AT adjustment HONDA CR-V 1998 RD1-RD3 / 1.G User Guide

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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DATA LINK CONNECTOR {DLC) I16P}Troubleshooting Procedures, page 1 1'60PRIMARY HEATED OXYGEN SENSOR
{PRIMARY HO2SI {SENSOR 1)Troubleshooling, page 11 110
SECONDARY HEATED OXYGENSENSOR{SECONDARY HO2S) {SENSOR 2)Troubleshooting, page 1 1-1 17
'97 - 98 models:
AIR CLEANERReplacement, page 1 1'194
Troubleshooting, page 1 'l -200
THROTTLE BODY (TB)Inspection, page 11 196Removal, page 11-197Disassembly, page 1 1-'198
POWERTRAIN CONTROL MODULE(PCM) (A/TI
Troubleshooting Procedures, page 1 1-60Troubleshooting. page 1 1'82
THROTTLE CABLEInspection/Adjustment, page 1 1-1 94Installation, page 11- 195
VENTILATION (PCV) VALVEInspection, page 1 1-201FAST IDLEVALVE (A/T}
(cont'd)
1 1-5
PGM-FIMAIN RELAYRelay Testing, page 11-l87Troubleshooting. page 1'1 188
SERVICE CHECK CONNECTOR {2PITroubleshooting Procedures, page 1 1-60
,a'=_-_
WAY CATALYTIC
Inspection, page 1 1-168
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Component Locations
Index {cont'd)
39 - q, models:
THROTTLE BODY ITB)Inspection, page 1 1-196Removal, page 11- 197Disassembly, page 11 198THROTTLE CABLEInspectaon/Adjustment, page 1 1 194Installation, page I l'195
AIR CLEANERR€placomenl, page 1 1-194
CRANKCASEVENTILATION IFCVI VALVElnspection, page 11 201
FAST IDLE THERMO VALVE IA/T)Inspection, page 11'168
1 1-6
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Troubleshooting
Troubleshooting Procedures (cont'dl
Symptom Chart
Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction Indicator Lamp (MlL) tocome on. lf the MIL was reported on, go to page 11-60.Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated,The probable cause and troubleshooting page reference can be found below.
Other Probable Causes for an engine that will not start:- Compression- Intake air leakage- Engine locked up- Timing belt- Starting system- Overheating- Battery
SYMPTOMPROBABLE CAUSE
Engine will not sta rt4, 2,3,5,20, 't5, 1
Hard starting2, 4, 12,17, 14, 't9
Cold fast idle too low7, a,9, 6, 17
Cold fast idle too high7,8,9,11,10
ldle speed fluctuates9,7,8, 't1, 10
Misfire or rough runningTroubleshoot for misfire on pages '11-126, 1|21LOl/\/ power2, 10,11, 13, '17, 18,20
Engine stalls2, 4, 12,1,20,9,5, 't6
Probable Cause List (For the DTC Ch8rt, see page ll-75.)
Probable CausePageSystem
Engine controt ruoaute (ecvtffi'I11-42
I 1-178Fuel oressure
PGM-Fl main relav
lgnition system
Crankshatt Position/Top Dead Center/Cylinder position sensor circuit
Intake Air Temperature (lAT) sensor ctrculr
ldle Air Control (lAC) Vatve
Fast idle thermo valve
ldle speed adjustment
Throttle body
Throftle cable
Manifold Absolute P."""rr"ffi
Throftle Position (TP) sensor
Barometric pressur" (gnno-
Ay'T gear position signal
Brake switch signal
Air Cleaner
Three Way Catalytic Converter (TWC)
Evaporative emission (EVAP) control
Contaminated fuel
1 1- 187
Section 4
5't1-'t31,146
6I 't-95
711-152
81'l-168
1 1- 169
1011-196'1111-'194
12'1 'l -90
1 1- 103
1411-137
15Section 14
161 1- 166
17r 1-194
181 1,199'1911-203
20
11-64
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Clutch
Speciaf Tools ....,..... ..........' 12-2
lllustrated lndex ........... .'." 12'3
Clutch Pedal
Adjustment ........."."."".12-4
Clutch Master Cylinder
RemovaUlnstallation '." 12'5
Slave Cylinder
Removal/lnstallation .'.. 12-6
Pressure Plate
RemovaUlnspection ..'." 12-7
Clutch Disc
Removal/lnspection ."'.. 12-8
Flywheel
Inspection ...................... 12-9
Replacement ....................................... 1 2-9
Clutch Disc, Pressure Plate
lnstallation ....................' 12-10
Release Bearing
Removal/lnspection ...... 12'11
lnstaflation ..................... 12-12
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lllustrated Index
NOTE:
. Whenever the transmission is removed, clean and grease the release bearing sliding surface
.lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage1\
2-6).
