Safety Recall: 2023 Honda CR-V FHEV e-CVT Replacement

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Service Bulletin 23-075 August 18, 2023 Version 1 Safety Recall: 2023 CR-V FHEV e-CVT Replacement AFFECTED VEHICLES Year Model Trim VIN Range 2023 CR-V Hybrid Check the VIN status for eligibility BACKGROUND A resolver is a rotation angle sensor for controlling an electric motor. The generator motor resolver covers in affected vehicles may have been damaged during the manufacturing process. Over time, this damage may cause the cover to separate from the resolver, potentially contacting and cutting the resolver wire harness and leading to resolver malfunction. This malfunction may cause the illumination of the MIL, the engine to transition to EV mode with range limited by battery capacity, and/or prevent the vehicle from restarting. CUSTOMER NOTIFICATION Owners of affected vehicles will be sent a notification of this safety recall. Do an In VIN status inquiry to verify eligibility. Some vehicles affected by this campaign may be in your new or used vehicle inventory. Failure to repair a vehicle subject to a recall or campaign may subject your dealership to claims or lawsuits from the customer or anyone else harmed as a result of such. To see if a vehicle in inventory is affected by this safety recall, do a VIN status inquiry before selling it. CORRECTIVE ACTION Replace the e-CVT transmission. CUSTOMER INFORMATION:The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer. © 2023 American Honda Motor Co., Inc. — All Rights Reserved Page 1 of 44 PARTS INFORMATION Part Name Part Number Quantity ATR Kit 20041-69M-A02RM 1 Exhaust Pipe Gasket 18302-SP0-003 1 Exhaust Pipe Gasket 18303-T2B-A01 1 Drain Gasket (TOYO) 19012-PD2-004 1 Set-Ring (30X2.2) (Set Ring) 44319-S0X-A01 1 Set-Ring (30X2.2) (Set Ring) 44319-SD4-010 1 Bolt (12 Point 8X21) 90113-S10-000 4 Bolt-Washer (14X85) 90130-T20-A00 1 Flange Bolt (14X33) 90164-T20-A00 2 Flange Bolt (12X50) 90167-TBA-A00 2 Flange Bolt (14X50) 90168-SMG-E01 3 Flange Bolt (14×105) 90175-3A0-A00 1 Bolt-Washer (14X85) 90179-T20-A01 6 Flange Bolt (14X50) 90181-TLA-A00 2 Self-Lock Nut (10mm) 90212-SA5-003 6 Self-Lock Nut (12mm) (Clinch) (Sato Rashi) 90215-SB0-003 6 Spindle Nut 90305-S3V-A11 2 Flange Nut (12mm) 90371-TBA-A00 1 Drain Plug Washer (18mm) 90471-PX4-000 1 O-Ring (92X2.2) (Arai) 91304-PRH-003 1 Drain Plug Washer (20mm) 94109-20000 1 Split Pin (3.0X22) 94201-30220 2 Page 2 of 44 1. To order a replacement transmission, fill out the AT/CVT order form under Reman Parts/Special Orders section on the iN. NOTE: • If you have not contacted Tech Line, then use the last 7 digits of the VIN for the Tech Line Reference Number. • If the 11th character of the VIN has a letter instead of a number, replace it with a zero. • Select Tech Line Agent Name—Tech Line. Page 3 of 44 2. Fill out the AT/CVT Order Form under Reman Parts/Special Orders section on the iN. NOTE: Once the CVT order has been received, your order will be reviewed by RPO. Additional requests and images may be required by RPO before release of the CVT. REQUIRED MATERIALS Part Name Part Number Quantity Super High Temp Urea Grease 08798-9002 1 (1 container can repair up to 20 vehicles) HEVF Type-1 08200-9022 5 Honda Long Life Antifreeze/Coolant Type 2 OL999-9011 1 Page 4 of 44 TOOLS INFORMATION Tool Part Number Description 7MAC-SL00102/ 07MACSL00202 Ball Joint Remover 07AAF-SDAA100/07AAESJAA100 Protector 07AAK-SNAA120 Universal Lift Eyelet AAR-T1256 Engine Hanger VSB02C000016 Subframe Holder 070AG-SJAA10S Subframe Alignment Pin WARRANTY CLAIM INFORMATION Operation Number Description Flat Rate Time Defect Code Symptom Code Template ID Failed Part Number 2181DC CR-V Hybrid e-CVT Replace (Includes alignment) 5.8 hr 6RX00 HFF00 A23075A 20041-69K-A02 Page 5 of 44 REPAIR PROCEDURE 1. Set the wiper arms to service position. 1.1. Turn the vehicle to the ON mode. 1.2. Turn the vehicle to the OFF mode. Within 10 seconds after turning the vehicle to the OFF mode, hold the windshield wiper switch at MIST position for 2 seconds or more. 1.3. Release the wiper/washer switch. The wiper should stop at the service position. 2. Open the tailgate. 2.1. Press the outer handle and lift open the tailgate. 3. Open the hood. 3.1. Pull the hood release handle under the driver’s side lower corner of the dashboard. Page 6 of 44 3.2. Push the hood latch lever (located under the front edge of the hood to the center) to the side and raise the hood. Once you have raised the hood slightly, you can release the lever. 3.3. Lift the hood to open. 4. Disconnect the 12 volt battery terminals. 