7-18 HONDA CR-V 1997 RD1-RD3 / 1.G Workshop Manual

Engine Block
Speciaf Tools .............7-2
lllustrated lndex ................................... 7-3
Flywheel and Drive Plate
Replacement ..,.,....7-5
Connecting Rod and Grankshaft
End Play .................7-6
Main Bearings
Cfearance ...............7 -7
Selection ................7-8
Connecting Rod Bearings
Clearance ...............7-8
Selection ................7-9
Pistons and Crankshaft
Removal .................7-9
Crankshaft
Inspection .............. 7-11
Pistons
fnspection ..............7-12
fnstaflation .............7-20
Cylinder Block
Inspection ..............7-13
Piston Pins
Removal ..,.......,,..... 7-14
Installation ............. 7-15
Inspection .............. 7-16
Connecting Rods
Selection ................7 -14
Piston Rings
End Gap .................7 -17
Ring-to-Groove Clearance ............... 7 -17
Replacement .........7-18
Alignment .............. 7-18
Crankshaft Oil Seal
lnstallation ............. 7-19
Crankshaft
lnstalfation .............7-20
Oil Seals
fnstalfation ....,..,.....7-23
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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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Piston Rings
2.
Replacement
1.Using a ring expander, remove the old piston rings.
Clean all the ring grooves thoroughly with a
squared-off broken ring or a ring gtoove cleaner
with a blade to fit the piston grooves.
The top ring groove is 1.2 mm (0.042 in) wide, rhe
second ring groove is 1.2 mm (0.042 in) wide, and
the oil ring groove is 2.8 mm (0.11 in) wide. File
down a blade if necessary.
Do not use a wire brush to clean ring lands, or cutring lands deeper with cleaning tool.
3. Install the new rings in the proper sequence andposition (shown in the right column).
NOTE: lfthe piston is to be separated from the con-
necting rod, do not install new rings yet.
7-18
RING EXPANDER
Alignment
l. Installthe rings as shown.
Piston Ring Dimensions:
|- T fB
+k-'1
A
Top Ring {standard}:
A: 3.1 mm (0.12 in)
B: 1.2 mm 10.05 inl
Second Ring (standard):
A: 3.'1 mm (0. f 3 in)
B: 1.2 mm (0.05 in)
NOTE: The manufacturing marks must
upward.
be tacing
MARK
z:-\ropnrNG+S
SECOND RING +
,A-\
o**^o( €ffi+-sPAcER
\zu-\
v
TOP RING
'97 - 98 models:
'99 - O0 mod€ls:
l-;
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Steering
Special Toofs ............. 17-2
Component Locations
Index ................ ....... 17-3
Troubleshooting
General Troubleshooting ................ 1 7-4
Noise and Vibration ......................... 17-8
Fluid Leaks ............. 17-10
Inspection and Adiustment
Steering Operation .......................... 17-12
Power Assist Check
With Vehicle Parked ....................
Steering Linkage and Gearbox .......
Pump Belt
Rack Guide Adjustment ...................
Fluid Rep|acement ...................,,.,....
Pump Pressure Check .................,,...
*Steering Wheel
Removal ................. 17-18
*Steering Column
Removal/lnstallation ................ ....... 17 -2O
lnspection .............. 17-21
Steering Lock Replacement ............ 17 -22
Power Steering Hoses, Lines
Ffuid Leakage Inspection ................. 17 -23
Repfacement .......... 17-23
Power Steering Pump
Repfacement .......... 17-24
Disassembly ...........17-25
fnspection .............. 17-26
Reassembly ............ 17-28
Power Steering Gearbox
Removal ................. 17-31
Disassembly ........... 17-34
Reassembly ............ 17-40
Ball Joint Boot Replacement .......... 17-50
Installation ............. 17-51
17-12
17-13
17-14
l7-15
17-15
17-16
Disassembly/Reassembly............... 17-18
4'%/b.......... -r'-7--a/
SUPPLEN\EN AL RES\RA(N SYSTES{ (SRS\
This model has an SRS which includes a driver's airbag in the steering wheel hub. a passenger's airbag in the dashboardabove the glove box ('97 - 00 models), and seat belt tensioners in the seat belt retractors ('98 - 00 models). Informationnecessary to safely service the SRS is included in this Service Manual. ltems marked with an asterisk (*) on the contentspage include, or are located near, SBS components. Servicing. disassembling or replacing these items will require specialprecautions and tools, and should only be done by an authorized Honda oearer.
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontalcollision. allSRS service work must be performod by an authorized Honda dealer.lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniurycaused by unintontional deployment of th€ airbags {'97 - 00 models), and seat belt tensioners ('98 - 00 modelsl.Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when theignition switch is ON (lll.
