air condition compressor HONDA CR-V 2000 RD1-RD3 / 1.G Workshop Manual

to
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SuspensionSection 18
BrakesSec'tion 19
Air ConditioningSection 22
* When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
Readjust deflection or tension to used belt values.
o
Unit of length: mm {in)
MEASUREMENTSTANDARD {NEW)
WheelalignmentCamber FrontRearCaster FrontTotaltoe FrontnearFront wheel turning angle Inward wheelOutward wheel
0"00' 1 1'- 1"00' 1 1'2"10' ! 1"0J3(011/8)rN 2 ri (1/161 1/r6)37"00' ! 231'30'(Referencei
Wheel bearingEnd playFrontRear0 - 0.05 {0- 0.002}0 - 0.05 (0 0.002i
Rim runout Aluminum wheel AxialBadialSteelwheel AxialRadial
STANOARD (NEW)SERVICE LIMIT
0 - 0.7 (0 0.03)0,0.7 (0 - 0.03)0 1.0 (0 - 0.04)0 - 1.0 {0 - 0.04)
2.0 (0.08)'r.5 {0.06)2.0 {0.08)1.s (0.06)
MEASUREMENTSTANDARD INEWI
Parking brakeleverPlay in stroke at 196 N (20 kgf,44lbf)lever force
To be locked when Dulled: 2 - 6 notches
Foot brake pedalPedal height (with tloor mat removed)
Free playNT
155 (6 1/8)161 (6 5/16)1 5 (1/16 - 3/16)
Master cylinderPiston-to-pushrod clearance0 - 0.4 (0- 0.02)
Disc brakeDisc thickness Front '97, '98 models'99, '00 modelsDisc runoutDisc parallelismPad thickness
FrontFrontFront
STANDARD {NEW'SERVICE LIMIT
22.9 - 23.1 (0.902 - 0.909)23.6 23.8 (0.929 - 0.937)
10.5 - 11.5 (0.4't 0.45)
21.0 (0.83)
21.0 (0.83)
0.10 {0.004)0.015 (0.0006)
1.6 (0.06)
Rear brake drumLD.Lining thickness
2r9.9 220.0 (8.657 - 8.661)3.9 - 4.5 (0.15 - 0.18)221.O 8.70112.0 (0.08)
MEASUREMENTSTANDARD {NEWI
Air conditioningLubricant type:KEIHIN SP 10 (P/N 38897 - Pl3 - A01AH or 38899 -
Pl3 - A01)Lubricant capacity Condensermf {floz, lmp oz) EvaporatorLine or hoseReceiver
25 (5/6,0.9)
40 {1 1/3, 1.4)10 {1/3,0.4)10(.]/3,0.4)
Compressor(KEIHIN)Lubricant type: SP 10Lubricant capacity ml ({l 02, lmp oz}Stator coil resistance at 68'F (20"C) OPulley-to-pressuae plate clearance
130'3'{4 1fi'3o, 4.6;"}3.05 - 3.350.51 0.15 (0.02 1 0.006)
Compressor belt*Deflection with 98 N (10 kgl,22lblibetween pulleys7.5 - 10.5 {0.30 - 0.41) with used belt5.0 - 7.0 (0.20 - 0.28) with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge390 - 540 (40 55,88-120)withusedbelt740 - 880 {75 90, 170 - 200) with new belt
2-11
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METRICITEMENGLISHNOTES
AIR CONDITIONINGCooling capacity3,520 Kcal/h j 14,000 BTU/h
Compressor Type/manutacturerNo. of cylinderCaPacityMax. speedLubricant capacityLubricant type
Scroll/KElHlN
85.7 mf/rev | 5.23 cu'in/rev10,000 rpm130mf 1 algIlozsP-10
Condenser TypeCorrugated fin
Evaporator TypeCorrugated fin
Blower TypeMotor inputSpeed controlMax. capacity
Sirocco fan200 w 112 v4-Speeo440 m3/h 15,500 cu fvh
Temperature control
Compressor clutch TypePower consumptionDry, single plate, poly-V-belt drive40 W max./12 VAt 68'F (20 C)
Befrigerant TypeOuantity
HFC-134a 1R-134a)zoo o' g 24j an oz
STEERING SYSTEMTypeOverall ratioTurns, lock to lockSteering wheel diameter
Power assisted, rack and pinion
SUSPENSIONType Front
Bear
Shock absorber Front and Rear
Independent double wishbone, coil springwith stabilizerIndependent double wishbone, coil springwith stabilizerTelescopic, hydraulic nitrogen gas tilled
WHEEL ALIGNMENTCamber
CasterTotaltoe
FronthearFrontFrontRear0inln 1/16 in0mmln2mm
0'- r"00'2.10'
BRAKE SYSTEMTvpe
Pad surface areaLining surface areaParking brake
Front
RearFrontRearTvpe
Power-assisted selt-ad,ustingventilated discPower assisted self-adiusting drum49 cm, x 2 7.6 sq-in x 273 cm, x2 11.3 sq-in x 2Mechanical actuating, rear two wheel brakes
Drum brake
TIRESize and pressureSee tire inlormation label.
