rod HONDA CR-V 1998 RD1-RD3 / 1.G Owner's Manual

Piston PinsConnecting Rods
Assemble the Piston Pin Tools as shown.
PISTON BASE HEAO07HAF -PL20102
PISTON BASE07973 - 6570500
Adjust the length A of the piston pin dflver.
A: 49.70 mm 11.957 in)
PIN DRIVER HEAIPE00320
\
RIr1
nT---
u
ffi-"""-
u_ll
3. Place the piston on the piston base, and press the
pin out with a hydraulic press. Make sure that the
recessed portion of the piston aligns with the lips
on the collar.
7-14
Removal
1.
PISTON07973 -
PISTON PIN BASE INSERT07GAF - PH60300
PISTON PIN DRIVER SHAFT07973 - PEt 0310
PILOT COLLAR07LAF - PR30100Embossod mark facing up.
Selection
Each rod falls into one of four tolerance ranges (from 0
to + 0.024 mm {0 to + 0.0009 in). in 0.006 mm (0.0002 in)
increments) depending on the size of its big end bore.
lt's then stamped with a number 1.1.2,3, or 4) indicating
the range.
You may find any combination ot 1,2,3, or 4 in any
engrne.
Normal Bore Size: ,18.0 mm (1.89 in)
Inspect the connecting rod for cracks and heat damage.
CONNECTING ROD BOREREFENENCE NUMBERHalf of number is stamped onbearing cap, the other half onconnectno roo.
www.emanualpro.com

Piston Pins
lnstallation
The arrow must face thetiming belt side ot theengine and the connectingrod oil hole must face therear of the engine.
CONNECTING ROOotL Hor.E
1. Adjust the length B of the piston pin driver and shaft.
B: 49.70 mm (1.957 in)
PISTON PIN DRIVER SHAFT0t973 - P€qxtlo
Place the piston on the
pin in with a hydraulic
recessed portion of the
on the piston base head.
ffi*r,"ron'nl
PILOT COLLAROTLAF - PF3O1(x'
PISTON PIN BASE INSERT07GAF - PH6o3ttO
PISTON BASE HEADOTHAF - PL2O102
PISTON BASE07973 - 6670500
piston base and press the
press. Make sure that the
piston aligns with the lugs
7-15
www.emanualpro.com

Piston Pins
lMeasure the diameter of the piston pin.
Piston Pin Diameter:
Standard lNewl: 20.996 - 21.000 mm
{0.8266 - 0.8268 in}
20.998 - 21.002 mm(0.8267 - 0.8268 in)
Inspection
1.
Oversize:
2. Zeto the dial indicator to the piston pin diameter.
7-16
3. Measure the piston pin to piston clearance. lf the
piston pin clearance is greater than 0.024 mm
(0.0009 inL remeasure using an oversized piston pin.
NOIE: All replacement piston pins are oversize.
Piston Pin-to-Piston Clearance:
Standard lNewl: 0.010 - 0.017 mm
10.0004 - 0.0007 in)
Check the difference betlveen the piston pin diame-
ter and the connecting rod small end diameter.
Piston Pin-to-Connecting Rod Interference:
Standard (New): 0.015 - 0.032 mm(0.0006 - 0.0013 inl
4.
www.emanualpro.com

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-;
www.emanualpro.com

PistonsCrankshaft
Installation
1. Apply a coat of engine oil to the ring grooves andcylinder bores.
It the crankshaft is already installed.
2. Set the crankshatt to BDC for each cylinder.3. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of theconnecting rod bolts.
4. lnstall the ring compressor, and check that the bear-ang is securely in place.
5. Position the piston in the cylinder, and tap it in usingthe wooden handle of a hammer. Maintain down-ward force on the ring compressor to prevent ringstrom expanding before entering the cylinder bore.6. Stop after the ring compressor pops free, and checkthe connecting rod-to-crank journal alignmentbefore pushing piston into place.
7. Install the rod caps with bearings, and torque theNUIS IO:
31 N.m (3.2 kgf.m,23 tbf.ft)
Apply engine oil to the bolt threads.
lf the crankshaft is not installed:
2. Remove the rod caps and bearings, and install theflng compressor.
3. Position the piston in the cylinder, and tap it inusing the wooden handle of a hammer. Maintaindownward force on the ring compressor to prevent
rings from expanding before entering the cylinderoore,
4. Position all the pistons at top dead center.
The arrow must facethe timing belt sideof the engine.
CONNECTING ROOOIL HOLE
RUBBER HOSES
7 -20
\-\
3.
4.
1.
6.
Installation
Apply a coat of engine oil to the main bearings androd bearings.
Insert the bearing halves in the cylinder block andconnect|ng rods.
Hold the crankshaft so the rod journals for cylindersNo.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rodjournals into connecting rods No.2 and No.3.Install the rod caps and nuts finger tight.
outward.
Rotate the crankshaft clockwise, and seat the jour
nals into connecting rods No. 1 and No. 4, Install
the rod caps and nuts finger-tight. Install the capsso the bearing recess is on the same side as therecess an the rod.
Check the rod bearing clearance with plastigage(see page 7 8). then lorque the capnuts.
Torque:
3l N.m 13.2 kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
5.
7. Install the thrust washers on the No. 4 journal.
Line up the mark wheninstalling connecting rodcap.
www.emanualpro.com

