-134a
from the air conditioner system,
CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid
breathing the air conditioner refrigerant and lubricant vapor or mist,
lf accidental system discharge occurs, ventilate work area before resuming service.
R 134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested with compressed
air.
E@ Some mixtures of air and R-13,1a have been shown to be combustible at elevat€d pressures and can result
in fire or explosion causing iniury or property damage. Never use complessed air to pressure test R-l3,[a service equip-
ment or vehicle air conditioner systems.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
2. Keep moisture and dust out of the system. When disconnecting any lines, plug or cap the fittings immediately; don't
remove the caps or plugs until just before you reconnect each line.
3. Before connecting any hose or line. apply a few drops of refrigerant oilto the O-ring,
4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.
5. When discharging the system, use a R l34a refrigerant recovery/recycling/charging station; don't release refrigerant
into the atmosphere.
6. Add refrigerant oil after replacing the following parts.
Note these items when handling refrigerant oil:
o To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refriger-
ant oils.
. lmmediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
. Do not spill the refrigerant oil on the vehicle; it may damage the painu if the refrigerant oil contacts the paint, wash
it off immediately.
Condenser . 25 ml (5/6 tl.oz, 0.9 lmp.oz)
Evaporator.,................................40 m/ 11 113ll.oz,l.4 lmp.ozl
Line or hose ........... 10 ml (1/3 fl.oz, 0.4 lmp.oz)
Receiver/Dryer....... 10 ml (1/3 fl.oz, 0.4 lmp.oz)
Leakage repair............................ 25 m/ (5/6 ll.oz, 0.9 lmp.oz)
Compressor.......,..., For compressor replacement, subtract the volumg ol oil drained from the removed
compressor from 130 m{ (4 113 tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of
oif from the now comprossor: 130 ml (,1 113 tl,oz, 1.6lmp'ozl - Volume of removed
compressor = Volume to drain from new compressor.
NOTE: Even if no oil is drained trom the removed compressor, don't drain more than
50mt 11 213ll,oz,1.8 lmp.oz) from the newcompressor.
22-54I
rso m r rr:0.o., r.s r-o.o.t
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Troubleshooting
Tips and Precautions
Bef ore Troubleshootin g
. Check applicable fuses in the appropriate fuse/relay
box.
. Check the battery for damage, state of charge, and
clean. and tight connections.
. Check the alternator belt tension.
CAUTION:
. Do not quick-charge a battery unless the battery
ground cable has been disconnected, otherwise you
will damage the alternator diodes.
. Do not attempt to crank thc engins wilh the battery
ground cable loosely connected or you will severely
damage the wiring.
Handling Connestors
. Make sure the connectors are clean and have no loose
wire terminals,
. N4ake sure multiple cavity connectors are packed with
grease (except water-tight connectors).
. All connectors have push-down release type locks.
Some connectors have a clip on their side used to
attach them to a mount bracket on the body or on
another component. This clip has a pull type lock.
Some mounted connectors cannot be disconnected
unless you first release the lock and remove the con-
nector from its mount bracket.
LOCKINGPAWL ONOTHERHALF OFPulltodisengage
LOCKING TAB
CONNECTORBRACKET
Never try to disconnect connectors by pulling on
their wires; pull on the connector halves instead.
Alwavs reinstall olastic covers.
Before connecting connectors, make sure the termi-
nals are in place and not bent.
. Check for loose retainers and rubber seals.
RETAINER
The backs of some connectors are oacked with
grease. Add grease if necessary. lf the grease is con
taminated. reolace it.
{cont'd}
23-3
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Troubleshooting
Tips and Precautions (cont'dl
Insen the connector all the way and make sure it is
securely Iocked.
Position wires so that the open end of the cover faces
down.
V
Faceopen end
Handling Wires and Harnesges
. Secure wires and wire harnesses to the frame with
their respective wire ties at the designated locations.
. Remove clips carefully; don't damage their locks.