ELECTRICALBafteryStarterAlternator
In under-dash fuse/relay boxIn under hood fuse/relay box
In underhood ABS fuse/relay boxHeadlightsFront turn signal lights
Front parking lightsFront side marker lightsRear side marker lightsRear turn signal lightsErake/parking lightsBack-up lightsCeiling lights {fronvrear)License plate lightSpotlightsHigh mount brake lightlgnition key lightAshtray lightGauge lightsIndicator lightslllLrmination and pilot IightsHeater illumination lights
12 V, 36 AH/s HR12V 1.0, 1.1 kW12V 100A
7.5 A, 10 A, 15 A, 20 A7.5 A, 10 A, 15 A, 20 A, 30 A, 40 A'100 A7.5 4,20 A. 40 A12V 60/55 W12 V- 21 W ('97 model),12 V - 27 W ('98-00 models)12V 5 W {'97 model),3 CP ('98 - 00 models)12V-8W12 V,3 CP12V-21W12 V 2115 W12V 21 CP (18 W)12V-8W12V-8W12V-5W12V -21W
12 V- 1.4 W12V 1.4 W12 V 1.4 W,3 W,3.4 W12V-0.84W, 1.12 W, 1.4 W,3 W, LED12 V - 0.84 W, 1.4 W, LED12 V,1.4 W
2-13
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Lubrication Points
For the details of lubrication points and type of lubricants to be applied. refer to the illustrated index and various work pro-
cedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
Recomm6nded Engine OilEngine oil viscosity for ambient temperature ranges
100'F
-30 -20 .10 0 10 20 30 40'c
r1: Always use Genuine Honda Manual Transmission Fluid {MTF). Using motor oil can cause stiffer shifting because it
does not contain the orooer additives.*2: Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect
shift qualitv.+3r Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the
life of the system.*4: Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmis-
sion fluid can caused increased wear and poor steering in cold weather.
API SERVICE LABEL
/,.*-G\
/.'z-\e\t/6AE\ll-;-1 5w-30 /---l
w
API CERTIFICATION SEAL
ffi-20 0 20
NO.LUBRICATION POINTSLUBRICANT
EngineAPI Service Grade: Use SJ "Energy Conserving" grade oil. The oilcontainer may also display the API Certitication seal shownbelow. Make sure it says "For Gasoline Engines." SAE vjscosity:See chart below.
2
TransmissionManualGenuine Honda MTF*1
AutomaticGenuine Honda Premium Formula Automatic Transmission Fluid(ATF)*'
3Rear differentialGenuine Honda CVT Fluid
4Brake line (includes ABS line)Genuine Honda DOT 3 Brake Fluid*3
5Clutch LineBrake fluid DOT 3 or DOT 4*3
6Shift lever pivots (Manual transmission)Grease with molybdenum disultide
1Release fork (Manual transmission)LJrea Grease UM264 P/N 4'1211 - PYs - 305
IPower steering gearboxSteering grease P/N 08733 - B070E
Throttle cable end {Dashboard lower panel holelSilicone grease
10l112
14
Throttle cable end (Throttle link)Brake master cylinder pushrodPedal linkageBattery terminalsFuelfill lidClutch master cylinder pushrod
Multi purpose grease
1617181920
Hood hinges and hood lockTailgate hingesHatch glass hingesDoor hinges, upper and lowerDoor opening detent
Honda White Lithium Grease
21
22
Caliper Piston seal, Dust seal,Caliper pin, PistonShilt cable and select cable {Manual transmission)Silicone grease
23Brake line ioints (Front and rear wheelhouse)Rust preventives
24Power steering systemGenuine Honda Power Steering Fluid-.
