clutch switch HONDA CR-V 2000 RD1-RD3 / 1.G Workshop Manual

Engine Electrical
Speciaf Tools ............. 4-2
Starting System
Component Location Index ............ 4-3
Circuit Diagram ................................ 4-4
Starter Test ........... 4-5
Starter Solenoid Test ...................... 4'5
Starter Replacement ....................... 4-7
Field Winding Test ........................... 4-7
Starter Overhaul ............................,. 4-8
Brush Inspection ...........................,., 4-9
Overrunning Glutch Inspection ...... 4-9
Armature lnspection and Test ........4-10
Brush Holder Test ............................ 4-12
Starter Reassemb|y ......................... 4-1 2
Perf ormance Test ............................. 4- 1 3
lgnition System
Component Location Index ............ 4-14
Circuit Diagram ................................ 4-15
lgnition Timing Inspection and
Setting .......................................... 4-16
Distributor Replacement ........,........ 4-17
Distributor Overhaul .............,,......... 4-18
lgnition Control Module (lCM) Input
Test ..............................,................ 4-19
fgnition Coil Test .............................. 4-2O
lgnition Wire Inspection and
Test ............................................... 4-20
Spark Plug Inspection ..................... 4-21
-+
ENGINE
Charging System
Component Location Index ............ 4-22
Circuit Diagram ....................,........... 4-23
Troubleshooting .............................. 4-24
Alternator Replacement ..........,....... 4-30
Alternator Overhaul .......,,................ 4-31
Rectifier Test .........4-32
Alternator Brush Inspection ........... 4-32
Rotor Slip Ring Test ........................ 4-33
Stator Test ............. 4-33
Alternator Belt Inspection and
Adiustment ........4-34
Gruise Control
Component Location Index .,,,........ 4-36
Circuit Diagram ................................ 4-37
Control Unit Input Test ................... 4-38
Main Switch Test/Replacement ..... 4-40
Set/Resume Switch Test/
Replacement .......................,........ 4'40
Actuator Test ....,,., 4-41
Actuator Replacement ...............,.... 4-42
Actuator Cable Adiustment ............ 4-43
Clutch Switch Test .......................... 4-43
Brake Switch Test .................. .......... 4-44
Actuator Solenoid Test .............. ...,. 4-44
Actuator Disassembly ..................... 4-45
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Starting System
Component Location Index
BATTERYTest, section 23
CLUTCH INTERLOCKswtTcH {M/T)Test, page 4-43Switch position adiustment,section 12
IA/T GEAR POSITION SWITCH {A/T}Test, section 14Reolacement. section 14
Test, page 4 5Solenoid Test, page 4-6Replacement, page 4-7Overhaul, page 4 8Reassembly, page 4-12Performance Test, Page 4-13
4-3
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Starting System
Starter Test
NOTE: The air temperature must be between 59 and'100'F (15 and 38"C) before testing.
Recommended Procedure:
. Use a staner system tester.
. Connect and operate the equipment in accordance
with the manufacturer's instructions.
. Test and troubleshoot as described.
Alte.nate Procedure:
. Use the following equipment:- Ammeter, 0 - 400 A- Voltmeter, 0 - 20 V (accurate within 0.1 volt)
Tachometer,0 - 1,200 rpm
. Hook up a voltmeter and ammeter as shown.
NOTE: After this test, or any subsequent repair. reset
the ECM/PCM to clear any codes (see section 1 1).
Check the Starter Engagement:
'1. Remove the No. 44 (15 A) fuse from the under-hood
fuse/relay box.
2. Turn the ignition switch to START (lll) with the shift
lever in E or E position (A/T) or with the clutch
pedal depressed {M/T). The starter should crank the
eng ine.
. lf the starter does not crank the engine, go to
step 3.
. lf it cranks the engine erratically or too slowly, go
to "Check for Wear and Damage" on the next
page.
NEGATIVE TERMINAL
4.
5.
