Engine assembly HONDA CR-V 1999 RD1-RD3 / 1.G User Guide

Oil Pump
13.
Removal/lnspection/lnstallation (cont'd)
Check the housing-to-outer rotor radial clearance. lf
the housing-to-outer rotor radial clearance exceeds
the service limit, reDlace the set of inner and outer
rotors and/or the pump housing,
Housing-to-Outer Rotor Radial Clearance
Standard lNewl: 0.10 - 0.19 mm
{0.004 - 0.007 in}
Service Limit: 0.20 mm {0.008 inl
Inspect both rotors and the pump housing for scor-
ing or other damage. Replace pans if necessary.
Remove the old oil seal from the oil pump.
Gently tap in the new crankshaft oil seal until the
special tool bottoms on the pump.
14.
15.
16.
8-10
17.Reassemble the oil pump, applying liquid thread
lock to the pump housing screws.
Check that the oil pump turns freely.
Apply a light coat ot oil to the seal lip.
Clean and dry the oil pump mating surfaces.
Install the two dowel pins and a new O-ring on the
cylinder block.
Apply liquid gasket, part No. 08718-0001 or 08718-
0003, to the cylinder block mating surface of the oil
pump. Apply the liquid gasket evenly, in a narrow
bead centered on the mating surface. Do not apply
liquid gasket to the O-ring grooves.
Apply liquid gasket to the inner threads of the bolt
noles.
18.
19.
20.
21.
Apply liquidgasket along thebroken line.
PUMP HOUSING
NOTE:
. Do not install the pans if five minutes or more have
elapsed since applying liquid gasket. Instead, reapply
liquid gasket after removing old residue.
. After assembly, wait at least 30 minutes betore filling
the engine with oil.
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Radiator
1.
2.
3.
4.
Replacement
CONDENSERFAN,/SHROUDASSEMBLY
Drain the engine coolant.
Remove the upper and lower radiator hoses, and
ATF cooler hoses.
Disconnect the fan motor connector.
Remove the radiator upper bracket, then pull up the
raotalor,
5. Remove the fan shroud assemblies and other parts
from the radiator.
6. lnstall the radiator in the reverse order of removal.
NOTE:
. Set the upper and lower cushions securely.
. Fill the radiator with engine cooiant and bleed the air.
RADIATOR CAP
RADIATOR
6x1.0mm9.8 N.m 11.0 kgf.m,7.2 tbl.trl
6x1.0mm7 N.m (0.? kgd.m, 5 lbl.ftl
UPPER MDIATOR HOSE
Reler to section 14when installing.
DRAIN PLUG
LOWER CUSHION
LOWERTOR HOSE
RADIATORASSEMBLY
6x1.0mm7 N.|n 10.7 kgt.m,5 tbt.ftl
rriItriiii
10-4
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PGM-FI System
Powertrain Control Module {PCM} -'97 Model
NOTE: lf this symptom is intermiftent, check for a loose fuse No. 25 METER (7.5 A) in theunderdash f{rse/relay box, a poor connection at PCM terminal A18, or an intermittentopen in the GRN/ORN wire between the PCM (A18) and the gauge assembly.
PCM OON ECTOR A {32P}
Wire side of female terminals
PCM CONNECTOR A {32PI
Wire side ot temale terminals
11-42
The Malfunction lndicator LamD(MlL) nev6r comes on {even lortwo seconds) after ignition isturned on (lll, or it's on dimlyand flickers.
Turn the ignition switch ON {ll}.
- Rep.ir short or opon in thowire batween No. 25 METER(7.5 Alfuso and gauge a$€m-bty.- R6pl.c€ No. 25 METER 17.5 Alfus€.
ls the charging system light on?
Try to stan the engine.
Does the engine start?
Chock tor.n open in th6 wire3{PG1, PG2linesl:1. Turn the ignition switch ON (ll).2. Measure voltage betweenbody ground and PCM con-nector terminals A10 and A23individually.
Check for an op€n in the wir6 orbulb (MlL lin€l:1. Turn the ignition switch OFF.2. Connect the PCM connectorterminal A18 to body groundwith a iumper wire.3. Turn the ignition switch ON {ll).
n€peir open in tho wirelslhwoon PCM and Glol (loc!t.d
at thc tha.mo3tat houling thrthtd moro th.n 1.0 V.
ls thore l€ss than 1.0 V?
Substituto . known-good PCMand r€check. ll symptom/indica-tion goss away, rcplaca the origi-nal PCM.
