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

Under-hood Emissions Control Label
Emission Group ldentification
(1998 modell
Example:
50ST {50 States}:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OFCALIFORNIA REGULATIONS APPLICABLE TO 1998MODEL YEAR NEW LIGHT DUTY TRUCKS,
/$ST (itg Statos/Fodsrsll:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONSAPPLICABLE TO 1998 MODEL YEAR NEW LIGHT DUTYTRUCKS.
CAL {California}:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OFCALIFORNIA REGULATTONS APPLICABLE TO 1998MODEL YEAR NEW TLEV LIGHT DUTY TRUCKSPROVIDED THAT THIS VEHICLE IS ONLY INTRODUCEDINTO COMMERCE FOR SALE IN THE STATE OFCALIFORNIA.
DwlF AIo|NG oB cha\Gtftc I + coot r
-s€ msoru1or or FoNoA-IEaoTTxD-ibl1'v! Lrff EzEcoo-aN' a\D wATfB. M w r or_ut-ir coolqNt, oR-l;ir,FEaFEf-ENGINE MAY BE SEflIOUSLYSIONTENEO.DSEPLACI CoOTANT AnEs 85 itNlgsloF @ MILIS l@0 rnl, wHrcHEvEs coMEs
TNEREAFT€R, REPLACE EvEny fmAFSl m m M[Es i@ kml, wHcHrvEB coMEs
DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX. NOTTHE iAD]ATOR.DFOR FUFTNEfr INFO8MATION ON IN€ COOT]NC SYSIEM NEAD THE OWNEN'S MANUAL,. CHECK W|TH YOUR NONDA OEALEF.
@GD
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFOEMS TO I], S. EPAFEGIJLAIIONSAPPLICASLE TO 1993 MOOELY€AF NEW LIGHT DUIYTNUCXS.
CATALYSTrwqHozst2l/sFt/osD l cERI|FtEOvAlvttAsH lrr0.l010.02nmicolo) EX:01310.02mmSPAS( PIUG GAP I.O IINMlDLl SPTED 750 I 50 rym686,13G96PROCEOURESI2.0 L
TlNt UPCoND/ToNS: ENGINE AT NOiMIEMPETAIURT,ALLACCESSORIESTUNNIfAN OFf. TRAI1SMISSON IN NEUTMINO OIIIER AOJUSTI\TFIIS IIEEOED.
1-16
Engine and Evaporative Families
Engine Family:W HNX T O2.O UF1
Mod€l Year
W: 1998
Manufacturer Subcods
HNX: HONDA
Family Typo
V: LDV
T: LDT
Displacomsnt
Soqu€nco Characiors
Evaporative Fami
Family:
Model Yeat
W:1998
Manufastu16r Subcode
HNX: HONDA
Family Type
E: EVAP
R; EVAP/ORVR
Canister Work Capacity
Sgquonco Charaqtsrs
W HNX EOOSOAAB
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Emission Group ldentification
(1999 model)
Example:
50 state TLEV + NLEV {Unrestricted}
THIS VEHICLE CONFORMS TO U.S. EPA NLEV
REGULATIONS APPLICABLE TO 1999 MODEL YEAR
NEW TLEV LIGHT DUTY TRUCKS ANO CALIFORNIA
REGULATIONS APPLICABLE TO 1999 MODEL YEAR
NEW LIGHT DUTY TRUCKS.
'.WNEN AOO NG OR CNANGINC THE COOLANT. USE @SOLU I ON Of FONOA U-ECo-q.NOEDImcrtniuvcoourr mo wlttt NEVEF oILLJTE THE CooLANT,0RTHE LIFE 0F TNE
"Eifil:$o""niii?i,THffi ffi'"R @ M LEs lmo rhl, wNrcHEVEn coMEs
i'lrt^t orrrr, ^,r*a, rurr"* os @ M LEs 1@ kmr wNICHEVER coMEs
}CNECK OR ADD COOLANT AT THE RESER!'E TAN( NOT IHE NADIATOSDFOfi fWTHEF NFORMATION ON THE COOL NC SYSTEM READ THE OWNER'S MANUAL'' CHECK WIIH YOUS HONOA OEALER.
GD
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFOAMSTOU. S EPA NLEVFEGULANONS APPLICCBLI TO 1999 MOD€LYEA8 NEW TIEV LIGHT DUTY ]nUCKS ANDCALIFORNIA REGULATIONS APPLICASLE IO 19S9MOOEL YEAR NEW TLEV LIGHT DUTY IFIJCKS,,|F --'-
Ll: .-.-,1
I rFrll\=#_H*
CATALYST
VALVE IASN lN:010r0.02 mmlCoLDj EX 0131002 mmSPA8K PLUG GAP 10- l l nmIDLE SPEED 130 t 5{ rPmOBDIICERT]ATD
201
TUNE I]PCONDIIIONS INGINEAT NOBTEI\'PERATUR€ ATL ACCESSOS ES TLJRNFAN OFf IRANSMSSION N NEL]TMLNO OINER ADJUSTMTNTS NEEOEO.