. Inspect the hoses for damage. leaks. interference, and twisting.
LOCK PIN
*CLUTCH LINE19 N.m (1.9 kgj.m,14 tbtft)
8 x 1.25 mm13 N.m {1.3 kgf m,9.4lbtft)
PEDAL PIN.RESEFVOIR
HOSE
*RESERVOIR TANK
CLUTCH PEDALAdjustment, page 12-4*CI-UTCH MASTER CYLINDERFemoval/lnstallation, page 12-5
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbf.ft)
*CLUTCH LINE15 N.m (1.5 kgt m,11 tbr.ft)
*CLUTCH LINE24 N.m {2.4 kgf.m,17 tbf.ft)
CLUTCH DISCRemoval/lnspection, page 1 2-8Installation, page 12,13
8 x 1.25 mm25 N.m {2.6 kgt m,19 rbf.ftt
I x 1.25 mm22 N.m 12.2 kgl'm, 16lbfft)
.o-.9r
WM\,".0--
ffi-P"8Nmlloks{m'
FLYWHEELInspection, page 12IRepiacement, page 12-9
12 x 1.0 mm103 N.m (10.5 kgtm,75.9 lbf ftl
PRESSURE PLATERemoval/lnspection, page'12-7
Installation, page'12 13
RELEASE BEARINGRemoval/lnspection, page 12-1'!Installation, page 12-12
*CLUTCH LINE15 N.m (1.5 kgt m,11 tbf.ft)
12-3
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Differential
Tapered Roller Bearing Preload Adjustment (cont'd)
7. lf the tapered roller bearing preload is not within
the standard, select the thrust shim which will give
the correct tapered roller bearing preload from the
following table.
NOTE: Changing the thrust shim to the nexl size
will increase or decrease tapered roller bearingpreload about 0.3 - 0.4 N.m (3 - 4 kgf.cm, 2.6 -
3.5 lbf.in).
THRUST SHIM
8. Recheck the tapered roller bearing preload.
Part Numbe.Thickness
41381 - PX5 0001.90 mm (0.0748 in)
B41382 - PX5 0001.93 mm {0.0760 in)
c41383-PX5-000'1.96 mm (0.0772 in)
n41384-PX5-0001.99 mm (0.0783 in)
E41385-PX5-0002.02 mm (0.0795 in)
F41386-PXs-0002.05 mm (0.0807 in)
G41387-PXs-0002.08 mm (0.0819 in)
n41388-PX5-0002.11 mm (0.0831 in)
41389-PX5-0002.14 mm (0.0843 in)
J41390-PXs-0002.'17 mm (0,0854 in)
K41391 - PX5 - 0002.20 mm (0.0866 in)
4'1392-PX5-0002.23 mm (0.0878 in)
M41393-PX5-0002.26 mm (0.0890 in)
N41394-PX5-0002.29 mm (0.0902 in)
o41395, PXs - 0002.32 mm (0.09'13 in)
P41396-PX5-0002.35 mm (0.0925 in)
o41397-PX5-0002.38 mm (0.0937 in)
4't398-PXs-0002.41 mm (0.0949 in)
S41399-PXs-0002.44 mm (0.0961 in)
T41400-PXs-0002.47 mm (0.0972 in)
41873-P16-0001.66 mm (0.0654 in)
AB41874-Pl6-0001.69 mm (0,0665 in)
AC41875 P16 - 000'1.72 mm (0.0677 in)
AD41876-P16-0001.75 mm (0.0689 in)
AE41877-P16-0001.78 mm (0.0701 in)
AF41878-P16-0001.81 mm (0.07'13 in)
41879-P16-000'1.84 mm (0.0724in)
AH41880-P16-0001.87 mm {0.0736 in)
13-42
9. How to select the correct thrust shim:-1) Compare the tapered roller bearing preload
you get with the thrust shim that was removed,
with the specified preload of 1.4 - 2.5 N.m(14 -- 26 kgfcm, 12-23lbtinl.-2) lf your measured tapered roller bearing preload
is less than specified. subtract yours from the
specified,
lf yours is more than specified, subtract the
specified from your measurement.
