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

Cylinder Head
Installation (cont'dl
'13. Align the marks on the cylinder head plug to thecylinder head upper surface, then install the cylin
der head plug in the end of the cylinder head.
CYLINOER HEADPLUGReplace.
lnstallthe back cover.
To set the camshafts at TDC position for the No. lpiston, align the holes in the camshafts with theholes in the No. l camshaft holders and insert 5.0mm pin punches in the holes. Install the keys into
the camshaft grooves.
37 N m (3.8 *gl.m, 27 lbt.tr)
9.8 N.m (1.0 kgtm,7.2|hrftl
Push the camshaft pulleys onto the camshafts. thentighten the retaining bolts to the torque specified.
6-32
14.
KEYS
I x 1.25 mm
6x1.0mm
Install the timing belt (see page 6-1 1).
Adjust the valve clearance (see page 6-3).
Thoroughly clean the head cover gasket and thegroove.
lnstall the head cover gasket in the groove of thecylinder head cover. Seat the head cover gasket in
the recesses for the camshaft first, then work it into
the groove around the outside edges. Make sure thehead cover gasket is seated securely in the corners
of the recesses with no gap.
17.
'18.
19.
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21.
22.
Check that the mating surfaces are clean and dry.
Apply liquid gasket, part No. 08718 - 0001 or 08718- 0003, to the head cover gasket at the eight corners
of the recesses.
NOTE:
. Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.
. After assembly. wait at least 30 minutes before
filling the engine with oil.
Apply liquid gasket tothe shaded areas.
Hold the head cover gasket in the groove by placing
your fingers on the camshaft holder contacting sur-
faces (top of the semicirclesl.
Once the cylinder head cover is on the cylinder
head, slide the cover slightly back and forth to seat
the head cover gasket.
Inspect the cover washers. Replace any washer that
is damaged or dete(iorated.
23.
24.
25. Tighten the nuts in tvvo or three steps. In the final
step, tighten all nuts, in sequence. to 9.8 N.m (1.0
kgf.m, 7.2 lbf.ft).
Check that all tubes, hoses and connectors are
installed correctly.
26.
6-33
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PistonsCrankshaft
Installation
1. Apply a coat of engine oil to the ring grooves andcylinder bores.
It the crankshaft is already installed.
2. Set the crankshatt to BDC for each cylinder.3. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of theconnecting rod bolts.
4. lnstall the ring compressor, and check that the bear-ang is securely in place.
5. Position the piston in the cylinder, and tap it in usingthe wooden handle of a hammer. Maintain down-ward force on the ring compressor to prevent ringstrom expanding before entering the cylinder bore.6. Stop after the ring compressor pops free, and checkthe connecting rod-to-crank journal alignmentbefore pushing piston into place.
7. Install the rod caps with bearings, and torque theNUIS IO:
31 N.m (3.2 kgf.m,23 tbf.ft)
Apply engine oil to the bolt threads.
lf the crankshaft is not installed:
2. Remove the rod caps and bearings, and install theflng compressor.
3. Position the piston in the cylinder, and tap it inusing the wooden handle of a hammer. Maintaindownward force on the ring compressor to prevent
rings from expanding before entering the cylinderoore,
4. Position all the pistons at top dead center.
The arrow must facethe timing belt sideof the engine.
CONNECTING ROOOIL HOLE
RUBBER HOSES
7 -20
\-\
3.
4.
1.
6.
Installation
Apply a coat of engine oil to the main bearings androd bearings.
Insert the bearing halves in the cylinder block andconnect|ng rods.
Hold the crankshaft so the rod journals for cylindersNo.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rodjournals into connecting rods No.2 and No.3.Install the rod caps and nuts finger tight.
outward.
Rotate the crankshaft clockwise, and seat the jour
nals into connecting rods No. 1 and No. 4, Install
the rod caps and nuts finger-tight. Install the capsso the bearing recess is on the same side as therecess an the rod.
Check the rod bearing clearance with plastigage(see page 7 8). then lorque the capnuts.
Torque:
3l N.m 13.2 kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
5.
7. Install the thrust washers on the No. 4 journal.
Line up the mark wheninstalling connecting rodcap.