Slip pliers under the clip base and through the hole at
an angle, then squeeze the expansion tabs to release the
clrD.
After installing harness clips, make sure the harness
doesn't interfere with any moving pans.
Keep wire harnesses away from exhaust pipes and
other hot parts, trom sharp edges of brackets and
holes. and from exoos€d screws and bolts.
NOT GOOD
A -M/
lr lr*
T€sting and Repairs
. Do not use wires or harnesses with broken insulation.
Replace them or repair them by wrapping the break
with electricaltape.
. After installing parts, make sure that no wires are
pinched under them.
. When using electrical test equipment, follow the
manufacturer's instructions and those described in
this manual.
. lf possible, insert the probe of the tester from the
wire side (except waterproof connector).
. Seat grommets in their grooves properly.
. Use a probe with a tapered tip.
Refer to the instructions in the Honda Terminal Kit for
identification and replacement of connector termi-
nals.
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)
Supplemental Restraint System (SRS)
Special Tools .."....."" 24-14
Component/Wring Location
lndex - '97 model ..........'.." '.....""" 24-15
Component/Wiring Location
lndex - '98 - 00 models ..............." 24-16
Description .'.........."'.24'17
Circuit Diagram .........24'14
Precautions/Procedures
General Precautions ......".."'........... 24-19
Airbag/Seat Belt Tensioner
Handling and Stolage ....''........... 24-19
SRS Unit Precautions ...............'...... 24-20
lnspeciion After Deployment .......'.24'20
) SpringJoaded Lock Connector
with Built-in Short Contact '...'....24-21
Spring-loaded Lock Connectors .."' 24-22
BackProbing SPring-loaded Lock
Conneetors ,.......24-22
Disconnecting the Airbag Connectors and
the Seat Beh Tensioner
Connectors ....'....24-23
Steering-lelated Precautions .......... 24-25
Troubleshooting
Self -diagnostic Procedures ............. 24-26
Reading the DTC .................. .....".."' 24'26
Erasing the DTC Memory ................24-28
Troubleshooting lntermittent
Faifures "'...........24'24
Diagnostic Trouble Gode {DTC}
Chart -'97 model ....""....... "......24-29
Diagnostic Trouble Gode (DTCI
Chart -'98 - 00 models ............. 24-31
SRS Indicator Light Wire
Connections ','," 24'33
Ff owcharts ....-........24'34
Driver's Airbag
Repf acement ..'......21'87
Front Passenger's Airbag
Repfacement .....'.',24'AS
Gable Reel
Replacement .......'.24-91
SRS Unit
Replacement .........24-95
Airbag/Seat Belt Tensioner
Disposaf .................24'97
)-e
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Precautions/Procedures
)General Precautions
Carefully inspect any SRS part before you install it.
Do not install any part that shows signs of being drop-
ped or improperly handled, such as dents, cracks or
deformation:
- Airbags- Cable reel- SRS unit- Seat belt tensioners
N
)-
Use only a digital multimeter to check the system, lf
it's not a Honda multimeter, make sure its output is
10 mA (0,01 A) or less when switched to the smallest
value in the ohmmeter range. A tester with a higher
output could damage the airbag circuit or cause acci-
dental deployment and possible injury.
Do not install used SRS Dans from another vehicle,
When making SRS repairs, use only new pans.
Except when performing electrical inspections,
always disconnect both the negative cable and posi-
tive cable from the batterv. and wait at least three
minutes before beginning work.
Replacement of the combination light and wiper/
washer switches and cruise control switch can be
done without removing the steering wheel:
- Combination light and wiper/washer switch replace-
ment {see section 231.- Cruise control sevresume switch replacement (see
section 41.
Whenever the ignition switch is ON {ll}, or has been
turned OFF for less than three minutes, be careful not
to bump the SRS unit; the airbags could accidentally
deploy and cause damage or injuries.
Whenever the airbag has been activated, replace the
SRS unit.