For example with a 2.17 mm (0.0854 in) thrust
shiml
@ specified 2.5 N.m (26 kgf.cm,23 lbiin)- you measure 0.6 N.m (6 kgf.cm,5 lbf.in)
1.9 N.m (20 kgicm, 18 tbt.in) tess
@ you measure 3.3 N.m (34 kgf.cm,30 lbf.in)- specified 2.5 N.m (26 kgncm,23 lbf.in)
0.8 N.m (8 kgf.cm,7lbt.in) more
Each shim size up or down from standard
makes about 0.3 - 0.4 N.. (3 - 4 kgf'cm,
2.6 - 3.5 lbf.in) difference in tapered roller bear-
ing preload.
In example @, your measured tapered roller
bearing preload was 1.9 N.m (20 kgf.cm,
18 lbf.in) less than standard so you need a
thrust shim five sizes thicker than standard {trythe 2.32 mm (0.0913 in) thrusr shim. and
recheck).
ln example @, your measurement was 0,8 N.m
{8 kgf.cm, 7 lbf.in) more than standard, so you
need a thrust shim two sizes thinner (try the
2.1'l mm {0.0831 in) thrust shim, and recheck).
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Mainshaft Thrust Clearance
Adjustment
l. Remove the 78 mm shim
the transmission housing.
4.
and oil guide plate from
Install the 3rd/4th synchro hub, spacer collar, sth
synchro hub, spacer, and ball bearing on the main-
shaft. then install the above assembly in the trans-
mission housing.
lnstallthe washer on the mainshaft.
Measure distance @ between the end of the trans-
mission housing and washer,
NOTE:
. Use a straight edge and vernier caliper.
. Measure at three locations and average the read-
Ing.
END otTRANSMISSION
MAINSHAFT
WASHER
3RD/4TH SYNCHRO HUB
SPACER COLLAR
sTH SYNCHRO HUB
SPACER
78 mm SHIM
13-64
BALL BEARING
5, Measure distance @ between the end of the clutch
housing and bearing inner race.
NOTE:
. Use a straight edge and depth gauge.
. Measure at three locations and avorage the read-
Ings.
END ot CLUTCH HOUSING
BEARING
Select the proper 78 mm shim from the chan by
using the formula below.
Shim S€lection Formula:
From the measurements you made in steps 4 and 5:-1. Add distance @ (step 5) to distance @ (step 4).
-2. From this number. subtract 0.93 (which is the
midpoint of the flex range of the clutch housing
bearing spring washer).
-3. Take this number and compare it to the avail-
able shim sizes in the chart.
(For example)
A: 2.39 2.61
+ Bi O.22 - 0.93
= 2.61= 1.68
Try the 1.68 mm (0.0661 in) shim.
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Mainshaft Thrust Clearance
Adjustment (cont'dl
-7. Slide the mainshaft base over the mainshaft.
Attach the mainshaft holder to the mainshaft as
follows:
NOTE:
. Back-out the mainshaft holder bolt and
loosen the two hex bolts.
. Fit the holder over the mainshaft so its lip is
towards the transmission.
. Align the mainshaft holder's lip around the
groove at the inside of the mainshaft
splines, then tighten the hex bolts.
MAINSHAFT HOLDERBOLT
MAINSHAFT EASE07GAJ - PG20130
-9. Seat the mainshaft fully by tapping its end with
a plastic hammer.
-10. Thread the mainshaft holder bolt in until it just
contacts the wide surface of the mainshaft
base.