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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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Oil Filter
Replacement (cont'd)
Installthe oil filter by hand.
After the rubber seal seats, tighten rhe oil filter
clockwise with the special tool.
Tighten: 7/8 turn clockwise
Tightening torque:22 N.m (2.2 kgt'm 16lbt.ft)
OIL FILTER WRENCH07912-61 10001
8-6
Some filters have eight numbers (1 to 8) printed on
the surface of the filter.
The following explains the procedure for tightening
filters using these numbers.
l) Make a mark on the cylinder block under the num-
ber that shows at the bottom of the filter when the
rubber seal is seated.
2) Tighten the filter by turning it clockwise seven
numbers from the makes point. For example, if a
mark is made under the number 2 when the rub-
ber seal is seated, the filter should be tightened
until the number 1 comes up to the marked point.
Number when rubberseal is seated.Number af ter tightening.
5.After installation. fill the engine with oil up to the
specified level, run the engine for more than threeminutes, then check for oil leakage and oil level.
GAUTION: Installation using other than the aboveprocedure could result in serious engine damage
due to oil leakage.
MARK
Number when rub-
ber seal is seated567IJ
Number after tight-
ening8123467
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Fuel Pump
Testing
lf you suspect a problem with the fuel pump, check that
the fuel pump actually runs; when it is oN (ll), you will
hear some noise if you hold your ear to the fuel fill port
with the fuel fill cap removed. The fuel pump should run
for two seconds when ignition switch is first turned ON (ll).
lf the fuel pump does not make noise, check it as follows:
1. Fold the left rear seat cushion forward, and remove
the base frame cover (see section 20).
2, Remove the access panel from the floor.
3. Make sure the ignition switch is OFF, then discon-
nect the fuel pumP 5P connector.
4. Connect the PGM-FI main relay 7P connector termr-
nal No. 4 and No, 5 with a jumper wire.
PGM.FI MAINRELAY 7P CONNECTOR (Cit:}2l
I'TtlJilt f -r'-r ll.l5l517l,frTt-,at\FUEL pUMp Lr- . tcl tyEL/cRNl
rYEL/cRNl IIJUMPER Wir€ side of
WIRE female terminals
5. Check that battery voltage is available between the
fuel pump 5P connector terminal No. 4 and body
ground when the ignition switch is turned ON (ll).
FUEL PUMP 5P CONNECTOR {C562}
12
3a5
lf battery voltage is available, check the fuel
pump ground. lf the ground is OK, replace the
fuel oumo.
lf there is no voltage, check the wire harness (see
page 11-188).
FUEL PUMP(YEL/GRNI
wire side offemale terminals
Raplac6mont
1. Fold the left rear seat cushion forward, and remove
the base frame cover (see section 20).
2. Remove the access panel from the floor.
3, Relieve the fuel pressure (see page 11-178).
4. Disconnect the fuel lines.
5. Disconnect the 5P connector from the fuel pump.
6. Remove the fuel pump mounting nuts.
7. Remove the fuel pump from the fuel tank.
Install the fuel pump in the reverse order of
removal.
8.
11-183
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Fuel Supply System
Fuel Gauge
Tssting
NOTE: Refer to section 23 for the fuel gauge system cir-cuit diagram.
'1. Check the No. 25 METER (7.5 A) fuse in the under-dash fuse/relay box before testing.
2. Fold the left rear seat cushion forward, and remove
the base frame cover {see section 20).
3. Remove the access panel from the floor.
4. Disconnect the 5P connector from the fuel pump.
5. Measure voltage between the 5P connector termi-nals No.2 and No. 5 with the ignition switch ON ( ).There should be between 5 and 8 V.
FUEL PUMP5P CONNECTOR
tc56al
a
a
Wire side of female t€rminals
lf the voltage is as specified, go to step 6.lf the voltage is not as specified, check for:- an open in the YEUBLK or BLK wrre.- poor ground (c552).
11-184
7.
Turn the ignition switch OFF.
Attach a jumper wire between the No. 2 and No. 5terminals, then turn the ignition switch ON fll).
Check that the pointer of the fuel gauge starts mov-ing toward the "F" mark. Turn the ignition switchOFF before the pointer reaches "F" on the gauge
dial. Failure to do so may damage the luel gauge.
