Head install HONDA CR-V 1997 RD1-RD3 / 1.G Workshop Manual

MEASUREMENTSTANDAFD INEWISERVICE LIMIT
lgnition coilRated voltage VPrimary winding resistance 0 at 68'F (20'C)120.63 0.77
lgnition wireBesistance at 68"F (20 C) ktl25 max.
Firing order1 3 4-2
Spark plugTypeGapSee Section 41.0 - 1.1 (0.039 - 0.043)
lgnition timingAt idle BTDC161 2 {Red)
Alternator belt*rDeflection with 98 N {10 kgf, 22 lbf)8.5 11.510.33 0.45)with used belt5.5 - 8.0 (0.22 - 0.31) with new belt
Belt tension N {kgf, lbt)Measured with bek tension gauge340 - 490 {35 - 50, 77 110) with used belt690 880 (70 90, 150 - 200i with new belt
AlternatorOutput A (at 13.5 V, hot and 6,000 alternator rpm AIIM/IBrush length
959010.5 (0.41)1.5 (0.06i
Staning motorOutput kW A/fMica depth MfiCommutator runoutCommutator O.D.Brush lengthBrush spring tension N (kgf, lbf)
1.11.00.5 - 0.8 {0.02 - 0.03)0,0.02 (0 0.0008)27.9 28.0 (1.0984 1.1024)14.0 14.5 (0.55 0.57)13.7 - 17.7 (1.40 - 1.80,3.09 - 3.97)
0.2 (0.008)
0.0s (0.002)
27.0 (1.06)
9.0 (0.35)
Standards and Service Limits
Engine Electrical - Section 4
'1 When using a new belt, ddiust deflection to new value. Run the engine for 5 minutes then turn it of{. Beadiust deflection to used belt value.
Cylinder Head/Valve Train - Section 6
MEASUREMENTSTANDARD {NEW} SERVICE LIMIT
Compression250 rpm and Nominalwide open throttle MinimumkPa (kgflcm', psi) Maximum variation
1 ,230 i'12 .5 , 11Al930 (9.s, 135)200 12.0,2al
Cylinder headWarpageHeight131.95 - 132.05 {5.195 - 5.199)0.05 {0.002)
CamshaftEnd playCamshaft to hoider oil clearanceTotal runoutCam lobe height '97,'98 models lNEX'99,'00 models lNEX
0.05 0.1s (0.002 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 {0.001)max.33.204 \1.3072133.528 {1.3200)33.1 16 \1 .321 4)33.528 {'1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
Valve clearance (Cold)* lNEXValve stem O.D. lNEXStem'to-guide clearance lNEX
0.08 - 0.12 (0.003 0.005)0.16 0.20 (0.006 - 0.008)6.580 - 6.590 (0.2591 0.2594)6.550 - 6.560 (0.2579 0.2s83)0.02 - 0.05 {0.00t 0.002)0.05 - 0.08 (0.002 0.003)
u* to.rutt6.52lO.257l0.08 {0.003i0.'1t (0.004)
width tNEXStem installed height lNEX
1.25 - 1.55 (0.049 - 0.061)1.25 1.55 (0.049 - 0.061)40.765 - 41.235 {1.6049 1.6234)42.765 - 43.235i'1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 {1.6333}43.485 {1.7120i
Valve springFree length lNEX42.36 (1.668i
44.32 t1 .1 451
Valve guideI,D, INEXInstalled height tNEX
6.61 6.63 10.260 - 0.261)6.61 6.63 {0.260 - 0.261i13.75 - 14.25 10.541 0.561i15.75 - 16.25 {0.620 0.640i
6.6510.26216.65 (0.262i
*: Measured between the camshaft and rocker arm,
2-2
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Distributor Replacement
Removal:
1. Disconnect the connector from the distributor.
2. Disconnect the ignition wires from the distributor
ignition (Dl) cap.
3. Remove the mounting bolts from the distributor,
then remove the distributor from the cylinder head.