25Air conditioning compressorCompressor oil: SP 10 lP/N 38897 - P13 - A0lAH or38899-P13-A01)For Refrigerant: HFC 134a (R,134a)
3-2
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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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Fuel Cut-off Control
. During deceleration with the throttle valve closed, current to the fuel injectors iscutoffto improvefuel economyat
speeds over 970 rpm ('97 - 98 models), 920 rpm ('99 - 00 modelsl.
. Fuel cut-off action also takes place when engine speed exceeds 6,500 rpm ('97 - 98 models), 6900 rpm ('99 - 00
models), regardless of the position of the throttle valve, to protect the engine from over-rewing.
With Ay'T model. the PCM cuts the fuel at engine speeds over 5,000 rpm when the vehicle is not moving.*'
4,./C Comoressor Clutch Relav
When the ECM/PCM receives a demand for cooling from the air conditioning system, it delays the compressor from
being energized, and enriches the mixture to assure a smooth transition to the Ay'C mode.
Evaporative Emission (EVAP) Purge Control Solenoid Valve
When the engine coolant temperature is above 154"F (68'C), the ECM/PCM controls the EVAP purge control solenoid
valve which controls vacuum to the EVAP purge control canister,
Alternator Control
The system controls the voltage generated at the alternator in accordance with the electrical load and driving mode.
which reduces the engine load to improve the fuel economy.
PCM Fail-saf e/Back-up Functions
1. Fail-safe Function
When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-pre
grammed value for that sensor that allows the engine to continue to run.
2. Back-up Function
When an abnormality occurs in the ECM/PCM itself, the fuel injectors are controlled by a back-up circuit independent
of the system in order to permit minimal driving.
3. Self-diagnosis Function IMalfunction Indicator Lamp (MlL)l
When an abnormality occurs in a signal from a sensor, the ECM/PCM supplies ground for the MIL and stores the DTC
in erasable memory. When the ignition is initially turned on {ll), the ECM/PCM supplies ground for the MIL for two
seconds to check the MIL bulb condition.
4. Two Trio Detection Method
To prevent false indications, the Two Trip Detection Method is used for the HO2S*1, fuel metering-related. idle control
system, ECT sensor and EVAP control system self-diagnostic functions. When an abnormality occurs, the ECM/PCM
stores it in its memory. When the same abnormality recurs after the ignition switch is turned OFF and ON (ll) again,
the ECM/PCM informs the driver by lighting the MlL. However, to ease troubleshooting, this function is cancelled
when you jump the service check connector, The MIL will then blink immediately when an abnormality occurs.
5. Two (or Three) Driving Cycle Detection Method {'97 model)
A "Driving Cycle" consists of starting the engine, beginning closed loop operation, and stopping the engine. lf misfir-
ing that increases emissions or EVAP control system malfunction is detected during two consecutive driving cycles.
or TWC deterioration is detected during three consecutive driving cycles, the ECM/PCM turns the MIL on. However, to
ease troubleshooting, this function is cancelled when you jump the service check connector. The MIL will then blink
immediately when an abnormality occurs.
*1: '97 - 98 models*2: '99 - 00 models
5.
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ldle Gontrol System
Air Conditioning Signal (cont'dl
(From page 11-'155)
JUMPERWIRE
UNOER.HOOD FUSE/RELAYBOX 9P CONNECTOR tqt52)
123I
56I
ACC IBLK/RWire side ofACC IBLK/REDIWire side of femaletermrnats
A t32PlPCM CONNECTORS C t3rp)
Wire side ol lemale terminals
Ch6ck for an open in th€ wire(ACC linel:Momentarily connect the under-hood fuse/relay box 9P connectorterminal No.5 to body groundwith a jumper wire several times.
ls there a cl;cking noise fromthe 4!/C compressor clutch?
ls there a clicking noise fromthe 4!/C compressor clutch?See air condiiioner inspection{see section 221.
