clearance HONDA CR-V 1997 RD1-RD3 / 1.G Owner's Guide

PGM-FI System
Random Misfire
lF()gool", tftod-' and some or lpiogol throughTo3oti
The scan tool indicates Diagnostic Trouble Code (DTC)
P0300*,, P1300*1 and some of po30t - pO3O4; Randommisfire.
Descriotion
Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (cKF) sensorwhich is attached to the crankshaft.lfmisfiring strong enough to damage the catalyst is detected, the MIL will blink during the time of its occurrence, and DTcP0300*', P1300*1 and some of DTCs P03ol through P0304 will be stored. Then, after misfire has ceased, the MtL will comeon,
lf misfiring that increases emissions is detected during two consecutive driving cycles, the MIL will come on, and DTcand some of DTCS p0301 through p0304 wi

be stored.NOTE: lf some of the DTCS listed below are stored at the same time as a misfire DTc, troubleshoot those DTcs first. thentroubleshoot the misfire DTC.
P0106, P]128, P1'129; MAp sensorP0171. P0172; Fuet metering
P0505: ldle Control Svstem
P1336, P1337; CKF sensor
P1361, P1362: TDC sensor
Pl381. Pl382: CYP sensor
P1508: IAC valve *1:,97 model*2: '98 - 00 models
Possiblo Caus€
. Fuel pump insufficient fuel pressure, amountofflow. Fuel line clogging. blockage, leakage. Fuel filter clogginga Fuel pressure regulator stuck open. Distributormalfunction
. lgnition coil wire open, leakage. lgnition control module malfunction. Valves carbon deposita Compression lowa Fuel does not meet Owner's Manual spec., lack offuel
Troubleshooting
By test-driving, determine the conditions during which misfire occurs. Depending on these conditions, test in the orderdescribed in the table below.
Possible cause
[ ;;;;- -....
Crankshaft
speed fluctuation
sensor
Fuel
pressureDistributor and
lgnition wirestcMValve
Clearance
Conditionsection 611-178section 23section 23section 6
Only low rpm and load,6)o
Only acceleratingooo
Only high rpm and loado@,a'@
Not specificationG\o@o@
NOTE: lf misfire doesn't recur, some possible causes are fuel that doesn't meet owner's manual spec, lack of fuel, carbondeposits on spark plu9, etc.
11-126
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Misfire Detected in One Cylinder
Ipffi1] Thescantoot indicates Diagnostic Trouble Code (DTC) P0301: Cylinder 1 misfire detected.
lF03O2l 16".""n toot indicates Diagnostic Trouble Code (DTC) P0302; Cylinder 2 misfire detected.
I P0303 | fne scan tool indicates Diagnostic Trouble Code (DTC) P0303: Cylinder3 misfire detected.
lF0il04l 16" ""un tool indicates Diagnostic Trouble Code (DTC) PO3O4: Cylinder 4 misfire detected
Description
Misfire detection is accomplished by monitoring the crankshaft speed with the crankshaft speed fluctuation (CKF) sensor
which is attached to the crankshaft.
lf misiiring strong enough to damage the catalyst is detected, the MIL will blink during the time of its occurrence. and DTC
P0301, P0302, P0303 and/or P0304 will be stored. Then, after the misfire has ceased, the MIL will come on.
lf misfiring that increases emissions is detected during two consecutive driving cycles. the MIL will come on, and DTc
P0301, P0302, P0303 and/or P0304 will be stored.
NOTE: lJ some of the DTcs listed below are stored at the same time as a misfire DTc, troubleshoot those DTcs first, then
troubleshoot the misfire DTC.
P0107, P0108, P'n2a, P1129t MAP sensor
Po'17 'l , P0112t Fuel suPP|Y system
P0441: EVAP insufficient Purge flow
P1336, P1337: CKF sensor
P1359, Pl361, P1362: TDC sensor
Pl381, P1382: CYP sensor
Possible Cause
. Fuel injector clogging, fuel leakage, air leakage
. Fuel injector circuit open or shorted
. Spark plug carbon deposits, fouling, malfunction
. lgnition wires open, leaking
. Distributor malfunction
. Compression low
. Valve clearance out of specification
(cont'd)
11-127
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(From page 11-128)
lntormittent misfire due lo sparkplug fouling, etc. (no mislire at
this tim€).
ls DTC P0301, P0302, P0303,or P0304 indicated?
ooes the misfire occur in theother cylinder?Replace the faulty spark Plug.