CAMSHAFTEND
MOUNTING BOLTS8 x 1.25 mm2,1N.m {2.,1kgrf.m, 17 lbf ftl
lnstallation:
1. Bring the No. 1 piston to compression stroke TDC.
2. Coata new O-ring with engine oil, then install it.
3. Align the lug on the end of the distributor and its
mating grooves in the camshaft end, then slip the
distributor into position.
NOTE: The lug on the end of the distributor and its
mating grooves in the camshaft end are both offset
to eliminate the possibility of installing the distribu-
tor 180o out of time.
4. Installthe mounting bolts, and tighten them lightly.
5. Connect the ignition wires to the distributor ignition(Dl) cap as shown,
No. 1CYLINDERMARK
6. Connect the connector to the distributor.
7. Set the ignition timing (see previous page).
8. After setting the ignition timing, tighten the mount-
ing bolts.
4-17
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Cruise Gontrol
Actuator Test (cont'dl
5. With voltage and vacuum still applied, try to pull the
actuator rod out by hand. You should not be able topull it out. lf you can. it is defectrve.
8.
9.
7.
Disconnect ground from the No. 3 terminal. The actu-
ator rod should return. lf it does not return, but the
vent hose and filter are not plugged, the solenoid
valve assembly is defective.
Repeat steps 2 through 5. and disconnect ground
from the No. l terminal. The actuator rod should
return. lf it does not return, but the vent hose and
filter are not plugged, the solenoid valve assembly
is defective.
lf you replace the solenoid valve assembly, be sure
to use new O-rings on each solenoid.
Disconnect power and ground from the 4P connector.
Disconnect the vent hose from the actuator. Connect
a vacuum pump to the actuator vent hose port, and
apply vacuum. The actuator rod should pull in com-pletely. lf not, the vacuum valve is stuck open.
Replace the actuator,
4-42
I
't.
Actuator Replacement
3.
4.
7.
Ar
Pull back the boot. and loosen the locknut. Then dis-
connect the cable from the bracket.
Disconnect the cable end from the actuator rod.
1.
4.
.J.
Disconnect the 4P connector from the actuator.
Disconnect the vacuum hose from the vacuum tank.
Pull out the vent hose.
Remove the three mounting bolts and the actuator
with the bracket.
ACTUATORACTUATOR
CABLE
lf necessary, disconnect the cable end from the link-
age over the accelerator pedal, then turn the grom-
met 90' in the bulkhead. and remove the cable.
Install in the reverse order of removal, and adjust
free play at the actuator rod after connecting the
cable (see page 4-43).
I
6.
I
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Valve Clearancev
Adjustment (cont'dl
6. Tighten the locknut, and check the clearance agajn.
Repeat the adjustment if necessary.
GAUGE
Rotate the crankshaft 180" counterclockwise (camshaft
pulley turns 90').
The "UP" marks should be on the exhaust side. Adjust
the valves on No. 3 cylinder.
.UP" MARKS
7.
8. Rotate the crankshaft 180" counterclockwise to brinq
No. 4 piston to TDC.
The "UP" marks should be pointing straight down.
Adjust the valves on No. 4 cylinder.
Rotate the crankshaft 180'counterclockwise to brino
No.2 piston to TDC.
The "UP" marks should be on the intake side. Adiust
the valves on No. 2 cylinder.
Install the cylinder head cover (see page 6-32).
Retorque the crankshaft pulley bolt (see page 6-7).
10.
11.
"UP" MARKS
"UP" MARKS
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Valve Seals
12.
Replacement (cylinder head removal not requiredl (cont'dl
Using an upward motion on the lever arm, compress
the valve spring and remove the keepers from the
valve stem. Slowly release pressure on the spring.
Repeat step 11 for the other valve in that cylinder.
Remove the valve seals (see page 6-24).
Installthe valve seals (see page 6-29).
lnstall the springs, the retainers and the keepers in
reverse order of removal.
'17. Repeat steps 9 to 16 for the other three cylinders.
