Exhaust HONDA CR-V 1997 RD1-RD3 / 1.G User Guide

Valves, Valve Springs
and Valve Seals
13. Measure the cam lobe height.
Cam Lobe Height Standard (Newl'97 - 98 models:
INTAKE: 33.20,1mm (1.3072 in)
EXHAUST: 33.528 mm (1.3200 inl'99 - 00 models:
INTAKE: 33.716 mm 11.327t1in)
EXHAUST:33.528 mm (1.3200 in)
Inspect this area lor wear.
Removal
ldentify the valves and valve springs as they are
removed so that each item can be reinstalled in its origi-
nal Dosition.
1. Using an appropriate-sized socket and plastic mallet.
lightly tap the valve retainer to loosen the valve keeP
ers before installing the valve spring compressor'
2. Install the spring compressor. Compress the spring
and remove the valve keeper.
VALVE SPRING COMPRESSORKD No. 3&!. whh *'5 JAW o.
VALVE SPRING COMPRESSORATTACHMEUT07757 - PJ1010A
(cont'd)
6-23
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Valve Guides
Valve Movement
1. Measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust (wobble method),
lntake Valve Stem-to-Guide Clearance:
Standard (Newl: 0.04 - 0.10 mm
(0.002 - 0.004 in)
Service Limit 0.16 mm (0.006 in)
Exhaust Valve Stem-to-Guide Clearance:
Standard {Newl: 0.10 - 0.16 mm
(0.004 - 0.006 inl
Service Limit: 0,22 mm (0.009 inl
lf the measurement exceeds the service limit,
recheck using a new valve.
lf the measurement is now within the service limit,
reassemble using a new valve.
lf the measurement still exceeds the limit, subtract the
O.D. of the valve stem, measured with a micrometer,
from the l.D. of the valve guide, measured with an
inside micrometer or ball gauge.
Take the measurements in three places along the
valve stem and three places inside the valve guide
The difference between the largest guide measure-
ment and the smallest stem measurement should
not exceed the service limit.
lntake Valve Stem-to-Guide Clearance:
Standard (New): 0.02 - 0.05 mm
{0.001 - 0.002 in)
Service Limit: 0.08 mm (0.003 in)
Exhaust Valve Stem-to-Guide Clearance:
Standard (New): 0.05 - 0.08 mm
(0.002 - 0.003 in)
Service Limit: 0.11 mm (0.004 in)
2.
3.
Replacement
1. As illustrated below, use a commercially available
air-impact valve guide driver attachment modified
to fit the diameter of the valve guides. In most
cases, the same procedure can be done using the
sDecial tool and a conventional hammer.
VALVE GUIDE DRIVER(Commerciallv available)
2.
3.
(0.25 inl I
_,1-r
,_T-_lrl
'11.3 mm(0.{,r in}
orVALVE GUIDE DRIVER, 6.6 mm0t9a:I - G5t01q)
Select the proper replacement guides. and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300"F (150"C). Monitor the temperature with
a cooking thermometer. Do not get the head hofter
than 300'F (150"C); excessive heat may loosen the
valve seaIs.
6.4 mm
CAUTION: To avoid burns, uss heavy gloves when
handling the heated cylinder head.
(cont'd)
6-25
*]-- sz mm' l2.21inl
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Valve Guides
Replacement (cont'dl
5.
Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (O.l
in) towards the combustion chamber. This willknock off some of the carbon and make removaleasier. Hold the air hammer directly in line with thevalve guide to prevent damaging the driver.
CAUTION: Always wear satety goggles or a faceshield when driving valve guidss.
Turn the head over and drive the guide out towardthe camshaft side of the head.
li a valve guide won't move, drill it out with a 8.0mm (5/16 in) bit, then try again. Dritt guides onty inextreme cases; you could damage the cylinder headif the guide breaks.
Remove the new guide(s) from the freezer, one at atlme, as you need them.
6.
7.
6-26
'o C'
8. Apply a thin coat of clean engine oil to the outsideof the new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified installed height. lfyou have all 16 guides to do, you mav have toreheat the head.
Valve Guide Installed Height:
Intake: 13.75 - 1i1.25 mm
{0.5,[1 - 0.561 in)
Exhaust: 15.75 - 16.25 mm(0.620 - 0.640 inl
ATTACHMENT
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Cylinder Head
Reaming
NOTE: For new valve guides only.
1. Coat the reamer and the valve guide with cutting oil.
2. Rotate the reamer clockwise the full length of the
valve guide bore.
