Piston rings HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Valve Seals
Replacement (cylinder head removal not required)
The procedure shown below applies when using the in-
car valve spring compressor (Snap-on YA8845 with
YA8845-2A 7/8" auachment). Use approved eye protec-
tion.
1. Turn the crankshaft so that the No. 1 and the No. 4
pistons are at top dead center (TDC).
2. Remove the cylinder head cover.
3. Remove the distributor.
4. Loosen and disconnect the timing belt from the
camshaft pulleys.
5. Remove the camshaft holder bolts. then remove the
camshaft holders, the camshafts and rocker arms.
lntake Valve Seals
6. Using the 6 mm bolts supplied with the tool, mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit as shown.
7. Insert the cross shaft through the top hole of the
two uprights,
at.
9.
Select the 7/8 in. diameter long compressor attach-
ment, and fasten the attachment to the front hole of
the lever arm with the speed pin supplied.
Position the piston at TDC, and insen an air adaptor
into the spark plug hole. Pump air into the cylinder
to keep the valve closed while compressing the
springs and removing the valve keepers.
10. Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
head.
Position the lever arm under the cross shaft so the
lever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for the
spring being compressed. Use the rear position slot
on the lever as shown,
't1.
OIL PASSAGE
OIL PASSAGES
(cont'd)
6-5
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Valve Seals
12.
Replacement (cylinder head removal not requiredl (cont'dl
Using an upward motion on the lever arm, compress
the valve spring and remove the keepers from the
valve stem. Slowly release pressure on the spring.
Repeat step 11 for the other valve in that cylinder.
Remove the valve seals (see page 6-24).
Installthe valve seals (see page 6-29).
lnstall the springs, the retainers and the keepers in
reverse order of removal.
'17. Repeat steps 9 to 16 for the other three cylinders.
Exhaust valve Seals
18. Using the 5 mm bolts supplied with the tool, mount
the two uprights to the cylinder head at the end
camshaft holders. The uprights fit as shown.
19. Insert the cross shaft through the bottom hole of
the two uprights.
Select the 7/8 in. diameter short compressor attach
ment, and fasten the attachment to the No. 4 hole of
the lever arm with the speed pin supplied.
Position the piston at TDC, and insert an air adaptor
into the spark plug hole. Pump air into the cylinder
to keep the valve closed while compressing the
springs and removing the valve keepers.
13.
14.
15.
16.
20.
t1
22. Put shop towels over the oil passages to prevent
the valve keepers from falling into the cylinder
neao.
23. Position the lever arm under the cross shaft so the
lever is perpendicular to the shaft and the compres-
sor attachment rests on top of the retainer for the
spring being compressed. Use the rear position slot
on the lever as shown.
Using a downward motion on the lever arm, com-
press the valve spring and remove the keepers from
the valve stem. Slowly release pressure on the
spring.
Repeat step 24 for the other valve in that cylinder.
Remove the valve seals (see page 6-24).
Install the valve seals (see page 6-29).
Install the springs, the retainers and the keepers in
reverse order of removal.
Repeat steps 21 to 28 on the other three cylinders.
24.
21.
28.
29.
o-o
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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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lllustrated Index (cont'd)
NOTE: New rod bearings
(see pages 7-91.
must be selected by matching connecting rod assembly and crankshaft identification markings
PISTON INSTALLANON DIRECTION:
Lubricate all internal parts with engine oil
during reassembly.EXHAUST
INTAKE
PISTON RINGSReplacement. page 7-18Measurdment, page 7-17Alignm€nt, page 7-18
PISTONInspection, page 7-12
l1\AAtr\
\9q9Q9e/
PISTON PINRemoval, page 7-14
Installation, page 7-15Inspection. page 7-16
ENGINC BLOCKCylinder bore inspection. pago 7-13
Warpage inspoction, Page 7-'13
CONNECTING ROD BEARING CAPlnstallation, page 7-20NOTE: Install the caps so thebearing recess is on thesame side as the recessin the rod.
CONNECTING ROD CAP8 x 0.75 mm31 N.m {3.2 kgl.m.23 tbf.ftl
CONNECTING
COiINECI'ING RODBEARINGSClearance, page 7-8
Solection. page 7-9
NUT
End play, page 7-6Selection, page 7-14
Inspect the top ot each cylinder borefor carbon build up or a ridgebelore removing the piston.
Remove the ridge if necessary, page 7-10Apply engine oil to the bolt threads.NOTE: After torquing each bearingcap, rotate the crankshaft to check forbinding.
7-4
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Pistons and
Crankshaft
Selection
Connecting Rod Code Location
Numbers have been stamped on the side of each con-
necting rod as a code for the size of the big end. Use
lhem, and the letters stamped on the crankshaft (codes
for rod journal size), to choose the correct bearings.
lf the codes are indeciDherable because of an accumula-
tion of dirt and dust, do not scrub them with a wire
brush or scraper. Clean them only with solvent or deter-
gent.
8€aring ldentif ication
aolor code is on theedge oltne Deanng.
Larger big end bore
---------------r. sma er bearino {thicker)
RedPinkGreen
PinkGreenBrown
GreenBrownBlack
GreenBrownElackBlue
Half of number isstamped on beanngcap and the othelhalf is stamped onrod.
Connecting Rod Journal Code Locations {Lettersl
llAort ll
llBo'll ll
llcotrll ll
I l-.. ilril It-lSmaller'odSmallerbeanng(thicker)
234
Removal
Remove the oil pan assembly.
Remove the right side cover.
1.
Remove the oil screen.
Remove the oil pump.
OIL SCREEN
(cont'd)
7-9
OIL PUMP
5. Remove the baffle plate.
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Pistons and Crankshaft
Removal (cont'dl
6. Remove the bolts. To prevent warpage, unscrew the
bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
Remove the rod caps/bearings and main caps/bear-
ings, Keep all caps/bearings in order
Lift the crankshaft out of the engine. being careful
not to damage the journals.
7.
7-10
9.
10.
Remove the upper bearing halves from the connecting
rods, and set them aside with their respective caps.
Reinstall the main caps and bearings on the engine
in proper order.
lf you can feel a ridge of metal or hard carbon
around the top of each cvlinder, remove it with a
ridge reamer. Follow the reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they 8re pushed out.
12.
11.
14.
Use the wooden handle of a hammer to drive the
pistons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
To avoid mixup on reassembly, mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.
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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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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-;
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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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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.
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