Exhaust valve Seals
18. Using the 5 mm bolts supplied with the tool, mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit as shown.
19. Insert the cross shaft through the bottom hole of
the two uprights.
Select the 7/8 in. diameter short compressor attach
ment, and fasten the attachment to the No. 4 hole of
the lever arm with the speed pin supplied.
Position the piston at TDC, and insert an air adaptor
into the spark plug hole. Pump air into the cylinder
to keep the valve closed while compressing the
springs and removing the valve keepers.
13.
14.
15.
16.
20.
t1
22. Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
neao.
23. Position the lever arm under the cross shaft so the
lever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for the
spring being compressed. Use the rear position slot
on the lever as shown.
Using a downward motion on the lever arm, com-
press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spring.
Repeat step 24 for the other valve in that cylinder.
Remove the valve seals (see page 6-24).
Install the valve seals (see page 6-29).
Install the springs, the retainers and the keepers in
reverse order of removal.
Repeat steps 21 to 28 on the other three cylinders.
24.
21.
28.
29.
o-o
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Timing Belt
lllustrated Index
Cl
k6
CYLINDER HEADCOVERRefer to page 6-32when installing.
6x1.0mfi11 N.m {1.1 kgtm,8.0 rbtft)
HEAD COVER GASKETReplace when leaking,damaged or deteriorated.Apply liquid gasket atthe eight corners of theWASHERReplace if damagedor deteriorated,
RUEBER SEALReplace il damagedot detetiorated.
kgf.m,
\@
7.2 tbtft)
TIMING BELTInspection, page 6-9Adjustment, page 6-9Removal, page 6-10Installation, page 6-1 1
8 x 1.25 mm37 N.m (3.8 kst.m,27 lbf ftl
MIDOLE COVER
6x1.0mm9.8 N.m {1.0 kgf.m,1.2lbt.ftl
RUBBER SEALSReplace when damagedor deteriorated,
LOWER COVER
TIMING BELTORIVE PULLEYReplacement, page 6'7
ADJUSTING BOLT10 x 1.25 mm54 N.m (5.5 kgl.m, 40 lbf.ft)
CNANKSHAFT PULLEYneplacement, page 6-7
lnstall with concavesurface facing out,Remove any oal and clean,BOLT
CRANKSHAFT SPEEOFLUCTUATION ICKF}SENSOR
6x1.0mm9.8Nm(1.0kgl.m,7.2 tbl.ft)
14 x 1.25 mm177 N.m (18.0 kgf'm,130 tbf.fr)Replacement, Page 6-7Do not use an impactwrench when installing.
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1.
2.
Inspection
Remove the cylinder head cover.
lnspect the timing belt for c.acks and oil or coolant
soaking. Replace the belt if it is oil or coolant
soaked. Remove any oil or solvent that gets on the
belt.
lnspect thisarea for wear.
After inspecting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgnm, 130 lbf.ft).
Install the cylinder head cover (see page 6-32).
3.
Tension Adjustment
NOTE:
. Always adjust the timing belt tension with the engine
coto.
. Always rotate the crankshaft counterclockwise when
viewed from the pulley side. Rotating it clockwise
may result in improper adiustment of the belt ten-
sion.
'1. Remove the cylinder head cover
2. Set the No. 1 piston at TDC (see page.6-12).
3. Rotate the crankshaft five or six revolutions to set
the belt.
Set the No. 1 piston at TDC.
Loosen the adjusting bolt 1/2 turn (180') only.
4.
5.
ADJUSTING BOLT5,4 N.m (5.5 kgf.m,40 tbtftlFor adiustment only,
7.
8.
Rotate the crankshaft counterclockwise three teeth
on the camshaft pulley.
Tighten the adjusting bolt to the specified torque.
After adjusting, retorque the crankshaft pulley bolt to
177 N.m (18.0 kgf.m, 130 lbf.ft).
Installthe cylinder head cover (see page 6-32).9.
rotation,
6-9
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8. Remove the cylinder head cover.
NOTE: Refer to page 6-32 when installing the cylin-
der head cover.