6.
7.
8.
Check the battery, battery positive cable, ground.
staner cut relay, and the wire connections for loose-
ness and corrosion. Test again.
lf the staner still does not crank the engine, go to
step 4.
Unplug the connector (BLK /VHT wire and solenoid
terminal) from the starter.
Connect a jumper wire from the baftery positive (+)
terminal to the solenoid terminal.
The starter should crank the engine.
. lf the starter still does not crank the engine,
remove it, and diagnose its internal problem.
. lf the starter cranks the engine, go to step 6.
Check the ignition switch (see section 23).
Check the starter cut relay {see section 23}.
Check the IVT gear position switch (A/T) or the clutch
interlock switch (M[).
Check for an open in the wire between the ignition
switch and starter.
(cont'd)
4-5
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Starting System
Starter Test (cont'dl
Check lor Wear and D8mage
The starter should crank the engine smoothly and
steadily. lf the staner engages, but cranks the engine
erratically, remove it, and inspect the starter drive gear
and torque converter ring gear or flywheel ring gear for
oamage.
Check the drive gear overrunning clutch for binding or
slipping when the armature is rotated with the drive
gear held. lf damaged, replace the gears.
Check Cranking Voltage and Current Draw
Cranking voltage should be no less than 8.7 volts on Ay'T
models, and 8.0 volts on M/T moders.
Current draw should be no more than 230 amperes on
A,/T models, and 200 amperes on M/T models.
lf cranking voltage is too low, or current draw too high,
check for:
. dead or low battery.
a open circuit in starter armature commutator seg,
ments.
. starter armature dragging.
. shorted armature winding.
. excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
lf speed is too low, check for:
a loose baftery or starter terminals.
. excesslvely worn staner brushes
. open circuit in commutator segments.
. dirty or damaged helical splines or drive gear.
a defective drive gear overrunning clutch.
Check Starter Disengagement
With the shift lever in @ or @ position (A,iT) or with the
clutch pedal depressed {M/T). turn the ignition switch to
START (lll). and release to ON (ll).
The starter drive gear should disengage from the torque
converter ring gear or flywheel ring gear when you
release the key.
lf the drive gear hangs up on the torque converter ring
gear or flywheel ring gear, check for
. solenoid plunger and switch malfunction.
. dirty drive gear assembly or damaged overrunning
clutch.
Starter Solenoid Test
1. Check the hold-in coil for continuity between the S
terminal and lhe armature housing (ground). The
coil is OK if there is continuity.
STARTER
B TERMINALMOUNTING NUT9 N.m 10.9 kgtm,7 tbtftl
TERMINAL
ARMATUREHOUSING(GROUND}
BLK/WHTWIRE
Check the pull in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.
2.
4-6
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Gruise Control
Component Location Index
CRUISE CONTROL UNITInput Test, page 4 38
CRUISE INDICATOR LIGHT(Built into gauge assembly)Bulb Locations. section 23
swtTcHTest, page 4-44
SET/RESUME SWITCHTest, page 4 40Beplacement, page 4-40
ACTUATOfi ASSEMBLYand VACUUM TANKTest, page 4 41Solenoid Test, page 4 44
CLUTCH INTERLOCKswrTcH {M/T)Test, page 4-43Switch poskion adjustment,section 12
Pedal Height Adjustment,section 19.
ACTUATOR CAELEAdjustment, page 4-43A/T GEAB POSITIONswlTcH (A/TlTest, section '14
+36
I
BAT
(
I
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Disconnest the lilP connector from the control unit.
Csvity WireTest condition
R€conn€ct tho 14P connGctor to the control unit.
Test: Desired resultPossible cause it result is not obtained
BRNAr'VHTUnder all conditionsCheck for resistance to groundl
There should be 80 - 120 o.
Faulty actuator solenoid
Poor ground (G202)
An open in the wire1BRNUnder all conditionsCheck for resistance to groundl
There should be 40 - 60 0.