Check lor fuel iniector maltunc-
t|on:1. Exchange the fuel injectorfrom the problem cylinderwith one from another cylin-der.2. Let the engine idle for two min
utes.3. Test'drive the vehicle severaltimes in the range of the freezedata,
lntermittent misfiro due lo bad
contrct in the fuel iniector con-nector {no misfire at this time).
ls DTC P0301, P0302, P0303,or P0304 indicated?
Does the misfire occur in theother cylinder?Replace lhe faulty luel inlector.
Check following items- Valvo clearance- Cvlinder l€ak-down- Compression- Crsnkshaft Speed FluctuationICKF) sensol
NOTE: lf there is no freeze data of misfiring, test drives under various condi_
tions are necessary.
11-129
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lnstellation
1. Open the throttle valve fully, then install the throttle
cable in the throttle linkage, and install the cable
housing in the cable bracket.
97 - 98 modols:
THRoTTLE LINKAGE CABLE
INNER CABLE
- (Xl modols:
LOCKNUT
'99
2.Sta.t the engine. Hold the engine at 3.000 rpm with
no load (in Park or neutral) until the radiator fan
comes on, then let it idle.
Hold the cable sheath, removing all slack from the
cable.
Set the locknut on the cable bracket.
Adiust the adjusting nut so that its free play is 0 mm.
Rimove the cable sheath from the throttle bracket,
reset the adjusting nut and tighten the locknut.
ADJUSTING
BRACKET
'97 - 98 modals:
lhere should beno clearance.
AD.'USTING NUT
'99 - 00 modeb:
CABLEBRACKET
9.8 N.ml'1.0 kgt'm,7.2 tbr.ft)
9.8 N.m(1.0 kg{.m,7.2lbllrl
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Intake Air System
Throttle Body
Doscription
The throttle body is a single-barrel side-draft type. The
lower portion of the throttle valve is heated by engine
coolant from the cylinder head. The idle adjusting screw
which regulates the bypass air is located on the top of
the throttle bodv.
The illustration shows'97 - 98 models,'99 - 00 rnodelsare similar.
1 1-196
lnspection
Check that the throttle cable operates smoothly without
binding or sticking.
lf there are any abnormalities, check for:. Excessive wear or play in the throftle valve shaft.. Sticky or binding throttle lever at the fully closed posi-
tton.
. Clearance between throttle stop screw and throttle
lever at the fully closed position.
97 - 98 models:
THROTTLE LINKAGE
Replace the throttle body if there is excessive play in the
throttle valve shaft or if the shaft is binding or sticking.
THROTTLE LINKAGE
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Clutch Pedal
Adiustment
NOTE:
. To check the clutch interlock switch and clutch
switch, see section 23.
. The clutch is self-adjusting to compensate for wear.
CAUTION: lf there is no clearance bstwa€n the mas-
ter cylinder piston and push rod, ths roloase bearingis held againsi the diaphragm spring, which canresuh in clutch slippage or other clutch probloms.
1. Loosen locknut A, and back off the clutch switch (or
sdjusting bolt) until it no longer touches the clutchpeoar.
2. Loosen locknut C, and turn the push rod in or out toget the specified stroke (@) and height (@) at theclutch oedal.
3. Tighten locknut C.
4. Thread in the clutch swirch (or adjusting bolt) untilit contacts the clutch oedal.
7.
5.
8.
q
Turn the clutch switch {or adjusting bolt} in an addi-
tional 3/4 to 1 full turn.
Tighten locknut A.
Loosen locknut B on the clutch interlock switch.
Measure the clearance between the floor board and
clutch pedalwith the clutch pedal fully depressed.
Release the clutch pedal 15 - 20 mm (0.59 - 0.79 in)
from the fully depressed position and hold it there,Adjust the position of the clutch interlock switch sothat the engine will start with the clutch pedal in
this position.
Tighten locknut B.10.
LOCKNUT B9.8 N.m 11.0 kgf.m, 7.2 lbf.ftl
CLUTCH INTERLOCK SWITCH
CLUTCH SWTTCH{or ADJUSTING BOLTI
L(rcKNUT A9.8 N.m {1.0 kg{.m,7.2 lbf.ftl
CLUTCH MASTER CYLINDER
PUSH ROD
Pedal in contact with swhch
LOCKNUT C18 N.m (1.8 kgf.m, 13lbtftl
@ {STROKE at PEDAL): 135 - 1its mm (5.31 - 5.71 in}
@ (TOTAL CLUTCH PEDAL FREE PLAY)i7 -22mm (0.28-0.87 in) inctude the pedat ptay 1 - 9 mm (0.0it- 0.35 inl@ (GLUTC,H PEDAL HE|GHTI: ltxt mm (7.20 inl ro rhe ftoor
o (CLUTCH PEDAL DTSENGAGEMENT HEtcHTl: 72 mm {2.txt inl minimum to the floor
\,/a_-_--/
12-4
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Flywheel
Inspection
2.