- R6pai. open in th. wileibelwoon rcM lAl8l dnd g.ugea3rombly.- Roolac€ the MIL bulb.
ls the MIL on?
Substitut6 a known-good PCMand rocheck. ll 3ymptom/indica-tion goes away, replace the o.igi-n.l PCM.
PGl IBLKI
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NOTE:. When there is no Diagnostic Trouble Code (DTC) stored, the MIL will stay on if the SCSservice connector is connected and the ignition switch is on.. lf this svmotom is intermittent, check for:- A loose Fl E/M (15 Aifuse in the underdash tuse/relay box- A loose No. 13 FUEL PUMP {15 A) fuse in the under-dash fuse/relay box- An intermittent short in the wire between the PCM (C7) and the service check con-
- An intermittent short in the wire between the PCM (A18) and the gauge assembly- An intermittent shon in the wire betlveen the PCM (D4) and the MAP sensor- An intermiftent short in the wire between the PCM {D10) and the TP sensor.PGM-Fl main relay.'See the OBD ll scan tool or Honda PGM Tester user's manuals lor specilic operatinginstructions,
NOTE: An open or short in the wire between the PCM (C8) and the DLC will keep thescan tool or Honda PGM Tester lrom communicating with the PCM. You should ioterpretthis as no DTCS are indicated.
PCM CONNECTORc l3lPl scs .BRNI
lTo page 11 84)Wire sid6 of f€male terminalg
(cont'dl
11-83
The Malfunciion lndicator Lamo{MlL) stavs on o. comes on afteltwo seconds,
Check the Oiegnosiic TroubleCode (DTC):
1. Connect an OBD ll scan toolor Honda PGM Tester.2. Turn the ignition switch ON 1lli.3. Read the DTC with the scantool or Honda PGII Tester.
Go to troubleshooting procedures(s€€ page 11501.Are any DTCIs) indicated?
Ch6ck lh6 DTC by MIL indication:1. Turn the ignition switch OFF.2. Connect the SCS service con-nector to the service checkconnector.3. Turn the ignition switch ON (ll).
- Repair opon or short in wi.6between the PCM (C8) andData Link Connector.- Go to troubloshooting proce-
dur€s {3ee page 11-601.
Does the MIL indicate any DTc?
Try to start the engine.
Does the engine start?
Check tor a short in the wire{SCS line):1. Turn the ignition switch OFFand turn the ignition switchoN flt).2. Measure voltage between thePCM connector terminal C7and body ground.
Repair short to body ground inthe wire between PCM lCTl andservice check connector.ls there approx. 5 V?
(To page 1'l-84)
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PGM-FI System
Tho Maltunction Indicator Lamo(MlL) n6Yor como3 on leven lortwo laconds) rft6r tho ignhion isturnod ON {lll.
Turn th6 ignition switch ON (ll).
- Repair lhort or opcn in thowire between the No. 25METER 17.5 Al fu3e snd thegauge assembly.- Repl.co the No. 25 METER17.5 Al fus€.
ls the low oil pressure light on?
Try to start the engine.
Chock for an opsn in th€ wiro orbulb {MlL line,:1. Turn the ignition switch OFF.2. Connect the ECM/PCM con-nector terminal A18 to bodyground with a iumper wire.3. Turn the ignition switch ON (ll).
Rep.ir open in the wi.osbotween the ECM/FCM lA18land the gaugo rasombly.Roplece the MIL bulb.
ls th6 MIL on?
Substitute a known-good ECM/PCM and rochock. lf rymptom/indication goes eway, replacetho o gind ECM/PCM.
Turn the ignition switch OFF.Inspect the Fl E/M 115 A) tusein the undeFhood fuse/relaybox.
- Repair short in the wirebetween lhe Fl E/M (15 AlfusG and the PGM-Fl m.in.slay.- Roplsce th€ Fl E/M (15 Alfu3€.
Inspect the No. 13 FUEL PUMP(15 A) fuse in the under-dashfuse/relay box.
- Repair short in th6 wirebetween tho No. 13 FUELPUMP 115 A) luse and thePGM-FI main .elay.- ReDlace tho No. 13 FUELPUMP 115 Al tuse.