07GAJ - PG20130
-8.
t--E-Hlf\f,A l\. xex
l"\y I aors
t____=__)"n-____"8
\
MAINSHAFTHOLDER07GAJ - PG20110
- 11. Zero a dial gauge onthe end ofthe mainshait.
-12. Turn the mainshaft holder bolt clockwise; stop
turning when the dial gauge has reached its
maximum movement, The reading on the dial
gauge is the amount of mainshaft end play.
NOTE: Turning the mainshaft holder bolt more
than 60 degrees after the needle of the dial
gauge stops moving may damage the transmis-
sion.
MAINSHAFT HOLDER07cru - PG20110
-13. lf the reading is within the standard, the clear-
ance rs correct.
lf the reading is not within the standard,
recheck the shim thickness.
Standard: 0.11 - 0.18 mm (0.00i1- 0.007 inl
DIAL GAUGEMAGNET STAND AASE07979 - PJ40001
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Automatic Transmission
Special Tools . 14'2OescriptionGeneral Operation . .... 14 3Power Flow . . .. '14_6
Electronic Control System .. .. . . .. .14_15Hydraulic Control .. 14 24Hydraulic Flow....-....... .. . .... .. .. . 14_29Lock'up Syslem .. .'t4'39Electrical SystemComponenl Locdlrons 14 45
PCM Circuil Dragram (A/T Control Svstem)'97 Model ....................... . . .. - . ... .14-46'98Model ................. . ... .. .. .1450'99 00Models.... . .... . . . 1452
PCM Terminal Voltage/Measuring ConditionsA"/T Control System-'97Model ...... ..14'48A,/T Control System -'98 00 Models . . .. . . 14 54
Troubleshooting Procedures .. ..... ... - 14_56Svmotom to comoonent CharlEiectr,cal Syslem -'97 Model . . 14 60Electrical System -'98 - OO Models . .. . . 14_62Electrical Troubleshooting ('97 Model)Troubleshooting Flowaharts .... ..... . .. . . 14_64
Electrical Troubleshooting ('98 - 00 Models)Troubleshootinq Flowclt"n" .... . ....- . .14-93ElectricalTroublesliooting('99 00Models)Troubleshootino FlowchartO/D OFF Indicator Light Does Not Come On 14 131
O/D OFF Indicator Liaht On ConstantlY . . . .1!-132O/D OFF Indicator Light Does Not Come OnEven Though O/D Switch ls Pressed . .... - 14_133
Lock up Control Solenoid Valve A,/B AssemblyTest....................-......... . .14-135Replacement . .ll_135Shifr ControlSolenoid Valve Ay'B Assembl,Test .............................. . .. 14-136
Replacement..............- . .14'136Linear Solenoid AssemblYTest.............................................. .. .... . 14_137Replacement .. . 14138Marnshaftlcountershafl Speed SensorsReplacement ...-... 14_138A/T Gear Position SwitchTest ..........................-... . .. 14-139ReplacementA/T Gear Positionlndicator.................. 14-140
Valve Eodynepair ............................... ..... . . .. - . .. ... 14 192
Assembly .................... .. 1{_193
Valve CapsDesciiption....-........................ .. ...... 14194
tnspeition ................... .. 14' 195
N4ain Valve BodyDisassembly/lnspection/Reassemblv - ...... .. 14_196
Secondarv Valve BodYDisassemblv4nspectron/ReassemblY .. . 14 198
Reoulator Valve Bodvbisassembtv,lnspiction/Reassemblv . 14199
Servo EodvDisassembly/lnspection/Reassembly ... ....14'200
Lock'uo Valve BodYDis;ssembly/lnspection/Reassembly .... . 14_201
MainshaftDisassembly/lnspection/Reassembly .. .. .. ..14'202
Inspection ....-.............. ..11_203
Sealing RingsReilaceient ...... ..... . 14'204
CountershaftDisassembly/lnspection/Reassembly .. . . . . . 11-205
Disassembly/Reassemb|y . . ........ ...... . .. 14_206Inspedron ................ . .... . 14 207
One wav ClutchDisassembly/lnspection/ReassemblY ... 11_209
Sub-shaftDisassembly/lnspection/Reassembly ... . .. . 14-210
oisassembly/Re6ssembly . . ... .-...... . . ..14-211
Sub-shaft BearingsReplacement .......14'212
Clutchllfustrated Index .......... . . .14-213
Disassembly .... .. .....14-216Reassembfy .... . .. .. . 14'218
Differentialllfustrated Index " 14-222Backlash Inspection . .... . .14'223
Bearing Repiacement .. 11-223
Differe-ntial Carrier Replacement .. .. . . . .. ..11-2?4
OifSeal Replacement. . .. 14'225
Side Clearance lnspection . . - .. ... . - ...... . .. 11'226
Transmission Housing BearingsMainshaJVCountershaft EearingsRepfacement .......14221Sub'siralt Eearing Replacement . . . . . . . . . ..11'224
Toroue Converter Housing BearingsMainshattEearing/OilSe6lReplacement . .. l4229
Countershaft Bea;ing Replacement.. .... .. ..14-230
Input Test - '97 - 98 ModelsInput Test '99 - 00 Models
Symptom to-Component ChartHydraulic System ...............