JL
Iooro nr tist rc orn svtncrE MUsT BE coMoufitooNArounwNEElDslvE SPEEDiitriunor mo ovuvo uenn orr Enw sE a NoN.loaDE D rEsr PRoCE ouRE MU sT 8E Pf Rr-
Engine and Evaporative Families
Engine Family:X HNX T02,O UA2
Model Year
X:1999
Manutao{urer Subcode
HNX: HONDA
Family Type
V: LDV
T: LDT
Displacoment
Saquence Charactors
Evaporative Family:X HNX EOO8OAAB
Model Yoal
X:1999
Manutacturar Subcode
HNX: HONDA
Family Typo
E: EVAP
R: EVAP/ORVR
Canbter Work Capacity
S€quonce Chartsters
1-17
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Under-hood Emissions Control Label
Emission Group ldentification
(2000 model)
Example:
DWFEN aDD r,tc 0R ChA\CtN! rlt cooraN. ust MsoLU- oN or fioNpA q-af6MrNp-ol
lfi ;!,."5:P!$t:1t9ffilf 1
vEn u u'r +-E coo|-d',r os-Fiiiiifi-'DREpf cE coolaNrAFTEBt3tlomistoR@MtLEs r@km),wH ctlEvrscoMEsT|E8EAFTER, BEprAcE EVEny ErdFst oB @ MttEs lmr,t, ffitcHEVER coMEsDCIIICX OF ADD COOLA I I'-FE AISIRVI TAI{I\. NOI THE MDIAIOR":3lliJ#fl "lj,9lx6L;T&Iji(0or|]\G s,5TEM 8r!D TrE owrEp s MA\u.r.
m
IMPORTANT VEHICLE INFORMATION
IHIS \/IHICLE CONFONMS TO U. S. EPA NLEVSEGULATIONS APPIJCq3LE TO 2OOO IVOOELYEAF NEW T!!V LIGHT DUTY TBUCKS ANDCALIFONNIA SEGULATIONS APPLICASLE TO 2OOOMOO€L YIAA NEW TLEV LIGHT.OUTY TFIJCKS.
CATALYST
vALvt LA5h tN:0,10r0.02 mm{C0t0l El:0.13!002 mhSPAn(PLUGGAP 1.0-11mmlDlE SPEEo 734150lpmO8O CENTFIED
?.0 t
TUNI UP CoNDIToNS: ENGINE AT NORMTTMPERAIURE ATLACCESSORIES fu BNITAN OFF TiANSMISS ON IN N€UTRALNO OTHER AD.ILJSTMENIS NEEDEO.
.l-L
|oAoEDr/MTESTNG oFTHsvtHrctE uLrst gt couolorooN,{raua.wxEtt onuspreosyNoiRoN zEo DvNAMoMETER. olrEiwsE. A NoN.LoAoEo rEsr pBocEounr uust sr pair
1
50 State TLEV + NLEV (Unrestricied,
THIS VEHICLE CONFORMS TO U.S. EPA NLEVREGULATIONS APPLICABLE TO 2OOO MODEL YEARNEW TLEV LIGHT DUTY TRUCKS AND CALIFORNIAREGULATIONS APPLICABLE TO 2OOO MODEL YEARNEW LIGHT DUTY TRUCKS.
1-18
Engine and Evaporative Families
Engine Family:Y HNX TO2.O UA2
Model Y€ar
Y: 2000
Manufaqturer Subcodo
HNX: HONDA
Family Type
V: LDV
T: LDT
Displacement
Saquenco Charasters
Evaporative Family:Y HNX EOOSOAAB
Modol Yea.
Y: 2000
Manufacturer Subcode
HNX: HONDA
Family Type
E: EVAP
R: EVAP/ORVR
Canister Work Capacity
Soquenca Charactet3
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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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Engine Block - Section 7
o
o*1: '97,'98 models 15 mm (0.6 in)'99,'00 models 20 mm (0.8 ini
Unit of length: mm (in)
MEASUREMENTSTANDARD (NEWISERVICE LIMIT
Cylinder blockWarpage of deck surfaceBore diameterBore taper
0.07 (0.003) max.84.00 - 84.02 (3.307 3.308)0.10 (0.004)
84.07 (3.310)
0.05 (0.002)
PistonSkirt O.D.*1trom bottom of skartClearance in cylinderGroove width {For ringi TopSecondoil
83.98 - 83.99 (3.306 - 3.307)0.01 - 0.04 (0.0004 - 0.001611.240 - 1.250 {0.0488 - 0.0492)1.220 1.230 {0.0480 - 0.0484)2.805 2.825 10.1104 - 0.1112)
83.97 (3.306)
0.05 {0.002)1.26 (0.0s0)
1.25 (0.049)
2.44lo.112l
Piston ringRing-to'groove clearance ToPSecondRing end gap ToPSecondoil
0.055 - 0.080 (0.0022 0.0031)0.035 0.060 (0.0014 - 0.0024)0.20 0.30 (0.008 - 0.012)0.40 - 0.55 (0.016 0.022)0.20 - 0.50 (0.008 - 0.020)
0.13 (0.005)
0.13 (0.005)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
Piston Pino.D.Pin-to-piston clearance
20.996 - 21.000 (0.8266 - 0.8268i0.010 - 0.017 (0.0004 - 0.0007)
Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.015 - 0.032 (0.0006 - 0.0013)20.968 -20.981 10.8255 -0.8260)
48.0 (1.89)
0.15 - 0.30 {0.006 - 0.012ioro to.oroi
CrankshaftMain journaldiameter
No. 1,2,4 and 5 iournalsNo. 3 journal
Rod iournal diameterTaperOut ol roundEnd play
Bunout
54.976 - 55.000 (2.'l644 - 2.1654)54.970 54.994 (2.1642 - 2.1651)44.976 - 45.000 /.1.1707 - 1.711110.005 (0.0002)max.