Engine Gontrol Module/Powertrain Control Module (ECM/PCM) -'98 - 00 Models
NOTE:. lf this symptom is intermittent, check tor:- A loose Fl E/M {15 A) fuse in the under-hood fuse/relay box- A loose No. 25 METER {7.5 A) fuse in the under-dash fuse/relay box- A loose No. 13 FUEL PUMP (15 Alfuse in the underdash fuse/rolay box- An intermiftent short in the wire between the ECM/PCM (A18) and the gauge assem-
- An int€rmiftent short in the wire between the ECM/PCM (C19) and the MAP sensor- An intermiftent short in the wire between rhe ECM/PCM (C28), the TP sensor, theEGR valve lift sensor and/or {uel tank Dressure sensor- A laulty PGM-FI main relay
ECM/PCM CONNECTOR A (32P}
Wire side of female terminals
(To page 11-871
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3. Before connecting a new fuel tube/quick-connect fit-
ting assembly, remove the old retainer from the
mating pipe.
with thetabs pulled
apart, removeand discardthe retarner
Ncw FUEL TUBE/OUICK.CONNECTFI?TING ASSEMBLY
4.Align the quick-connect fittings with the pipe. and
align the retainer locking pawls with the connector
grooves. Then press the quick-connect fittings onto
the pipe until both retainer pawls lock with a click-
Ing sound.
NOTE: lf it is hard to connect, put a small amount of
new engine oil on the pipe end.
5. Make sure the connection is secure and that the pawls
are firmly locked into place; check visually and bypulling the connector.
Reconnect the battery negative cable, and turn the
ignition switch ON (ll). The fuel pump will run for
about two seconds, and fuel pressure will rise. Repeat
two or three times, and check that there is no leakage
in the fuel supply system.
6.
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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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Transmission AssemblY
Removal
@FMak. sw. iack" and safety stands are placed propel-
ly, and hoist brackets are attached to collect position
on the engine,
. Apply parking brake and block rear wheels so vehicle
will not roll off stands and lall on you while working
under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
1. Disconnect the negative {-) cable first, then the pos-
itive (+) cable from the batterY.
2. Remove the intake air duct and air cleaner houslng
(see section 5).
3. Remove the slave cylinder and clutch hose bracket'
NOTE:
. Do not operate the clutch pedal once lhe slave
cvlinder has been removed.
. Take care not to bend the clutch line.
4. Disconnect the
ground cable.
starter cables and transmission
TRANSMISSIONGROUND CABLE
Disconnect the back-up light switch connector and
wire harness clamP.
(cont'd)
13-7
WIRE HARNESS CLAMP
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Transmission Assembly
Removal (cont'd)
20. Remove the intermediate shaft.
21.Tie plastic bags over the both ends of the intermedi-
ate shaft. Coat all precision finished surfaces withclean engine oil.
Remove the rear engine stiffene. and clutch hous-Ing cover.
13-10
23. Remove the right front mounvbracket.
RIGHT FRONTMOUNT/BRACKET
Place a jack under the transmission, raise it just
enough to take it off of the mounts, then remove
the transmission mount bracket and transmission
mount.
TRANSMISSION MOUNT
MOUNT BRACKET
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Transmission Assembly
1.
Installation
Check that the dowel pins are installed in the clutch
housing.
Apply grease to the release fork and release bear-
ing.
{P/N 08798 - 90021{P/N 08798 - 9002)0.{ - 1.0 g
{0.0'l - 0.04 ozl
RELEASEBEARING
(P/N 08798 -
9002)
RELEASEFORKBOOT
?
(P/N 08798 - 9002)'1.0 - 1.6 g {0.0,1- 0.06 o2l
Install the release bearing, release fork, and release
fork boot to the clutch housing.
Install the starter motor and hose clamp.
10 x 1.25 mm4{ N'm (4.5 kgf.m,32 tbf.ftl
13-72
HOSE
5. Place the transmission on the transmission jack,
and raise it to the engine level.
6. Install the transmission mounting bolts and the rear
engine mounting bolts.
TRANSMISSIONMOUNTING EOLT12 x 1.25 mn
7.
64 N.m {6.547 tbt.ft)
REAR ENGINE MOUNNNG BOLTSReplace.Itl x 1.5 mm8:l N.m 18.5 kgt m, 61 lbf.ft)
Rise the transmission, then install the transmission
mount bracket and transmission mount.
. Torque the mounting bolts and nuts in thesequence shown.
. Check that the bushing are not twisted or offset.
O. @: 12 x 1.25 mm
64 N.m (6.5 kgf.m, 47 lbf'ft)
O: Temporary tightening
@: 12 x 1.25 mm
74 N.m (7.5 kgf'm,54 lbf.ft)
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