Repai. op6n in the wire betwoenthe PcM (A17) and tho A/Cclutch relay.
Check the A/C operation:1. Start the engine.2. Turn the blower switch ON.3. Turn the A"/C switch ON.
Check for an open in the wire(ACS line):Measure voltage between PCMconnector terminals Ag and C5.
Does the A,/C operate?
Air conditioning signal is OK.
Repair open in the wire betweenthe PCM lCSl and the A/C awitch.ls there less than 1.0 V?
- Subqtitute a known-good FCM.nd r€ch6ck. lt 3ymptom/indi-cation goes awav, replece theoriginal rcM.- Soe th€ eir conditioner in3pec-tion (s6€ aec.tion 22).
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ldle Control System
Air Gonditioning Signal (cont'd)
JUMPERWIRE
UNDER-HOOD FUSE/RELAYBOX 9P CONNECTOR {G'52I
23a
5589
ACC (BLK/R
Wire side otACC (BLK/RED'
Wire side otfemaleterminals
ECM/PCM CONNECTORS
Wire sid€ of female torminals
(From page '11,157)
Check Ior dn opon in the wiroIACC linel:Momentarily connect the under-hood fuse/relay box 9P connectorterminal No. 5 to body groundwith a jumper wire several times.
ls there a clicking noise lromthe y'y'C compressor clutch?
ls there a clicking noise fromtho A,/C comprossor clutch?Sae rir conditional in3pactionlroa saction 221.
Repai. open in th6 wiro lr€twlanthe ECM/PCM lAl7l .nd tho A/Cclutch rolay.
Check tho op.ration of tho A/C:1. Stan the engine.2. Turn the blower switch ON.3. Turn the Ay'C switch ON.
ChGGk for an open in the wi.eIACS linel:Measure voltage betweon ECM/PCM connector terminals A27and 820.
Does the !y'C operate?
Air conditioning 3ignal i3 OK.
Rap.ir opon in the wir6 bdtunaanrh. Ecil/FcM lA27l rnd rh. A/crwitch.
ls voltage less than 1.0 V?
Sub6lftna a known{ood ECM/PCM and rechock. lf symp-tom/indicetion goes away.roplace the original ECM/rcM.See the ah conditionor inspoc-tion {3e€ section 22},
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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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Description
The air conditioner system removes heat from the passenger compartment by circulating refrigerant through the systemas shown below.
High'temperature/ High-temperature/
high-pressure gas h igh-pressure liquid
Suction and compression Radiation of heat
High-temperature/
high-pressu re liq uidr raps oeons,
and removes
motsture
More liquidified
row-pressure vapor
EVAPoRAToR (-l EXPANSToN vAL
SUCTION LINEtLow-PRESSURE S|OEt
LIOUID LINE
CONDENSER
coMpREssoR Il- coruoerusenl* necetve
Less moisturized
low-pressure vapor
Absorption of heat
DISCHARGE LINEIHIGH.PRESSURE SIDEI
This vehicle uses HFC-I34a (R-l34a) refrigerant which does not contain chlorofluorocarbons. Pay attention to the follow-ing service items:
. Do not mix refrigerants CFC-12 (R-12) and HFC-l34a (R-134a). They are not compatible.. Use only the recommended polyalkyleneglycol (PAG) refrigerant oil (SP-10) designed for the R-134a compressor.Intermixing the recommended (PAG) refrigerant oil with any other refrigerant oil will result in compressor failure.. Afl Ay'C system parts (compressor, discharge line. suction line, evaporator, condenser. receiver/dryer, expansion valve,O-rings for joints) have to be proper for refrigerant R-134a. Do not confuse with R-12 parts.
. Use a halogen gas leak detector designed for refrigerant R-134a.. R-12 and R-134a refrigerant servicing equipment are not interchangeable. Use only a recovery/recycling/charging stationthat is U.L.iisted and is certified to meet the requirements of SAE J2210 to service R-134a air conditioning system.. Always recover the refrigerant R-134a with an approved recovery/recycling/charging station before disconnecting anylVC fitting.
EVAPORAYOR
22-7
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