4.1. Make sure the vehicle is in the OFF (LOCK) mode. 4.2. Disconnect and isolate the negative battery terminal, with the 12 volt battery sensor attached, from the 12 volt battery. 4.3. Open the positive terminal cover. Page 7 of 44 4.4. Disconnect the positive terminal from the 12 volt battery. NOTICE • Always disconnect the negative side first. • To protect the 12 volt battery sensor connector from damage, do not hold it when removing the terminal. • Do not disconnect the 12 volt battery sensor from the cable. 5. Remove the PCU coolant expansion tank cap. 6. Remove the cargo floor lid. Page 8 of 44 7. Remove the service plug. The power cables carry high voltage when the electric powertrain is energized. To avoid serious injury from electrical shock, do not turn on the system with the power cables disconnected. 7.1. Remove service plug lid. 7.2. Push the tab and cancel the catch. Then, slide the tab to the unlocked position until you hear a click. 7.3. Raise the lever and remove the service plug. 7.4. Wrap the service plug base with insulating tape. Page 9 of 44 8. Lift the vehicle to comfortable working height. 8.1. Position the lift pads under the vehicle’s front and rear support points. NOTE: Be sure the lift pads are properly placed to avoid damaging the vehicle. 8.2. Raise the lift a few inches, then rock the vehicle gently to be sure it is firmly supported. 9. Remove the front wheels. Page 10 of 44 10. Remove the engine undercover. 11. Drain the transmission fluid. 11.1. Remove the drain plug and the sealing washer. Page 11 of 44 12. Drain the PCU coolant. 12.1. Attach a tube to the drain valve, then loosen the radiator drain plug to drain the PCU coolant. 12.2. When the coolant has drained completely, remove the drain plug and install a new O-ring. 12.3. Reinstall the drain plug and tighten. 13. Remove exhaust pipe. Page 12 of 44 14. Disconnect the front suspension area parts. 14.1. Front stabilizer link ball joint (bottom fastener on both sides). 14.2. Remove both front lower arm ball joint fasteners. 14.3. Remove both front lower arm bolts (front lower arm assembly). Page 13 of 44 15. Disconnect both tie-rod end ball joints. 15.1. Separate both tie-rod end ball joints from the knuckles. 15.1.1. Install a hex nut or a ball joint thread protector onto the threads of the ball joint. NOTE: Make sure the nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint pin. 15.1.2. Apply grease to the ball joint remover on the areas shown. This will ease the installation of the tool and prevent damage to the pressure bolt threads. Page 14 of 44 15.1.3. Loosen the pressure bolt and install the ball joint remover. NOTE: • Insert the jaws carefully, making sure not to damage the ball joint boot. • Fasten the safety chain securely to the suspension arm or the subframe. Do not fasten it to a brake line or wire harness. 15.1.4. Adjust the jaw spacing by turning the adjusting bolt. 15.1.5. Make sure the head of the adjusting bolt is in the position to allow the jaw to pivot. 15.1.6. Tighten the pressure bolt until the ball joint pin pops loose from the ball joint connecting hole. If necessary, apply penetrating type lubricant to loosen the ball joint pin. NOTE: Do not use pneumatic or electric tools on the pressure bolt. 16. Disconnect the wire harness and connectors. 16.1. Disconnect the EPS connectors. Page 15 of 44 16.2. Disconnect e-CVT transmission harness connectors. 16.3. Remove the e-CVT transmission ground cable. 17. Lower the vehicle. 18. Remove the engine cover. Page 16 of 44 19. Remove the air cleaner area parts. 19.1. Remove the inlet chamber assembly. 19.2. Remove the resonator chamber assembly. Page 17 of 44 20. Remove the front grille cover. 21. Remove the cowl cover. 21.1. Disconnect the washer spray tube. 21.2. Remove the windshield wiper arms. Page 18 of 44 21.3. Remove both front fender trims. 21.4. Remove both hood hinge covers. 21.5. Remove the cowl cover. Page 19 of 44 21.6. Disconnect the connector from PCU and wrap the items with insulating tape. NOTE: • Cover the connector using a rag or shop towel. • Do not wrap around the insulating tape on the sealed part. Page 20 of 44 22. Remove the PCU assembly. NOTE: • Immediately clean off oil, coolant, dirt, or grease to the terminal parts or the sealed parts. • Do not stick adhesive tape, or anything similar, directly to the terminal parts or the sealed parts. Page 21 of 44 23. Remove the upper transmission mounting bolt. 24. Remove or move the radiator area parts: 24.1. Expansion tank lower bracket 24.2. Water filler NOTE: Do not disconnect the water bypass hoses. Page 22 of 44 25. Disconnect the shift cable. 26. Remove the water hose bracket. 27. Remove the under-hood fuse/relay box bracket. Page 23 of 44 28. Loosen the under-hood fuse/relay box. 29. Disconnect the steering joint. 