Remove the crankshaft pulley (see page 6-7).
Remove the middle cover and lower cover. Do not
use these covers to store removed items.
9.
10.
11.
MTDDLE 6x1.0mm
COVER 9.8 N.m {1.0 kgt m,
LOWERCOVER
9.8 N.m (1.0 kgt.m, 7.2 lbf.ftl
Mark the direction of rotation on the timing belt.
Loosen the adjusting bolt 180'. Push the tensioner to
remove tension from the timing belt, then retighten
the adiusting bolt.
AINUSTING BOLT54 N.m (5,5 kgt m,.(} tbf.rrl
12.
13. Remove the timing belt.
Installation
Install the timing belt in the reverse order of removal;
Only key points are described here,
1. Set the timing belt drive pulley so that the No. 1 piston
is at top dead center (TDC). Align the groove on the
timing belt drive pulley to the pointer on the oil pump.
GROOVE
DRIVE PULLEYClean.
2. Set the camshaft pulleys so that the No. I piston is at
TDC. Align the TDC marks on the camshaft pulleys to
the pointers on the back cover.
POINTER
CAMSHAFTPULLEYClean.
POINTER
r-t
(cont'd)
6-11
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Timing Belt
Installation (cont'd)
3. Install the timing belt tightly in the sequence shown.
O Timing belt drive pulley (crankshaft) J @ Adjust-
ing pulley =r @ Water pump pulley r @ Exhaust
camshaft pulley --) @ Intake camshaft pulley.
NOTE: Make sure the timing belt drive pulley and
camshaft pulleys are at TDC.
4. Loosen and retighten the adjusting bolt to tension
the timing belt.
5. Clean. then install the lower cover and middle
cover.
Install the crankshaft pulley, then tighten the pulley
bolt (see page 6-7).
Rotate the crankshaft pulley about five or six turns
counterclockwise so that the timing belt positions
on the pulleys.
Adjust the timing belt tension {see page 6-9).
1.
6-12
9. Check that the crankshaft pulley and camshaft pulleys
are both at TDC.
POINTER ON
lf the camshaft pulleys are not positioned at TDC,
remove the timing belt. adjust the position following
the procedure on page 6-11. then reinstall the timing
belt.
Installthe cylinder head cover (see page 6-32).
After installation, adjust the tension on each belt.
. See section 4 for alternator belt tension adjust-
menr.
. See section 22 for NC compressor belt tension
adjustment.
. See section 17 for P/S pump belt tension adjust-
ment.
10.
11.
12.
POINTER
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CKF Sensor
Replacement
1.
|o|'ln PUUCY BMCKET SOLIl0 r 1.25 mm14 .m 14.5 kgl.m,3:' lbtftl
Remove the guard bar and splash shield (see page
5-7 t.
Loosen the lock bolt and mounting bolt, then
remove the P/S pump belt.
MOUNTING BOLT8 x 1.25 mm
PUMPBELT
Loosen the adjusting bolt and idler pulley bracket
bolt, then remove the Ay'C comDressor belt.
ADJUSTING BOLTLOCKNUT8 x 1.25 mm24 N.m {2.4 kgf.m, 17 lbf.ft)
24 N.m (2.{ kgf.m, 17 lbf.ttl
24 N.m 12.4 lgf.m, 17 lbl.ftl
4. Loosen the locknut and mounting nut, then remove
the alternator belt.
LOCKNUT8 x 1.25 mm24 N.m (2.4 kgl.m, 17 lbtftl
10 x 1 .25 mma4 N.m (4.5 kgt m, 33 lbtft)
E
6.
7.
aJ.
Remove the cylinder head cover.
Remove the crankshaft pulley (see page 6-7).
Remove the middle cover and the lower cover.
Disconnect the CKF sensor connector, then remove
the CKF sensor.
6x1.0mm11 N.m {1.r kgnm,8.0 lbfft)
9. Install the CKF sensor in reverse order of removal.
BELT
CKF SENSOR
6-13
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