Ac and heat HONDA CR-V 1998 RD1-RD3 / 1.G Service Manual

lnstellation
1. Open the throttle valve fully, then install the throttle
cable in the throttle linkage, and install the cable
housing in the cable bracket.
97 - 98 modols:
THRoTTLE LINKAGE CABLE
INNER CABLE
- (Xl modols:
LOCKNUT
'99
2.Sta.t the engine. Hold the engine at 3.000 rpm with
no load (in Park or neutral) until the radiator fan
comes on, then let it idle.
Hold the cable sheath, removing all slack from the
cable.
Set the locknut on the cable bracket.
Adiust the adjusting nut so that its free play is 0 mm.
Rimove the cable sheath from the throttle bracket,
reset the adjusting nut and tighten the locknut.
ADJUSTING
BRACKET
'97 - 98 modals:
lhere should beno clearance.
AD.'USTING NUT
'99 - 00 modeb:
CABLEBRACKET
9.8 N.ml'1.0 kgt'm,7.2 tbr.ft)
9.8 N.m(1.0 kg{.m,7.2lbllrl
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Intake Air System
Throttle Body
Doscription
The throttle body is a single-barrel side-draft type. The
lower portion of the throttle valve is heated by engine
coolant from the cylinder head. The idle adjusting screw
which regulates the bypass air is located on the top of
the throttle bodv.
The illustration shows'97 - 98 models,'99 - 00 rnodelsare similar.
1 1-196
lnspection
Check that the throttle cable operates smoothly without
binding or sticking.
lf there are any abnormalities, check for:. Excessive wear or play in the throftle valve shaft.. Sticky or binding throttle lever at the fully closed posi-
tton.
. Clearance between throttle stop screw and throttle
lever at the fully closed position.
97 - 98 models:
THROTTLE LINKAGE
Replace the throttle body if there is excessive play in the
throttle valve shaft or if the shaft is binding or sticking.
THROTTLE LINKAGE
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Emission Control System
System Description
The emission control system includes, a Three Way
Catalytic Converter {TWC), Positive Crankcase Ventilation
(PCV) svstem and Evaporative Emission (€VAP) Control
system. The emission control system is designed to meet
federal and state emission standards.
Tailpipe Emission
Inspsction
!@ Do not smoke during this procsdura. Keep
any open tlame away from your work area.
1. Start the engine. Hold the engine at 3,000 rpm with
no load (in Park or neutral) until the radiator fan
comes on, then let it idle,
Connect a tachometer.
Check and, if necessary, adjust the idle speed, (see
page 11-169, 170).
Warm up and calibrate the CO meter according to the
meter manufacturer's instructions.
Check idle CO with the headlights, heater blower, rear
window defogger, cooling fan, and air conditioner off.
(Canada) Pull the parking brake lever up. Start the
engine, then check that the headlights are off.
CO meter should indicate 0.1% maximum.
4.
Three Way Catalytic Converter (TWCI
DsscriDtion
Three Way Catalytic Convertsr lTwcl:
The Three wav Catalvtic Converter (TWC) is used to
convert hydrocarbons (HC), carbon monoxide (CO), and
oxides of nitrogen (NOx) in the exhaust gas to carbon
dioxide (COr), dinitrogen (Nr) and water vapor,
{cont'd)
1 1-199
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Emission Control System
Three Way Catalytic Converter {TWCI (cont'd}
1P0420 Thescantool indicates Diagnostic Trouble Code (DTC) P0420: Catalyst system efficiency belowthreshold.
DescriDtion
This system evaluates the catalyst's capacity by means of the HO2S (Primary and Secondary) output during stable driving
conditions. lf deterioration has been detected during three consecutive driving cycles, the MIL comes on and DTC P0420 will
be stored.
NOTE: lf some of the DTCS listed below are stored at the same time as DTC P0420, troubleshoot those DTCS first. then
troubleshoot DTC P0420.
