honda cr v 19997 2000 User Manual
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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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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 www.emanualpro.com
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. www.emanualpro.com
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. www.emanualpro.com