Checking
Removal ...,lllustrated Index (4WD)
Interlock SystemInterlock ControlUnit lnputTest. -..... -.. .... . - 14 144* Key Interlock Solenoid Test .- .. . . . - . . . ..... 14_146* Shift Lock Solenoid Test ..............-.-. . .. . ... .... 14 147*Shift LockSolenoidReplacement...... .. . .. .. 14 148* park pin Switch Test ......... 14 119' Park Pin Switch Replacement- '97 - 98 Models ....... 14-150* Park Pin Swirch/Over Drive (O/Di SwitchReplacemenl '99-00Models . .. 14_151over-Drive (O/D) Switch {'99 00 [4odels]Test........_..................... .......14-152Hydr.ulic System
..............._............... t4 142.................................. 14-143
Control Lever AssemblyR6placement ......,.,Reverse ldler Gear
lllustrated lndex
.......... 14-230
14 231
11-231
1nsta1|ation ..................Park StopInspeclion/AdjustmenlTransfer AssemblY.......14.232
RoadTest.............-.... ........ .StallSpeedTest ....._........................ ....... 14-159Fluid Level......_................... 14'160
Disessembly .................... 14-235Transfer Drive Gear BearingReplacementTrans{er Driven Gesf Shaft BearingReplacementTransfer Housing Roller BearingReplacementTransfer Cov€r A Bearing Outer RaceReplacementTransfer Housing Bearing Outer RaceReplacement ......-..,,,,,.....ReassemblvTransmassaonBeassembly ... -.. .... .14 250
Torque Converier/Drive Plate . .-. .... .. . ... .....14_258
Transmissionlnstatlation .................. ....... 14'259
Cooler Flushing . . ......11-261ATF Cooler HosesConnection.................. ....... 14-266I Shift LeverRemoval/lnstallation . .. 14'261
Disassemblv/Reassemblv - '97 - 98 Models . . 14_264
Disassembli/Reassemblv -'99 - 00 Models . 14-269
Over'Orive (O/D) Switch WireClearanceAdjustment. - ... . . . .. .. . 14'270
Detent Spring Replscement . . -.. ... .14'271*Shift CableAdiustment ....... 14'272
Repfacement.............. . 11'273
14 15711-237
11-237
14-238
$-234
11-23914-240
Transmigrion
Inspeclron ....., ...........Transfer AssemblyRemova1,.,,,..............,lnstallalion ........... .. ...Transmission
14 164
14-16514,167
14-169
End Cover/Transmissio . 14'174Transmission Housing .... ... .. . . .... .. 14-176Torque Converter Housingly'alve Body.. - ... -. 14 178
lllustrated lndex (2WD)End Cover/Transmissio ....... 14 180Transmission Housing . . ... . .. .... ... 14'182Torque Convener Housing/r'alve Body ......- 14-184
End CovefRemovat ...................... ....... 14'186Transmission HousingRemoval ...................... .. 14_188Torque Convener HousingA/alve BodYRemovat ................-..... .-..... 14-190
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