3.
Llnspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the fly-
wheel for wear, cracks, and burning
Measure the flywheel runout using a dial indicator
through at least two full turns. Push against the fly-
wheel each time you turn it to take up the crank-
shaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (Newl: 0.05 mm (0.002 in) max.
Service Limit: 0.15 mm {0.006 inl
lf the runout is more than the service limit, replace
the flywheel and recheck the runout
Turn the inner race ot the flywheel bearing with your
finger. The bearing should turn smoothly and qui-
etly. Check that the bearing outer race fits tightly in
the tlywheel. lf the race does not turn smoothly, qui-
etly, or fit tight in the flywheel, replace the bearing.
FLYWHEEL
RING GEAR
FLYWHEEL
L
2.
Replacement
Installthe special tool as shown.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, and remove the flywheel.
MOUNNNGBOLTS
FLYWHEEL
(cont'd)
12-9
RING GEAR HOLDER07LAB - PV00r00ol07924 - PD20003
3. Remove the ball bearing from the flywheel.
BALL BEARING
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Manual Transmission
Diff€rential
lndex ...................... ......... 13-38
Backlash Inspestion ..,....,.,.....................,......, 13-38
Final Driven Gear Replacement .................... 13-39
Tapered Roller BearingReplacement ............. 13-39
Bearing Outer Race Replacement ......,.,........ 13-i10
Tapered Roller Bearing PreloadAdiustment ............... 13-il1
Oil Seal Reolacement .................................... 13-/l:}
Transfer Assembly
lllustrated Index ............. 13-il4
Inspection ..,....,.,......,...... 13-46
Disassembly ................... 13-47
Transfer Drive Gear BearingReplacement ...,..................,....................... 13-ilg
Transfer Driven Gear Shaft BearingReplacement .............................................. 13-ilg
Transfer Shaft Disassembly/Reassembly .............. 13-50
Transler Cover A Bearing Outer RaceRep1acement.........,.,.,..........,....,...,.........,., 13-50
Transter Housing Bearing Outer RaceReD1acement.............................................. 13-51
Reassembly ..-............,... 13-52
Mainshaft Bearing/Oil Seal
Beplacement .................. 13-62
Countershaft Bearing
Replacement .,,.,.,., ..,...... 13-63
Mainshaft Thrust Clearance
Adiustment .................... 13-6,1
Transmission Assembly
Reassembly .,.,.,.,..,.,....,., 13-67
fnstaffation .,.,.............,... 13-72
Gearshift Mechanism
Overhaul ................ .........13-17
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20.
2't.
19. Remove the reverse lock cam.
lf necessary, check the clearance of the reverse shift
holder (see page 13-20).
Remove the reverse shift holder.
HOLOER
22. '97 - 99 models: Remove the reverse gear shaft and
the reverse idler gear.'00 model: Remove the reverse gear shaft, reverse
idler gear, thrust washer and the coller.
13-17
23. Remove the mainshaft and countershaft assemblies
with the shift forks from the clutch housing.
NOTE; Before removing the mainshaft and counter-
shaft assemblies, tape the mainshaft spline to pro-
tect it.
ASSEMBLY
Tape the main'
shaft splines.
WASHER
SPRING WASHER
24. Remove the differential asssmbly.
COUNTEBSHAFT
HOUSING
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2.
Clearance InsPection
1. Measure the clearance between the shift arm A and
select arm.
Standard: 0.05 - 0 25 mm (0.002 - 0'01 inl
Service Limit:0.5 mm (0.02 in)
lf the clearance are more than the service limit,
measure the diameter of the select arm pln
Standard: 7.9 - 8.0 mm (0.311 - 0.315 in)
SELECTARM
lf the diameter of the select arm pin is less than
the service limit, replace the select arm wrtn a
new one.
lf the diameter of the select arm pin is within the
service limit, replace the shift arm A with a new
one.
SELECT ARM
SHIFT ARM A
SHIFT ARM C
SHIFT ARM B
3. Measure the clearance between the shift arm B and
shift arm c.
Standard: 0.05 - 0.25 mm (0.002 - 0.01 inl
Seryice Limit:0,5 mm (0.02 inl
lf the clearance are more than the service limit,
measure the diameter of the shift arm C.
Standard: 12.9 - 13.0 mm (0 508 - 0.512 in)
SHIFT ARM C
lf the diameter of the shift arm C is less than the
service limit, replace the shift arm C with a new
one.
lf the diameter of rhe shift arm C is within the
service limit, replace the shift arm B with a new
o ne.
13-19
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