Continue to rotate the reamer clockwise while
removing it from the bore.
Thoroughly wash the guide in detergent and water
to remove anY cutting residue.
Check clearance with a valve (see page 6-25).
Verify that the valves slide in the intake and exhaust
valve guides without exerting pressure.
3.
4.
5.
6.
vALvE GUIDE REAMER,6.6 mm0798i1 - 657010O
REAMER HANDLE
e
Warpage
NOTE: lf camshaft-to-holder oil clearances (see page G22)
are not within specification, the head cannot be resur-
faced.
lf camshaft-to-holder oil clearances are within specifica-
tions, check the head for warpage. Measure along the
edges, and three ways across the center.
. if warpage is less than 0.05 mm (0.002 in) cylinder
head resurfacing is not required
lf warpage is between 0.05 mm (0.002 in) and 0.2 mm
(0.008 in), resurface cylinder head.
Maximum resurface limit is 0.2 mm (0.008 in) based
on a height of 132.0 mm (5.20 in).
Cylind€r Hesd Height:
Standard {New}: 131.95 - 132.05 mm
15.195 - 5.199 inl
PRECISION STRAIGHT EDGE
6-27
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Valve Seats
Reconditioning
lf the guides are worn (see page 6-25), replace them (seepage e25) before reconditioning the valve seats.
1. Renew the valve seats in the cylinder head using avalve seat cutter.
Carefully cut a 45o seat, removing only enoughmaterialto ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutterand the lower edge of the seat with the 60" cutter.Check width of seat and adjust acco.dingly.
Make one more very light pass with the 45o cutter toremove any possible burrs caused bv the other cut-ters.
Valve Seat Width (lntake and Exhaust):
Standard {N.w}: 1.25 - 1.55 mm (0.049 - 0.051 in)Servica Limit: 2.0 mm (0.08 in)
o
o
5. After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue compound to the valve
face, and insert the valve in its original location in
the head, then lift it and snap it closed against the
seat several times.
ACTUALSEATINGSURFACE
VALVESEAT
7.
PRUSSIAN
The actual valve seating surface, as shown by the
blue compound, should be centered on the seat.. lf it is too high (closer to the valve stem), you
must make a second cut with the 60" cutter tomove it down, then one more cut with the 45"
cutter to restore seat width.
. lf it is too low (closer to the valve edge), you
must make a second cut with the 30. cutter tomove it up, then one more cut with the 45. cutter
to restore seat width.
NOTE: The final cut should alwavs be made withthe 45" cutter,
Insert the intake and exhaust valves in the head,
and measure valve stem installed heioht.
Intake Vslve Siem Instslted Height:
Standard {Newl: it0.765 - 41.235 mm
11.6049 - 1.6234 inl
Sarvico Limit: itl.il85 mm (1.6333 in)
Exhaust Valve Stem Installed H6ight:
Standard {New}: 42.755 - €.235 mm
11 .61137 - 1 .7022 inl/(|.,185 mm (1.7120 in)
VALVE STEMINSTALLED HEIGHT
8. lf valve stem installed height is over the servicelimit. replace the valve and recheck. lf it is still overthe service limit. replace the cylinder head; thevalve seat in the head is too deeo.
Servico Limit:
f-]
6-28
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Valves, Valve Springs and Valve Seals
lnstallation
Coat the valve stems with oil. Insert the valves into
the valve guides.
Check that the valves move up and down smoothly.
Install the spring seats on the cylinder head.
Install the valve seals using the special tool.
NOTE: Exhaust and intake valve seals are not inter-
1.
changeable.
WHITESPRING
BLACKSPRING
INTAKE VALVE SEALEXHAUST VALVE SEAL
VALVE GUIDESEAL INSTALLER
lCommercially available)KO3372 or equival€ntot07GAD - PH70100
VALVE SPRING COMPRESSOR
lComm6rcially available)KD No. 383, with *35 JAw or
7.
Install the valve spring and valve retainer. Place the
end of the valve spring with closely wound coils
toward the cylinder head,
Install the valve spring compressor. Compress the
spring, and install the valve keepers.
VALVE SPRIT{G OOMPfi ESSORATTACHMENT0775' - PJ1010A
Lightly tap the end of each valve stem two or three
times with a plastic mallet to ensure proper seating
of the valve and valve keepers, Tap the valve stem
only along its axis so you do not bend the stem.
PLASTE
6-29
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Cylinder Head
Installation
Installthe cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surfaces.