11BRN/BLKUnder all conditionsCheck for resistance to ground:
There should be 70 - 110 O.
2GRY
lgnition switch ON (ll),
main switch ON and
brake pedal depressed,
then released
Check for voltage to ground:
There should be 0 V with the pedal
depressed and battery voltage with
the pedal released.
. Faulty brake switch. An open in the wire
BLKUnder all conditionsCheck for continuity to ground:
There should be continuity.
. Poor ground (G401). An open in the wire
5GRNMHT
Brake pedal depressed,
then released
Check for voltage to ground:
There should be battery voltage with
the pedal depressed, and 0 V with
the pedal released.
Blown No.52 1'15 Alfuse in the
under-hood fuse/relay box
Faulty brake switch
An open in the wire
LT GRN/
RED
Set button pushedCheck for voltage to ground:
There should be battery voltage.Blown No. 52 {'15 A} fuse in the
under-hood fuse/relay box
Faulty horn relay
Faulty sevresume switch
Faulty cable reel
An open in the wire7LT GRN/
BLK
Resume button pushed
10RED/BLU
lgnition switch ON lll)Attach to ground:
Cruise indicator light in the gauge
assembly should come on.
Elown bulbBlown No. 25 (7.5 A) tuse in theunder-dash fuse/relay box
Faulty dimming circuit in the gauge
assembly
An open in the wire
ELU^r'r'HT
lgnitjon switch ON {ll}and main switch ON;
raise the front of the
vehicle, block one wheel
and rotate the other
wheel slowly.
Check for voltage between the
ELUA/VHT @ and BLK O terminalsl
There should be 0 - 5 V or more-0 - 5 V or more repeatedly.
Faulty vehicle speed sensor (VSS)
An open in the wire
r3LT GRN
lgnition switch ON {ll}and main switch ONCheck for voltage to ground:
There should be battery voltage.
Blown No. 14 (7.5 A) fuse in theunder-dash fuse/relay box
Faulty main switch
An open in the wire
l4PNK
A'/T: Shift lever in E, EotE
lvl/T: Clutch pedal
releaseo
Check for continuity to ground:
There should be continuity.NOTE: There should be no continu-
ity when the shift lever is in otherpositions or when the clutch pedal is
oepresseo.
Faulty A/f gear position switch 1A,/TlFaulty or misadjusted clutch switch
fi{/r)Poor ground (G101)
An open in the wire
BLU
Start tho engine. turnthe main switch ON, anddrive the vehicle over 25
mph (40 km/h)with the
crurse control set
Check for voltage to ground:
There should be approx.5 V
. Faulty cruise control unit. Shod to ground
*: '98 - 00 models with Automatic Transmission.
4-39
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Actuator Cable Adiustment
'1.Check that the actuator cable operates smoothly
with no binding or sticking.
Start the engine. Hold the engine at 3,000 rpm with
no load (A,/T in E or E position, M/T in neutral)
until the radiator fan comes on, then let it idle.
Measure the amount of movement of the actuator
rod until ths cable pulls on the accelerator lever
(engine speed starts to increase). Free play should
be 11 t 1.0 mm (0.43 i 0.04 in).
LOCKNUT FREE PLAY: 11 t 1.0 mm
10.43 r 0.04 in)
lf free play is not within specs, loosen the locknut,
and turn the adjusting nut as requirsd,
NOTE: lf necessary, check the throttl€ cable frso
play (s€e section 11), then recheck the actuator rod
free play.
Retighten the locknut, and recheck the free play.
st
te
ACTUATOR ROD
Clutch Switch Test
1. Disconngct ths 2P connector from the clutch switch.
CLUTCH SWITCH 2P CONNECTORTerminalside ofmale terminals
2.
5.
Remove the clutch switch,
Check for continuity between the terminals accord-
ing to the table.
4. lf necessary, replace the switch or adjust the pedal
height (see section t2).