NOTE: The fuel gauge is a bobbin (cross-coil) type,hence the fuel level is continuously indicated evenwhen the ignition switch is OFF, and the pointer
moves more slowly than that of a bimetal type.
. lf the pointer of the fuel gauge does not move atall. replace the gauge.
. lf the gauge is OK, inspect the fuel gauge send-ing unit.
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Fuel Gauge Sending Unit
Tgsting
@ Do not smoke while working on tho fuel
systom. Keop open flamo 8waY from your work araa.
1. Fold the left rear seat cushion forward, and remove
the base frame cover (see section 20).
2. Remove the access panel.
3. With the ignition switch OFF. disconnect the 5P con-
nector from the fuel pump.
4. Relieve fuel pressure (see page 11-178).
5. Disconnect the fuel lines.
6. Remove the fuel pump,
7. Measure the resistance between the No. 2 and No. 5
terminals at E (EMPTY), 1/2 (HALF FULL) and F (FULL)
by moving the float.
lf you do not get the above readings, replace the
fuel pump.
11-185
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Fuel Supply System
Low Fuel Indicator System
Indicator Light Testing
NOTE: Refer to section 23forthe lowfuel lndicator circuit
clragram.
1. Check the No. 25 METER (7.5 A) fuse in the under-
dash fuse/relay box before testing.
2. Park the vehicle on level ground.
@ Do not smoke while working on the
fuel system. Keep open flame away trom the work
aroa. Drain fuel only into an approved container.
Drain the fuel into an aoDroved container. Then
install the drain bolt with a new washer.
Add less than 8 f (2.1 U.S. Gal. 1.8 lmp. Gal) of fuel,
and turn the ignition switch ON {ll). The low fuel indi-
cator light should come on within four minutes.
INDICATON LIGHT
. lf the light comes on within four minutes, go tostep 8.
. lf the light does not come on within four min-
utes. go to step 5.
Remove the seat cushion (see section 20).
Remove the fuel tank access panel from the floor,
and disconnect the 5P connector from the fuel pump,
Connect the No. 1 and No. 2 terminals with a jumper
wire.
. lf the lightcomeson, checkthe sending unit.. lf the light does not come on, check for:- an open in the GRN/yEL wire between thefuel unit and fuel gauge assembly.- blown bulb.- poor ground (G552).
FUEI- PUMP 5P CONNECTOR (C562)
JUMPER WIRE
IGRN/YEL}
7.
1 1-1 86
Wire sid€ ol tem€le terminals
8. Add 4 / of fuel (1.1 U.S. Gal, 0.9 lmp. Gal). The light
should go off within four minutes.
. lJ the light does not go off, check for:- a short in the GRNA/EL wire between the fuel
gauge sending unit and fuel gauge assembly.- faulty gauge assembly.
. lf the light goes off, the low fuel indicator light is
oK.
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Fuel Tank
Replacement
1. Relieve the fuel pressure (see page 11-178).
2. Fold the left rear seat cushion forward, and remove the base frame cover {see section 20).
3. Remove the access panel from the floor.
4. Disconnect the 5P connector 1C562) and 6P connector (C580) ('98-00 models)'
5. Disconnect the fuel return hose and quick-connect fittings {see page 11-175}
6. Jack up the vehicle, and support it with jackstands.
7. Remove the middle floor beam.
8. Remove the drain bolt, and drain the fuel into an approved contaaner.
g. Disconnect the hoses (see page 11-173, 174). slide back the clamps. then twist hoses as you pull, to avoid damaging
them.
10. Place a jack, or other suppon, under the tank
11. Remove the strap nuts, and let the straps fall free
12. Remove the fuel tank. lf it sticks on the u ndercoat applied to its mount, carefu lly pry it off the mount,
'13. lnstallthe drain bolt with a new washer, then coat the drain bolt with Noxrust 1248'
Allow the Noxrust to dry for 20 minutes.
14. Install parts in the reverse order of removal.
'97 modol:AOCESS PANEL
CONNECTOR
@ Do not smoke while working on fuol systam Keep open flame away from your work area'
DRAIN EOLT49 N.m15.0 kgf'm,36 rbt frl
(cont'd)
1 1-191
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