29.1. Remove the steering joint cover. 29.2. Set the steering column accordingly: 1. Steering column full tilt down position. 2. Steering column full telescopic out position. Page 24 of 44 29.3. Disconnect the steering joint. NOTICE • If the center guide is in place and has not moved, leave it in place. • If the center guide has come off, discard it. 30. Install the engine support hanger. NOTE: • Be careful when working around the windshield. • Be careful not to damage the hood opener cable when installing the engine support hanger at the front bulkhead. 30.1. Remove both front damper caps. Page 25 of 44 30.2. Install the universal lifting eyelet. NOTE: Make sure the universal lifting eyelet does not interfere with the surrounding parts. 30.3. Install the engine support hanger onto the vehicle. 30.4. Attach the hook to the slotted hole in the universal lifting eyelet. 30.5. Tighten the wing nut by hand to support the engine/transmission. Page 26 of 44 31. Remove the transmission mount. NOTE: Do not remove the bolt shown below from the transmission mount. If the bolt is removed, the transmission mount must be replaced as an assembly. 32. Remove the compliance bushing outer bolt. Page 27 of 44 33. Remove the transfer assembly. 33.1. Make reference marks across the No. 1 propeller shaft and the companion flange shaft. 33.2. Disconnect the propeller shaft from the transfer assembly. 33.3. Remove the transfer assembly. Page 28 of 44 34. Remove the flywheel cover. 34.1. Rotate the crankshaft pulley to remove the eight bolts from the drive plate. 35. Remove the left and right axle shafts. Page 29 of 44 36. Remove the intermediate shaft. 36.1. Disconnect the torque rod from the engine. 37. Attach the subframe adapter to the front subframe. 38. Remove the subframe bolts, then lower the subframe. Page 30 of 44 39. Disconnect the transmission fluid cooler hose from the transmission. 40. Remove the e-CVT transmission. 40.1. Remove the remaining transmission mounting bolts. 40.2. Check that the transmission is free of hoses and electrical wiring. 40.3. Using a transmission jack, hold the transmission as shown. Page 31 of 44 40.4. Remove the transmission carefully. NOTICE Be careful not to drop the flywheel. 41. Remove the dowel pin, if captured on the original transmission, and transfer it to the replacement unit. 42. Transfer the skid plate. 43. Install the new transmission. Tighten the lower mounting bolts to 64 N·m (47 lb-ft). Page 32 of 44 44. Reinstall the transmission fluid cooler hoses. 45. Reinstall the intermediate shaft. 46. Reinstall the left and right driveshafts. 46.1. Apply the Super High Temp Urea Grease (P/N 08798-9002) or equivalent, then remove the grease from behind the splined grooves at intervals of 2–3 splines so that air can bleed from the intermediate shaft. Page 33 of 44 46.2. Apply the specified grease to the contact area of both the outboard joint and front wheel bearing. 46.3. Install the driveshafts. 47. Reinstall the subframe using new bolts. Torque the new bolts according to the sequence below. Page 34 of 44 48. Reconnect the torque rod to the engine. 49. Install a new bolt at the compliance bushing. 50. Rotate the crankshaft to reinstall the eight bolts securing the drive plate to the flywheel. Page 35 of 44 51. Reinstall the flywheel cover. 52. Reinstall the transfer assembly. 53. Reattach the propeller shaft. Page 36 of 44 54. Reinstall the upper transmission mounting bolt. 55. Loosely reinstall the transmission mount. Page 37 of 44 56. Reinstall the mounting bolts and support nuts and torque to specification and sequence. NOTICE Failure to follow this sequence may cause excessive noise and vibration which can reduce engine mount life. 57. Remove the engine support hanger. 58. Reconnect the steering joint. 59. Reinstall the remaining parts in reverse order of removal. Page 38 of 44 60. Service plug. 60.1. Insert the service plug into the service plug base, then lower the lever. Push and slide the tab to the locked position while holding the lever. NOTICE Confirm that the service plug is securely locked and the lever does not come up. 60.2. Install the service plug lid. Page 39 of 44 61. Reconnect the 12 volt battery. 61.1. Clean the 12 volt battery terminals. 61.2. Connect the positive terminal to the 12 volt battery. 61.3. While holding down the terminal, torque the clamp to 4.4 N·m (3.2 lb-ft). 61.4. Connect the 12 volt battery sensor/negative terminal to the 12 volt battery. NOTE: To protect the 12 volt battery sensor connector from damage, do not hold it when installing the terminal. 