Terminal
Clutch Switch \
OEPRESSED
RELEASEDoo
4-43
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Engine Removal/lnstallation
Removal (cont'd)
17. Disconnect the power steering pressure {psp} switchconnector, and remove the wire harness clamo.
Remove the slave cylinder and clutch hose bracket(Mrr).
NOTE:
. Do not disconnect the pipe/hose assembly.. Do not operate the clutch pedal once the slavecylinder has been removed.. Take care not to bend the pipe/hose assembly.
5-6
18.
19. Disconnect the transmission ground cable (M/T).
Remove the cotter pins, then remove the steelwashers, plastic washers, shift cable, and select cablefrom the levers (M/T).
sElEcrCABI."E
21. Remove the cable bracket from the clutch housing(M/T).
GROUND CABI."E
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Powertrain Control Module Terminal Arrangement -'97 Model
FCM CONNECTOR A (32P)NOTE: Standard battery voltage is 12 V.
Wire side of lemale terminals
f€rminalnumlreJWirecolor
Telminalnama
DescriptionSignal
YELlNJ4 (No.4 FUELINJECTOR)Drives No. 4 {uel injector.With engine running: duty controlled
2BLUlNJ3 (No.3 FUELINJECTOR)Drives No. 3luel injector.
REDlNJ2 {No.2 FUELINJECTOR)Drives No.2 tuel injector.
BRNlNJl (No. l FUELINJECTOR)Drives No. 1 fuel injector.
5BLK WHTSO2SHIC (SECONDARY
HEATED OXYGEN SENSOR HEATER CONTROL)
D ves secondary heated oxygensensor heater.With ignition switch ON {ll): battery voltageWith fully warmed up engino running: dutycontrolled
6BLKAr'YHT
PO2SHTC (PRIMARY
HEATED OXYGENSENSOR HEATERCONTROL}
Drives primary heated oxygensensor heater,With ignition switch ON lll): battery voltagewith fully warmed up engine running: dutycontroll6d
I8RN/BLKLGl (LOGIC GROUND}Ground forthe PCM control circuit.Less than 1.0 V at all times
10BLKPG1 lPOWER GROUND}Ground for the PCM power circuit.
l1YEUELKIGPl lPOWER SOURCE}Power source for the PCM controlcircuit.
With ignition switch ON (ll): battery voltageWith ignition switch OFF: 0 V
12BLI(BLUIACV {IDLE AIRCONTROL VALVE}Drives IACV.With €ngine running: duty controlled
REDryEL
PCS (EVAP PURGECONTFOL SOLENOIDVALVE)
Drives EVAP purge controlsolenoid valve.
With engine running, engine coolantbelow 154'F (68"C): battery voltageWith engine running, engine coolantabove 154"F (68"C): duty controlled
16GRN/VELFLR (FUEL PUMP RELAY)Drives Iuel pump relay.0 V for two seconds after turning ignition
switch ON lll), then battery voltage
118LI(REDACC (A,/C CLUTCHRELAY}Drives Ay'C clutch relay.With comoressor ON: 0 VWith compressor OFF: baftery voltage
18GRN/ORNMIL (MALFUNCTION
INDICATOR LAMP}Drives MlL.With MIL turned ON: 0 VWith MIL turned OFF: baftery voltage
19*WHT/GRNALTC (ALTERNATOR
CONTROL}Sends alternator control signal.With tully warmed-up engine running:
battery voltageDuring driving with smallelectrical load:0 '
20YEUGRNICM (IGNITION CONTROLMODULE)Sends ignition pulse.With ignition switch ON (ll): baftery voltageWith engine running: pulses
22BRN/BLKLG2 (LOGIC GROUND}Ground tor the PCM control circuit.Less than 1.0 V at alltimes
23BLKPG2 {POWER GROUND}Ground lor the PCM power circuit.
24YEUBLKIGP2 {POWER SOURCE}Power source for the PCM controlcircuit.