P0137, P0138: Secondary HO2S (Sensor 2)
P0141: Secondary HO2S (Sensor 2) Heater
Possible Cause
. IWC Deterioration
. Exhaust system leakage
Troubleshooting Flowchart
- The MIL has been reDoried on.- DTC P0420 is stored.
Problem verification:1. Do the ECM/PCM Reset Procedure,2. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutrali untilthe radiator fan comes on.3. Connect the SCS service connector.4. Test-drive 40 - 55 mph (64 - 88km/h) for approx. lwo minutes.Then decelerate for at least 3seconds with the throftle completely closed. Then reducethe vehicle speed to 35 mph
156 km/h), and try to hold ituntil the readiness code
Intermittent tailure. system is OKat this time.ls DTC P0420 indicated?
Check the TWC (see section 9).lI nocessary, replace the TwC.
11-200
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Removal
!@@ Make sure the lifts, i8cks. and safety stands
are placed properly {see section 1}.
1. Raise the front of the vehicle, and support it with
safety stands (see section 1).
2. Set the parking brake, and block both rear wheels
securely.
3. Drain the manual transmission fluid Reinstall the
drain plug with a new sealing washer.
4. Disconnect the heated oxygen sensor (HO2S) con-
nector.
SELF.L(rcKNGNUTReplace.
SELF-LOCKI'{GNUTReplac€.
5. Remove exhaust oipe A.
6. Make reference marks across the propeller shaft
and the transfer assembly flanges'
Separate the propeller shaft from the transfer
assembly flanges,
Remove the rear stiffener, then remove the transfer
assembly.
NOTE: While servicing the transfer assembly, do
not allow dust or other foreign particles to enter the
transmission.
7.
REFEREI{CE i'ARKS
Replace.
Replace.
13-5
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Transfer Assembly
lnstallation
1. Install a new O-ring on the transfer assembly.
8 x 1.25 mm24 N.m (2.4 kgt m,17 rbt.ftl
10 x 1.25 mm44 N.m (4.5 kgJ.m,
2.
DOWEL PIN
Replace.TRANSFEBASSEMBLY
Clean the areas where the transfer assembly con
tacts the transmission with solvent or carburetor
cleaner, and dry with compressed air. Then apply
MTF to the contact areas.
Installthe transfer assembly on the transmission.
NOTE: While installing the transfer assembly on
the transmission, do not allow dust or other foreign
particles to enter the transmission.
lnstall the rear stiffener.
Install the propeller shaft to the transfer assembly
by aligning the reference marks,
8 x1.25 mm32 N.m 13.3 kg{.m,24 tbf.ftl
REFERENCE MARKS
6. Install the exhaust pipe A,
GASKETEXHAUST PIPE A
HO2S CONNECTOR
10 x 1 .25 mm54 N.m (5.5 kgt m,40 tbtfttReplace.
SELF.LOCKING
NUT8 x 1.25 mm16 N.m {1.6 kgf.m,12 tbt.ft)Replace.8 x 1.25 mmzzN.m l2.2kg!-m,16 rbf.trtReplace.
7.Connect the heated oxygen sensor (HO2S) connector.
Relill the transmission with MTF (see page 13-3).
Start the engine, and run it to normal operating tem-
perature (the radiator tan comes on). Turn the
engine off. and check fluid level.
8.
9.
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12. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove the exhaust pipe A.
GASKETReplace.
HO2S CONNECTOR
NUTReplace.
EXHAUST
SELF.LOCKINGReplace.
GASKETReplace.
Mark reference marks on the joint of the transfer
and the propeller shaft.
8 x 1.25 mmReplace.
Separate the propeller shaft from the transfer
assemDly.
REFERENCE MABKS
14.
15. Remove the cotter pins, and castle nuts. then sepa-
rate the ball ioints from the lower arm (see sectlon
18).
OAMPER PINCH BOLT
CASTLE NUTNUTReplace.
17.
16.
DAMPER FORKFOFKEOLTReplace.
Remove the right damper tork bolt, then separate
right damper fork and damPer.