SRS electrical wiring harnesses are identitied by yellow colof coding. Ralated components are located in the steeringcolumn, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box. Do not use elec-trical test equipment on these cilcuits,
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Steering Wheel
Removal
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
1. Align the front wheels straight ahead. then remove
the driver's airbag assembly (see section 24) from
the steering wheel.
2. Disconnect the horn connector and cruise control
switch connectors.
CONTROLSWITCHES CONNECTOR
3. Loosen the steering wheel bolt, then install a steering
wheel puller on the steering wheel and remove it.
Note these items when removing the steering wheel:
. Do not tap on the steering wheel or the steering
column shaft when removing the steering wheel.
. lf you thread the puller bolts into the wheel hub
more than five threads, the bolts will hit the cable
reel and damage it. To prevent this, install a pair
of jam nuts five threads up on each puller bolt.
STEERING WHEEL BOLT39 N.m 14.0 kgt.m,29 lbtftl
STEERING WHEEL EOLT
Disassembly/Reassembly
EOSS COVER PLATE
_^M
STEERING WHEEL
WHEEL BODY COVER
17-18
@,
ACCESS PANEL
h"\
BODYCOVER CAP
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Steering Column
Removal/lnstallation
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
Note these items when removing the steering column:. Before removing the steering column, remove thedriver's airbag assembly and cable reel (see section24).
. Before removing or installing, set the column shaft inthe neutral position by pulling up the steering columnto uppermost position, then lower it 8 mm (5/16 in).Tighten tilt lever.
FULL STROKE:23 mm 10.9 in)
MAXIMUM UPPER8 mm (5/16)
POSTTTON
Remove the steering wheel (see page 17-18).
Remove the driver's side dashboard lower cover
and knee bolster (see section 20),
Remove the column covers.
With A"/T, move the shift lever to the E position,
and remove the shift cable from the column. andset it aside (see section 14).
Remove the combination switch assembly from thesteering column shaft by disconnecting the connec-
tors, and removing the two screws.
Disconnect the steering joint from the engine com-panment.
Remove the steering column by removing theattaching nuts and bolts.
7.
1.
MAXIMUM LOWERPOSTTTON
SHAFT CENTER
111 mm 100 mm5mm
JOINT COVERBOOT BAND
9,8 N.m l r .0 kgf.m, 7 lbf.fO
JOINT DUST SEAL
22 N.m (2.2 kgl.m, 16lbtftl
TILT LEVER
UPPER ATTACHING NUTS16 N.m lr.6 kgf.m, 12 lbf.ftl
UPPER COLUMN COVER
COMAINANON SWITCH ASSEMBLY
JOINT
COLUMN BMCKET
LOWER ATTACHING BOLTS39 N.m lir,o kgf.m, 29 lbf.ft)
17-20
LOWER COLUMN COVER
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Power Steering Gearbox
Removal
Note these items during removal:
. Using solvent and a brush, wash any oil and dirt off
the valve body unit its lines, and the end if the gear-
box. Blow dry with compressed air.
. Be sure to remove the steering wheel before discon-
necting the steering joint. Damage to the cable reel
can occur.
. With 4WD. tilt the engine with a jack to expand the
clearance between the transfer assembly and rear
beam when removing the steering gearbox from the
rear oeam.
Do not remove the steering gearbox by removing the
transfer assembly from the transmission.
1. Drain the power steering fluid as described on page'17-15.
Raise the vehicle, and suppon it on safety stands in
the proper locations (see section 1).
Remove the front wheels,
Remove the drive/s airbag assembly {see section 24).
Remove the steering wheel {see page 17-18).
Remove the steering joint bolts, then disconnect the
steering joint by moving the joint toward the column.
UPPER JOINT BOLT
LOWER JOINT BOLT
13.
7. Remove the cotter pin from the nut, and remove the
castle nut {'97 - 98 models) or hex nut ('99 - 00
models).
COTTER PINReplace.
Install the 10 mm hex nut on the ball joint. Be sure
that the 10 mm hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
might be damaged by the special tool. Refer to sec-
tion 18 for ball joint remover usage instruction, Be
careful not to damaging the ball joint boot.
Separate the tie-rod ball joint and knuckle using the
special tool.
Remove the right and left tie-rod ends, then extend
the rack all the way to the right.
Remove the TWC (see section 9).
Disconnect the shift linkage from the transmission
(M/T: see section 13, A/T: see section 14).
With 4WD. separate the propeller shaft and transfer
assembly (see section 161.
10.
11.
(cont'd)
17-31
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