With ignition switch ON (ll): battery voltage
With engine switch OFF: 0 V
27GRNFANC (RADIATOR FANCONTROL)Drives radiator {an relay.With radiator fan running: 0 VWith radiator fan stopped: baftery voltage
*: USA
{cont'd)
11-67
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Troubleshooting
PCM CONNECTOR B I25PI
Powertrain Control Module Terminal Arrangement -'97 Model (cont'dl
Wire side of female terminalsPCM CONNECTOR B I25P}NOTE: Standard battery voltage is l2 V.
1 1-68L
TerminelnumbercolorTerminalnameOescriptionSignal
1LS 1A/T CLUTCHPRESSURE CONTROLSOLENOID VALVE -)
Drives A,/T clutch pressure controlsolenoid valveWith ignition switch ON (ll): duty con-trolled
2REDLS + (A"/T CLUTCHPRESSURE CONTROLSOLENOID VALVE +)
Drives A,/T clutch pressure controlsolenoid valveWith ignition switch ON (ll)r duty controlled
38LU//EL
SHA (SHIFT CONTROLSOLENOID VALVE A)Drives shift control solenoid valve A.In 2nd, R position. in 2nd and 3rd gear inD4, D3 position: Battery voltageIn lst gear in D4, D3 position, in 4th gear
in D4 position: 0 V
4GRN/BLKLC B (LOCK-UP CONTFOLSOLENOID VALVE B)Drives lock-up control solenoidvalve B,With full lock-up; Baftery voltageWith half lock-up: duty controlled
5YELLC A (LOCK.UP CONTROLSOLENOID VALVE A)Drives lock-up control solenoidWith lock'up ON: battery voltageWith lock-up OFF:0 V
IPNKATPD3 (Ay'T GEARPOSITION SWITCH}Detects A/T gear position switchsignal. _
In D3 position:0 Vln any other position: battery voltage
11GRN/VVHT
SHB (SHIFT CONTROLSOLENOID VALVE 8}Drives shift control solenoid valve B.In 1st, 2nd position, in 1st and 2nd gear inD4, D3 position: Battery voltageIn R position, ;n 3rd gear in 04, D3, in 4thgear in D4 position: 0 V
12WHT/BEDILU (INTERLOCK
CONTROL UNITiDetects interlock control unh signal.With ignition switch ON (ll)and brakepedal depressed: battery voltage
GRN/BLKD4IND (04 INDICATORLIGHT}Drives Dl indicator light.With D4 indicator light turned ON: batteryvoltageWith D4 indicator light turned OFF: 0 V
14NMSG (MAINSHAFT
SPEED SENSOR GROUND}Ground tor mainshaft speed sensor.
REDNM (MAINSHAFT SPEEDSENSOR)Detects mainshaft speed sensorsrgnal,With engine running: pulses
16ATPR (A"/T GEARPOSITION SWITCH)Detects A/T gear position switchsrgnal.InRposition:0VIn any other position: battery voltage
1'lBLUATP2 (A./T GEARPOSITION SWITCH)Detects A/T gear position switchsrg nal,In 2nd position: 0 VIn any other position: battery voltage
18BRNATP1 (4,,/T GEARPOSTTTON SWTTCH)Detects A/T gear position switchsrg nal,ln lst position: 0 VIn any other position: battery voltage
22GBNNCSG (COUNTERSHAFT
SPEED SENSOR GROUND)Ground tor countershaft speedsensor,
23BLUNC (COUNTERSHAFT
SPEED SENSOR)Detects countershaft speed sensorsrgnal.With agnition switch ON (ll), and lrontwheels rotating: pulses
24YELATPD4 (M GEARPOSITION SWITCH)Detects A,/T gear position switchsrgnal.In D4 positionr 0 VIn any other position: battery voltage
25LT GRNATPNP {A/T GEARPOSITION SWITCH)Detects A/T gear position switchsignal.In park or neutral:0 VIn any other position: about 5 V
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