Pry the right driveshaft out of the differential, and
pry the left driveshaft out of the intermediate shaft
(see section 18).
Pull out the inboard ioint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshatt ends. Coat all
precision finished surfaces with clean engine oil
18.
19.
\
{cont'd}
13-9
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Differential
Bearing Outer Race Replacement
Note these items:
. The bearing outer race and tapered roller bearingshould be replaced as a set.. lnspect and adjust the tapered roller bearing preload
whenever the tapered roller bearing is replaced.
'1. Remove the oil seals from the transmission housingand clutch housing (see page j3-43).
2. Drive the bearing outer race and thrust shim out ofthe transmission housing, or remove the bearingouter race and 75 mm shim from the clutch housingby heating the clutch housing to about 212"F(100"C) with a heat gun. Do not reuse the thrustshim if the outer race was driven out.
TRANSMISSIONHOUSING:
ATTACHMENT52x55mm07746 - 0010400
THRUST SHIM
BEARINGOUTER RACE
CLUTCHHOUSING:
13-40
4, lnstallthe oil seal (see page 13-43).
3. Install the thrust shim or 75 mm shim and the bear-ing outer race in the transmission housing andclutch housing using the special tools.
Note these items during bearing replacement:. Install the bearing outer race squarely.. Check that there is no clearance between thebearing outer race, thrust shim or 75 mm shimand housing.
TRANSMISSIONHOUSING:
HANDI-E07749 - 00 xxto
ATTACHMENT,62x68mm077ir6 - 0010500
BEARINGOUIER RACETHRUST SHIM
CLUTCHHOUSING:HANDLE07749 - 001tXX)o
ATTACHMENT.72xt5mm07745 - 00106{x)
OUTER RACE
75 mm SHIM
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Tapered Roller Bearing Preload Adiustment
lf any oJ the items listed below were replaced, the tapered
roller bearing preload must be adjusted.
. Transmission housing
. Clutch housing
. Differential carrier
o Tapered roller bearing and bearing outer race
. Thrust shim
. 75 mm sham
1. Remove the bearing outer race and thrust shim
from the transmission housing (see page 13-40)'
NOTE:
. Do not reuse the thrust shim if the bearing outer
race was driven out.
. Let the transmission cool to room temperature il
the bearing outer race was removed by heating
the clutch housing.
2. Do not use more than one thrust shim to adjust the
tapered bearing preload. First try the same size
thrust shim that was removed. There are no shims
used on the clutch housing side
SHIMTHRUST
/A
After installing the thrust shim, install the bearing
outer race in the transmission housing (see page
13-40).
With the mainshaft and countershaft removed,
install the differential assembly, and torque the
clutch housing and transmission housing.
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
TOBOUE; 8 x 1.25 mm: 27 N'm(2.8 kgf'm, 20 lbt'ftl
Rotate the differential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload at nor-
mal room temperature. Measure the starting torque
of the differential assembly in both directions with
the special tool and a torque wrench.
STANDAFD: 1.4 - 2.5 N'm
{1/r - 26 kgf'cm, 12 - 23 lbf in)
(cont'd)
4.
5.
07HAJ - PK4020'1
13-41
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Transfer Assembly
Transfer Shaft Disassembly/
Reassembly
1. Support the transfer driven gear on steel blocks,
then press the transfer shaft out of damper hub,
Align the damper hub grooves and transfer drivengear teeth, and reassemble the damper hub. needle
bearing, and transfer driven gear.
Install the transfer shaft using a press.
13-50
us Ing
Transfer Gover A Bearing Outer
Race Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Bemove the tapered roller bearing outer race from
transfer cover A by heating the cover to almost212"F (100oC) using a heat gun. Do not heat thecover over 212"F (100'C),
2. Install the 68 mm thrust shim in transfer cover A.
TRANSFER COVER A
ATTACXMCNT,52x68mft07746 - tD,t0500
Install the tapered roller bearing outer race
the special tools and a press.
BEARING OUTER RACE
BEARING OUTER RACE
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