Coat the thrust washer surtaces and bolt threads
with oil.
Installthe main bearing caps.
Check clearance with plastigage (see page 7-7), then
tighten the bearing cap bolts in 2 steps.
First slsp: 25 N.m {2.5 kgf'm, 18 lbf'ft}
Sscond step: 76 N'm (7.8 kgf'm. 56 lbf'ft)
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
NOTE: Whenever any crankshaft or connecting rod
bearing is replaced, it is necessary after reassembly
to run the engine at idling speed until it reaches
normal operating temperature, then continue to run
it for approximatelY 15 minutes.
10.Clean and dry the right side cover mating surfaces.
Apply liquid gasket, part No. 08718 - 0001 or 08718
- 0003, evenly to the block mating surface of the
right side cover and to the inner threads of the bolt
holes. Install it on the cylind€r block
11,
6x1.0mm9.E N.m {1.0 kgt m,7.2 tbf.ft)
NOTE:
. Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
old residue.
. After assembly, wait at least 30 minutes before
filling the engine with oil.
(cont'dl
7-21
RIGHT SIDE
OOWEL PINS
www.emanualpro.com

Radiator
Engine Coolant Refilling and Bleeding (cont'dl
Mix the recommended antifreeze with an equal
amount of water in a clean container.
NOTE:
. Always use Genuine Honda Antifreeze/Coolant.
Using a non-Honda coolant can result in corro-s\on, ca
sng t\e coo\
g sys\em \o ma\lunct\on
o. fail.
For best corrosion protection, the coolant con-
centration must be maintained year-round at50% minimum. Coolant concentrations less than
50% may not provide sufficient protection against
corrosion or freezing. Coolant concentrationsgreater than 60% will impair cooling efficiency
and are not recommended.
Do not use additional rust inhibitors or anti-rustproducts; they may not be compatible with the
coolant.
Engine Coolant Refill Capacity Iincluding 0.6 / 10.63US $, 0.53 lmp qtl for hoater and ressrvoirl:
A/T: 3.9 f {4.1 US $, 3.4 lmp qtl
M/T: 1.O t 14.2 US $, 3.5 lmp qrl
10-6
9. Pour coolant into the radiator uD to the base of the
filler neck. When pouring engine coolant. do not let
coolant spill on any electrical pans or the paint. lf
any coolant spills, rinse it oft immediately.
Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
Turn off the engine. Check the level in the radiator,
add coolant if needed.
Put the radiator cap on tightly. then run the engine
again and check for leaks.
11.
10.
12.
www.emanualpro.com

'98 - 00 model3:
The MIL has boon reDortod on.DTC m122 b rtorod.
P.oblom veiification:1. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutral) untilthe radiator tan comes on,then turn the ignition switchOFF.2. Turn the ignition switch ON lll).3. Check the throttle position
with the scan tool.
ls there approx. 10% when thethrottle is fully closed andapprox. 90% when the throttleis fully opened?
Intarmittent failure. system is OKat thia time. Check for poor con-n€ctions or loolo wires rt C130ITP s.nsorl and.t the ECM/FCM.
Check for an opon or short in thowire {VCC2 linel:1. Turn the ignition switch OFF.2. Disconnect the TP sensor 3Pconnedor,3. Turn the ignition switch ON (ll).
4. Meas! re voltage betweenthe TP s€nsor 3P connector ter-minals No. 1 and No.3.
ls there approx. 5 V?
Check lor an opon in wiro IVCC2linel:Measure voltage between ECM/rcM connector terminals C'18 andc2a.Chock for en op€n or Bhort in TP3an30r:1. Turn the ignition switch OFF.2. At the sensor side, measureresistance between the TPsensor 3P conneclor terminalsNo. 1 and No. 2 with the throt-tle fully closed.
B.psir opon in the wire b€{woontho ECM/PCM {C281 and th6 TP3en!xtt.ls lher€ approx. 5 V?
Subslitute e known-good ECM/PCM .nd r.chock. lf pro3cribedvoltrge iB now rYrilablo, replacath. originll ECM/PCM.
TP SENSOR 3P CONNECTOR {C130}
sG2IGRN/BLKI
vcc2IYEUBLUI
Wire side oI Iemale lerminals
Wire sid6 of temale terminals
Terminal side of male torminals
(cont'd)
1 1-105
ECM/PCM CONNECTOR C (31P}
sG2IGRN/BLKIa-,l 18 sl./|135
/1617lrs]zolzr zzl
232527)gJ lzgi3o sr I
T^vccz {YEL/8LUl
(To page 11-106)
www.emanualpro.com