61.5. Make sure both 12 volt battery terminals are at level or below the battery post. Page 40 of 44 61.6. Make sure the connection is tight by wiggling the terminals back and forth. NOTE: • To protect the 12 volt battery sensor connector from damage, do not hold it when removing the terminal. • If you cannot properly get the terminals to the proper condition or the terminals are not secure, replace either the terminal or 12 volt battery. Do not tighten the clamps beyond their specified torque. 61.7. Apply multipurpose grease to the terminals to prevent corrosion. 62. Reinstall the shift cable and adjust. 62.1. Push the shift cable until it stops, then release it. NOTE: Do not hold the shift cable guide to adjust the shift cable. 62.2. Pull the shift cable back one step from the P position so that the shift position is in R. 62.3. Turn the vehicle to the ON mode. 62.4. Check that the shift position indicator in the gauge control module display is in R. 62.5. Turn the vehicle to the Off (LOCK) mode. Page 41 of 44 63. Refill the PCU coolant. 63.1. Pour the PCU coolant until the expansion tank is filled to the MAX mark. NOTE: • Always use Honda Long Life Antifreeze/Coolant Type 2, and if necessary add Honda Extreme Cold Weather Antifreeze/Coolant Type 2. Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail. • Honda Long Life Antifreeze/Coolant Type 2 is a mixture of 50% antifreeze and 50% water. Honda Extreme Cold Weather Antifreeze/Coolant Type 2 is 100% concentration coolant. • Do not add water to either coolant. 63.2. Bleed the air from the PCU coolant with the HDS. Select the following menu buttons on the HDS screen in sequence: 1. Electric Powertrain (System Selection Menu) 2. Adjustment 3. Coolant Air Bleeding 4. START NOTE: • Pour coolant as needed when the coolant level drops. If the coolant level keeps changing or bubbles are seen even after 10 minutes, continue to drive the EWP until the coolant level stabilizes and bubbles cease. • When the POWER SYSTEM indicator comes on, clear the DTC with the HDS, then do “Coolant Air Bleeding” step again. 63.3. After 10 minutes, press STOP to finish driving the EWP forcibly. 63.4. Check the coolant level and add coolant as necessary until it is at the MAX mark, then install the expansion tank cap. 64. Refill the transmission fluid. 64.1. Remove the filler plug with the sealing washer. 64.2. Refill the e-CVT transmission with the recommended fluid, through the filler plug hole, to the proper level. 64.3. Temporarily install the filler plug with the sealing washer. 65. Check transmission fluid level. 65.1. Turn the vehicle to the OFF (LOCK) mode. Page 42 of 44 65.2. Turn the vehicle to the ON mode without stepping on the brake pedal. 65.3. Place the transmission in the P position/mode, then press the accelerator to the floor, twice. 65.4. Press the brake pedal, shift the transmission to the N position/mode, then press the accelerator pedal to the floor, twice. 65.5. Press the brake pedal, shift the transmission to the P position/mode, then press the accelerator pedal to the floor, twice. 65.6. Press the power switch while pressing down on the brake pedal. The vehicle is now in the maintenance mode and the engine will start. 65.7. Shift the transmission to D position/mode; drive the vehicle above 12 mph (20 km/h) for at least 1 minute. NOTICE Do not apply the brake hard when working on a running vehicle. It may cause damage to the driveline. 65.8. Turn the engine off. 65.9. Remove the filler plug with the sealing washer. 65.10. Check transmission fluid level. If needed, add fluid to the proper level. 65.11. Install the filler plug with a new sealing washer. Fluid Amount Details Application Operation Specified Amount With AWD At Fluid Change 2.8 L (3.0 US qt) At Overhaul 5.1 L (5.4 US qt) 66. Do a wheel alignment. 67. Do the VSA Sensor Neutral Position Memorization Procedure. Select the following menu buttons on the HDS screen in sequence: 1. ABS/VSA (System Selection Menu) 2. Adjustment 3. All Sensor Page 43 of 44 68. Do the Motor Rotor Position Calibration Procedure. Select the following menu buttons on the HDS screen in sequence: 1. ICM (System Selection Menu) 2. Adjustment 3. Motor Rotor Position Sensor Learning 69. Test drive vehicle. 70. California residents only: Fill out a Vehicle Emissions Recall – Proof of Correction certificate, and use HFF as the recall number. Have the service advisor give the certificate to your customer, and advise him or her to keep it as proof that the recall was completed. Your customer will need to submit this certificate to the DMV only if the DMV requests it. If you need more certificates, use reorder number Y0657. END Page 44 of 44

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