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honda cr v 19997 2000 User Manual

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    Page
    of 1395
    							
    Engine Electrical
    Speciaf Tools ............. 4-2
    Starting System
    Component Location Index ............ 4-3
    Circuit Diagram ................................ 4-4
    Starter Test ........... 4-5
    Starter Solenoid Test ...................... 45
    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 .......................,........ 440
    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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    Special Tools
    Ref. No.Tool NumberDescriptionOty I Page Reference
    o-o
    o
    A973X - 041 XXXXX
    07JGG - 001010A
    07PAZ - 0010100
    Vacuum Pump/Gauge, 0 30 in.Hg.
    Belt Tension Gauge
    SCS Service Connector
    4-41
    434
    4-16* Included in the Belt Tension Gauge Set, T/N 07JGG - 0010004
    o@
    o
    4-2
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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
    Circuit Diagram
    IGN TIONSWITCH
    / BAI \-+o cf-.|
    \i7 IBLKMHT
    II
    I
    tl
    tlELKMHT BLKWHT
    STARTEFCUl RELAY
    I A/T GEAR PosrroN!i swrTcH (A/T) |l/oN EorN |l p.siton / :!-- -_ --___J
    f;---lI TNTERLooK I
    fYlyl, I
    GRY
    IGRN
    8LK
    Gl0l
    UNDER.HOOD FUSE/RELAY 8OX
    N0.41 (100A) N0.42 (40A)
    -.1
    BLKRED
    I
    IGNITION CONTROLMOoULE ( CM)
    STARTEB(Field wnd ng lype)
    4-4
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    Starting System
    Starter Test
    NOTE: The air temperature must be between 59 and100F (15 and 38C) before testing.
    Recommended Procedure:
    . Use a staner system tester.
    . Connect and operate the equipment in accordance
    with the manufacturers 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.
    (contd)
    4-5
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    Starting System
    Starter Test (contdl
    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 AyT
    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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    RE
    Starter Replacement
    1.
    B TERMINALMOUNNNG NUTI N.m (0.9 kgl.m,7 rbt ftl
    Remove the two bolts holding the starter. then
    remove the starter.
    4. Install in the reverse order of removal. When
    installing the starter cable, make sure that the
    crimped side ofthe ring terminal is facing out,
    Crimped side of ringterminal
    TERMINAL
    Connect the battery positive cable and negative cable
    to the batterv.
    Disconnect the battery negative cable.
    Disconnect the starter cable from the B terminal on
    the solenoid. then disconnect the BLK/WHT wire
    from the S terminal.
    STARTER
    l0 x 1.25 mm4,1 N.m {4.5 kgf.m,33 tbt.ftl
    5.
    o
    Field Winding Test
    Check for continuity between the brushes. lf theres
    no continuity, replace the armature housing,
    Check for continuity between each brush and the
    armature housing {ground). lf there is continuity.
    replace the armature housing.
    t.
    ERUSHES
    4-7
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    Starting System
    Starter Overhaul
    STARTER SOLENOID
    STARTER SOLENOIDTest, page 4 6
    OVEBRUNNINGCLUTCH
    w
    -6^lMOLYBDENUMDISULFIDE
    SPRING CLIPReplace.
    BBUSH HOLDERTest, page 4-12
    ARMATURE HOUSING
    ARMATUREInspection and Test. page 4-10
    .....:|@{MOLYBDENUMDISULFIDEBAUSHInsPeclon, page 4-9
    ARUSH
    GEAR HOUSING
    4-A
    END COVER
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    Brush Inspection
    Measure the brush length. lf it is not within the service
    limit, replace the brush (or brush holder assembly).
    Brush Lsngth
    Standard {Newl: 14.0 - I1.5 mm (0.55 - 0.57 inl
    Servico Limit: 9.0 mm (0.35 in)
    NOTE: To seat new brushes after installing them in their
    holders. slip a strip of #500 or #600 sandpaper, with the
    grit side up, over the commutator and smoothly rotate
    the armature. The contact surface of the brushes will be
    sanded to the same contour as the commutator.
    BRUSH
    4-9
    2.
    1.
    Overrunning Clutch Inspection
    Slide the overrunning clutch along the shaft. Does it
    move freely? lf not, replace it.
    Rotate the overrunning clutch both ways. Does it
    lock in one direction and rotate smoothly in
    reverse? lf it does not lock in either direction or it
    locks in both directions, reDlace it.
    3.lf the starter drive gear is worn or damaged, replace
    the overrunning clutch assembly; the gear is not
    available separately.
    Check the condition of the torque converter ring gear
    or the flywheel ring gear if the starter drive gear
    teeth are damaged.
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    Starting System
    Armature Inspection and Test
    1. Inspect the armature for wear or damage due to
    contact with the field winding. lf there is wear or
    damage. replace the armature.
    Check the commutator surface. lf the surface is dirty
    or burnt, resurface with emery cloth or a lathe with-
    in the tollowing specifications, or recondition with
    #500 or #600 sandDaoer.
    lnspect for damage.
    4-10
    3. Check the commutator diameter. lf commutator
    diameter is below the service limit, reolace the
    armalure.
    Commutator Diameter
    Standard (Newl: 27.9 - 28.0 mm (1.09 - 1.10 in)
    Service Limilr 27.0 mm (1.06 inl
    lf the commutator runout is within the service
    limit, check the commutator for carbon dust or
    brass chips between the segments.
    lf the commutator runout is not within the ser-
    vice limit, replace the armature.
    Commutator Runout
    Standard (Newl: 0 - 0.02 mm (0 - 0.0008 in)
    Service Limit: 0.05 mm {0,002 inl
    4. Measure the commutator runout.
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