PGM-FI System
'99 - 00 models:
- The MIL has bsen reported on.- DTC P0131 ir storod.
Problem ve fication:1. Do the ECM/PCM Reset Pro-cedure,2. Start the engine. Hold theengine at 3,000 rpm with noload {in Park or neutral) untillhe radiator tan comes on.3. Check the Primary HO2S(Sensor 1) oltput voltage withthe scan tool during accelera-tion using wide op€n throttle.
Inl.rmittant failura, 3yrtam i! OKat thb tim.. Ch.ck tor poor con-nectiona oa looaa wlraa al C111{Pri|n.ry HO2S, Son3or 1l .nd .ttho ECM/FCM,
Does the voltage stay at 0.5 Vor less?
Check tho fuel pressure (see pago1r,178).
R.p.ir th. fu€l lupply ry!t.m.
Chock lor a short in tho HO2S:1. Turn the ignition switch OFF.2. Disconnect the Primary HO2S(Sensor 1) 4P connector.3. St6rt the engine and lot it idle.4. Check the Primary HO2S(Sensor 1) output voltage withthe scan tool,
Does it stay 6t 0.5 V or less?Rephc. th6 HO2S (S.n3or 11.
Chock for a short in tho wirc(PHO2S lino):1. Turn the ignition switch OFF.2. Disconnect the ECM/PCM con-nector C (31P).
3. Check tor continlity betweenthe Primary HO2S {Sensor 'l}
4P connector terminal No. Iand body ground.
Ragah rhort in tha wira balwoanth. ECM/PCM {Cl61 rnd thcPrirn.ry HO2S (S.n3or 11.
Substltut6 a known-good ECM/PCM and recheck. lf rymptom/indicrtion 00os away, raplaco thcoriginal ECM/PCM.
Primary Heated Oxygen Sensor (Primary HO2SI (Sensor 1l (cont'd)
PRIMARY HO2S (Son.or 1l aP CONNECTOR |C111)
PHO2S T--1rwHTr f-T---]
--1 1 2lI t--- 1t6)lslrlv L__r__J
_L
Wire side ol female terminals
11-112
www.emanualpro.com

'99 - 00 modols:
Th6 Mll has b€on reDortod on.DTC ml32 is itorod.
Problem vorification:'1. Do the ECi!4/PCM Reset Procedure,Start the ongine. Hold theengine at 3,000 rpm with noload (in Park or neutral) untilthe radiator fan comes on.Check the Primary HO2SlSensor 1) output voltage withthe scan tool during decelela-tion using completely closedthroftle.
Int.rmitt .fi tailuro, syltom b OKat thit tima. Check for poor con-nactiona oi loo3a wirar !t Cltl(Primrry HO2S, S.nror 1) .nd .tth. ECM/FCM.
Doos the voitage stay at 1.5 Vor more?
Check for an opsn in the PrlmaryHO2S:1. Turn the ignition switch OFF.2. Disconnect the Primary HO2S(Sensor 1)connector.3. Connect the Primary HO2S(Sensor 1) 4P connector t6rmi-nals No. 1 and No. 2 with a
iumperwire.4. Turn the ignition switch ON (ll).
5, Check the Primsry H02S(Sensor 1) output voltage withthe scan tool,
lsthere 1.5 V or more?
Check for an op6n in th6 wiro{PHO2S line):1. Turn tho ignition switch OFF.2. Connect ECM/PCM connectorterminals C16 and C18 with a
iumper wire.3. Turn the ignition switch ON lll).4. Check the Primary HO2S(Sensor 1) output voltage withthe scan tool.
Ropair opon in thc wire bc{w.cnthe ECM/PCM {Cl6}.nd thePrimary HO2S {S€nror 1}.ls there 1.5 V or more?
Substituto a known-good ECM/PCM snd rochock. lf 3ymptom/indicetion go€a awry, roplaca thoorigin.l ECM/PCM.
PRIMARY HOzS (S6n!or 1l aPCoNNECTOR lcltl)
Pt()2sIWHTIsG2{GRN/BTJ(I
Wire side of tem6le terminsls
ECM/PCM CONNECTOR C (31P}
IGRN/BLKI
JUMPER WIRE
Wire side ol temale t6rmin6ls
(cont'd)
-1 15
2789
/1617't819120A22
23E29g)31
PHO2S {WHTIsG2
11
www.emanualpro.com