The original radio has a coded theft protection circuit.
Be sure to get the customer's code number before dis-
connecting the battery cables.
)
Airbag/Seat Belt Tensioner
Handling and Storage
Do not try to disassemble an airbag or a seat belt ten-
sioner. They have no serviceable parts. Once an airbag
or a seat belt tensioner have been deployed. they cannot
be repaired or reused.
For temporary storage of an airbag or a seat belt ten-
sioner during service, please observe the following pre-
cautons:
. Store the removed airbag with the pad surface up.
The driver's/front passenger's airbag connectors and
seat belt tensioner connectors have a built-in short
contact (see page 24-211.
@ r th€ airb.g is impropcrty stor€d face down,
accidental deployment could propel the unit with enough
forc€ to caus6 serious iniury,
Store the removed on a secure flat surface awav from
any high heat source (exceeding 212"F/100'C) and
free of any oil, grease. detergent or water.
lmproper handling or storage can internally damage
the airbag and seat belt tensioner. making them inop-
erative.
lf you suspect the airbag and seat belt tensioner have
been damaged, install new units and refer to the
Deploymenvoisposal Procedures for disposing of the
damaoed units.
AIRBAG CONNECTORS
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Airbag/Seat Belt Tensioner
1.
Disposal (cont'dl
Connect a 12 volt battery to the tool'
. It the green light on the tool comes on, the air-
bag igniter circuit is defective and cannot deploy
the airbag. Go to Damaged Airbag Special
Procedure.
.lftheredlightonthetool comes on, the airbag is
ready to be deployed.
Push the tool's deployment switch. The airbag
should deploy (deployment is both highly audible
and visible; a loud noise and rapid inflation of the
bag, followed by slow deflation).
. lf the airbags deploy and the green light on the
tool comes on, continue with this procedure.
. lf an airbag doesn't deploy, yet the green light
comes ON, its igniter is defective. Go to Dam-
aged Airbag Special Procedure.
. During deployment, the airbag can become hot
enough to burn you, Wait thirty minutes after
deployment before touching the airbag.
Dispose of the complete airbag. No part of it can be
reused. Place it in a sturdy plastic bag, and seal it
securety.
CAUTION:
. Wear a faco shield and gloves when handling a
deployed airbag.
. Wash your hands and rinse them well with
water after handling a deployed airbag.
24-98
Deploying tho Airbag: Out-ot.vohicle
lf an intact airbag has been removed from a scrapped
vehicle, or has been found defective or damagsd during
transit. storage or seryice, it should be deployed as fol-
lows:
'L Confirm that the special tool is functioning properly
by following the check procedure on this page or on
the tool label.
2. Position the airbag face up, outdoors on flat ground
at least thirty feet (10 m) from any obstacles or peo-
Dte,
3. Follow steps 6, 7, 8. and 9 of the in-vehicle deploy-
ment proceoure.
Dlmaged Airbsg {or Seat Beh Ten3ion6r} Sp6cial
Procgdure
!@ r an airbag {or seat Beh rensioner} cannol
be doployod, it should not be treated as normal scrap; it
should still be considered a pot€ntially explosive device
lhat can cause serious iniury.
1. lf installed in a vehicle. follow the removal proce-
dure on page 24-3 and 24-87 through 90.
2. In all cases, make a short circuit by twisting together
the two airbag inflator wires.
3. Package the airbag in exactly the same packaging
that the new reDlacement Dart came in.
4. Mark the outside of the box "DAMAGED AIRBAG
{or TENSIONER) NOT DEPLOYED" so it does not
get confused with your parts stock.5. Contact your Honda District Service Manager forhow and where to return it for disposal.
Deployment Tool: Check Procedure
Connect the yellow clips to both switch protector
handles on the tool; connect the tool to a battery.
Push the operation switch: green means the tool is
OK: red means the tool is faultv.
Disconnect the baftery and the yellow clips.
I
t
l.
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