0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.0 r 4)0.03 (0.001)max.
0.010 (0.00041
0.010 (0.0004)
0.45 (0.0r8)
0.04 (0.002)
BearingMain bearing-to-iournal oil clearanceNo. 1, 2, 4 and 5 iournalsNo. 3 journal
Rod bearing-to-,ournal oil clearance
0.024 - 0.042 10.0009 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.020 - 0.038 (0.0008 0.0015)
0.06 (0.002)
0.06 (0.002)
0.05 (0.002)
o
2-3
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Spark Plug Inspection
Inspect the electrodes and ceramic insulator for:
. lmproper gap. Oil-fouling. Carbon deposits. Cracked centerelectrode insulator
Burned or worn electrodes may be caused by:
. Advanced ignition timing
. Loose spark plug
. Plug heat range too hot
. Insufficient cooling
Fouled plug may be caused by:
. Retarded ignition timing
. Oil in combustion chamber
. Incorrect spark plug gap
. Plug heat range too cold
. Excessive idling/low speed runnang
. Clogged air cleaner element
. Deteriorated ignition wires
I
2. Check the electrode gaP.
. Adjust the gap with a suitable gapping tool.
Electrode Gap
Standard 1.1 3 ' mm (0.043 Loo. in)
Replace the plug if the center electrode is rounded
as shown below:
Spark Plugs
'97 - '98 modsls:
ROUNDEOELECTRODE
,--, /(--/| | r--'--'--r-.--l-:=---:1
:
ZFR5F-11 (NGK)
KJ16CR-111 (DENSO)
'99 - 00 models;
ZFR6F-11 (NGK)
KJ2OCR-111 (DENSO)
Apply a small quantity of anti-seize compound to
the plug threads, and screw the plugs into the cylin-
der head finger-tight. Then torque them to 18 N'm
(1.8 kgf.m. 13lbf.ft).
4-21
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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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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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Piston Rings
End Gap
2.
1.Using a piston, push a new ring into the cylinder
bore 15 - 20 mm (0.6 0.8 in) from the bottom
Measure the piston ring end-gap with a feeler
ga uge:
. lf the gap is too small, check to see if you have
the proper rings for your engine.
. lf the gap is too large, recheck the cylinder bore
diameter against the wear limits on page 7 '13.
Piston Ring End-Gap:
Top Ring
Standard (Newl:0.20 - 0.30 mm
10.008 - 0.012 inl
Service Limit: 0.60 mm {0.024 inl
Second Ring
Standard lNew): 0.i10 - 0.55 mm
{0.016 - 0.022 inl
Service Limit: 0.70 mm (0.028 in)
Oil Ring
Standard (Newl: 0.20 - 0.50 mm
10.008 - 0.020 in)
Service Limit: 0.70 mm (0.028 in)
PISTON RING
--:4 llEND GAP -1f-
Ring-to-Groove Glearance
After installing a new set of rings, measure the ring-to-
groove clearances:
Top Ring Clearance:
Standard {New}: 0.055 - 0.080 mm
10.0022 - 0.0031 inl
Service Limit: 0.13 mm 10,005 inl
Second Ring Clearance:
Standard {Newl: 0.035 - 0.060 mm
{0.001'l - 0.0024 inl
Service Limit: 0,13 mm 10.005 inl
7-17
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Crankshaft Oil Seal
Rotate the rings in their grooves to make sure they
do not bind.
Position the ring end gaps as shownl
SECOND RING GAP
Appror.90"
DO NOT position any ring gap
at piston thrust surfaces,
OIL RINGGAPAppror.90'TOP RI.IIG GAPSPACER GAP
DO NOT position any ring gap
in line with the piston pin hole.OIL RING GAP
1.
lnstallation
The seal mating surface on the block should be dry
Apply a light coat of oil to the crankshaft and to the
lip of the seal.
Drive the crankshaft oil seal squarely into the right
sroe cover.
DRIVER
lnstall seal with thepart number sidefacing out.
Confirm that the clearance is equal all the way around
with a feeler gauge.
Clearance:0.5 - 0.8 mm {0.02 - 0.03 inl
NOTE| Refer to pages 7 23 and 8-10 for installation
of the oil oumD side crankshait oil seal.
0.5-0.8 mm{O.02 0.03 in)
7-19
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