2. Clean the oil control orifice. Install the cylinder headgasket, dowel pins and the oil control orifice on thecylinder block. Always use a new cylinder head gas-ket.
CYLII{DER HEADGASKETR€place.
DOWEL PIN
O.RINGRoplace.
DOWELPIN
OIL CONTBOLORIFICEClean.
Apply clean engine oil to the bolt threads and underthe bolt heads.
4. Tighten the cylinder head bolts in two steps. In thefirst step tighten all bolts, in sequence, to about 29
N.m {3.0 kgf.m,22 lbf.ft); in the finat step, tighten inthe same sequence to 85 N.m (8.7 kgf.m,63 lbf.ft).
Use a beam-type torque wrench. When using a pre-
set-type torque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Tighten the intake manifold mounting bolts (see
page 6-21).
Install the exhaust manifold bracket. and tighten thenew self-locking nuts (see page 6-20).
6-30
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7.Place the rocker arms on the pivots and the valve
stems. Put the rocker arms in their original posi-
lrons.
lnstall the camshafts, then install the oil seals with
the open side (spring) facing in. Make sure that the
keyways on the camshafts are facing up and the No.
1 piston is at TDC.
Clean and dry the cylinder head mating surfaces.
Apply liquid gasket (P/N 08718 - 0001 or 08718 -
0OO3) to the head mating surfaces of the No. 1 and
No. 6 camshaft holders on both the intake and
exhaust side.
L
No. I
EXHAUST
II{TAKE
Apply liquid gasket to th€ shaded areas.
't't,
'10. lnstall the camshaft holders.
NOTE:
o "1" or "E' marks are stamped on the camshaft
holders.
. The arrows marked on the camshaft holders
should point at the timing belt.
Tighten each bolt in two steps to ensure that the
rockers do not bind on the valves.
Wipe off the excess liquid gasket from the No. 1 and
No. 6 camshaft holders with a shop towel,
Specified torque:
9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
Apply engine oil to the bolt ihreads.
I?,ITAKE
EXHAUST
(cont'd)
6-31
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lllustrated Index (cont'd)
NOTE: New rod bearings
(see pages 7-91.
must be selected by matching connecting rod assembly and crankshaft identification markings
PISTON INSTALLANON DIRECTION:
Lubricate all internal parts with engine oil
during reassembly.EXHAUST
INTAKE
PISTON RINGSReplacement. page 7-18Measurdment, page 7-17Alignm€nt, page 7-18
PISTONInspection, page 7-12
l1\AAtr\
\9q9Q9e/
PISTON PINRemoval, page 7-14
Installation, page 7-15Inspection. page 7-16
ENGINC BLOCKCylinder bore inspection. pago 7-13
Warpage inspoction, Page 7-'13
CONNECTING ROD BEARING CAPlnstallation, page 7-20NOTE: Install the caps so thebearing recess is on thesame side as the recessin the rod.
CONNECTING ROD CAP8 x 0.75 mm31 N.m {3.2 kgl.m.23 tbf.ftl
CONNECTING
COiINECI'ING RODBEARINGSClearance, page 7-8
Solection. page 7-9
NUT
End play, page 7-6Selection, page 7-14
Inspect the top ot each cylinder borefor carbon build up or a ridgebelore removing the piston.
Remove the ridge if necessary, page 7-10Apply engine oil to the bolt threads.NOTE: After torquing each bearingcap, rotate the crankshaft to check forbinding.
7-4
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Oil Filter
The numbers in the middle of the API Service label tell
you the oil's SAE viscosity or weighl. Select the oil for
your vehicle according to this chart:
Ambient Temperature
100 F
40c-30 -20 -10
An oil with a viscosity of 5 W - 30 is preferred for
improved fuel economy and year-round protection in
the vehicle. You may use a 10 W - 30 oil if the climate in
your area is limited to the temperature range shown on
the chart.
API SERVICE LABEL
Run the engine tor more than
check for oil leakage.
4.three minutes, then
Replacement
CAUTION: After the engine has been tun, ths exhaust
pipes will be hot; be carelul when working around the
exhaust manitold.
1. Remove the oil filter with the special oil filter
wrench.
lnsoect the threads and rubber seal on the new filter.
Wipe off the seat on the engine block, then apply a
light coat of oil to the filter rubber seal.
NOTE: Use only filters with a built-in bypass system.
oil to rubber sealinstalling.
-G
Derore
(cont'd)
8-5
Inspect threads and
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