lock HONDA CR-V 2000 RD1-RD3 / 1.G Service Manual

Flywheel and Drive Plate
Replacement
Manual Transmission:
Remove the eight flywheel bolts, then separate the fly-
wheel from the crankshaft flange. After installation, tight-
en the bolts in the sequence shown.
ENGINEBLOCK
12 x 1.0 mm103 N.m 110.5 kgf.m,76 lbf.ft)
Automatic Transmission:
Remove the eight drive plate bolts, then separate the
drive plate from the crankshaft flange. After installation,
tighten the bolts in the sequence shown.
RING GEARInspect ring gearteeth for wear or damage,
RI G GEAR HOTDER07LAB - PV001|X)
12 x 1.0 mm7a N.m(7.5 kgt.m,5a lbf.ftl
/ AzXi{'jA\Ao
7-5,
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Main BearingsConnecting Rod Bearings
Selection
Crankshaft Bore Code Location
Letters have been stamDed on the end of the block as a
code Jor the size of each of the 5 main journal bores.
Use them, and the numbers or bars stamped on the
crank (codes for main journal size), to choose the correct
beanngs.
lf the codes are indecipherable because of an accumula-
tion of dirt and dust. do not scrub them with a wire
brush or sc.aper. Clean them only with solvent or deter-
gent.
Main Journ.l Cod. Locrtions lNumbcB oi Bar3l
Bearing ld.ntif icrtionColor code ison the edge ofthe bearing.
7-8
IcD
"""""""" Smallerbearing(rhicker)
Green
Green
ElaclAlue
Clearance
Remove the connecting rod cap and bearing half.
Clean the crankshaft rod journal and bearing half
with a clean shop towel.
Place the plastigage across the rod journal.
Reinstall the bearing half and cap, and torque the
nuts.
1.
7.
Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft)
NOTE: Do not rotate the crankshaft during inspec-
tion.
Remove the rod cap and bearing half, and measure
the widest part of the plastigage.
Connesting Rod Bearing-to-Journal Oil Clearancc:
Standard {Newl: 0.020 - 0.038 mm
{0.0008 - 0.0015 in)
Service Limit: 0.05 mm {0.002 inl
lf the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new.
complete bearing with the same color code {select
the color as shown on the next page), and recheck
the clearance. Do not file, shim, or sc.ape the bear-
ings or the caps to adjust the clearance.
lf the plastigage shows the clearance is still incor
rect, try the next larger or smaller bearing {the color
listed above or below that one). and check clear-
ance again. lf the proper clearance cannot be
obtained by using the appropriate larger or smaller
bearings. replace the crankshaft and start over.
PLASTIGAGE
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Crankshaft
Inspection
1. Clean the crankshaft oil passages with pipe cleaners
or a suitable brush.
2. Check the keyway and threads.
Alignment
3. Measure the runout on all main journals to make
sure the crank is not bent. The difference between
measurements on each journal must not be more
than the service limit.
Crankshaft Total Indicated Runout:
Standard lNew):0.03 mm (0.001 in) max.
Service Limit: 0.04 mm {0.002 in)
DIAL INDICATORRotate two completerevolut|ons.
Suppon with lathe-lype tool or V-blocks.
Out-of-Round and TaDer
4. Measure out-of-round at the middle of each rod and
main journal in two places. The difference between
measurements on each lournal must not be more
than the service limit.
Journal Out-of-Round:
Standard (Newl:0.005 mm 10.0002 inl max.
Service Limit: 0.010 mm (0.000i1in)
Measure out-ol'round at middle.
Measure taperat edges.
5. Measure taper at the edges of each rod and mainjournal. The difference between measurements on
each iournal must not be more than the service
limit.
Journal Taperi
Standard {Newl: 0.005 mm 10.0002 inl max.
Service Limit: 0.010 mm (0.0004 inl
7-11
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PistonsI
Inspection
LCheck each piston for distortion or cracks.
Measure the piston diameter at distance A from the
bottom of the skirt.
A: '97 - 98 models 15 mm 10.5 inl'99 - 00 models 20 mm 10.8 inl
Piston Diameter:
Standard (New): 8:1.980 - txl.990 mm(3.3063 - 3.3067 inl
Service Limit: 83.970 mm {3.3059 inl
SKIRT DIAMETER
7-12
3. Calculate the difference between the cylinder bore
diameter (see page 7-13) and the piston diameter.
Piston-to-Cylinder Clearance:
Standard {New): 0.010 - 0.040 mm
{0.0004 - 0.0016 inl
Service Limit: 0.05 mm {0.002 in}
lf the clearance is near or exceeds the service limit,
inspect the piston and cylinder block for excessive
wear.
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Cylinder Block
Inspection
Measure wear and taper in directions X and Y at
three levels in each cylinder. lf the measurements in
any cylinder are beyond the Service Limjt, replace
the block.
Cvlinder Bole Size:
Standard {Newl:84.00 - 84.02 mm
{3.307 - 3.308 inl
Service Limit: 84,07 mm (3.310 inl
Bore TaDer:
Limit: {Difterence between first and third measure-
ment) 0.05 mm {0.002 in)
2. Check the top of the block for warpage.
Measure along the edges and across the center as
sh own.
SURFACES TO BE MEASURED
Engine Block Warpage:
Standard (New):0.07 mm (0.003 in) max.
Service Limit: 0.10 mm {0.004 inl
PRECISION STRAIGHT EDGE
7-13
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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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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
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Crankshaft
12.
Installation (cont'd)
14.
13.
Apply liquid gasket to the oil pump mating surfaceof the block.
Apply a light coat of oil to the crankshaft, the lip ofthe seal, and the O-rings.
Apply grease to the lips of the oil seals.
Align the inner rotor with the crankshaft, then installthe oil pump. When the pump is in place, clean anyexcess grease off the crankshaft, then check that theoil seal lips are not distoned.
6x1,0mm9.8 N.m {1.0 kg{.m,,.2 tbf.ftl
I
{/^ I GASKET(..6 Replace."[z
O-RINGReplace.
OIL PUMP
6x1.0mm9,8 N.m 11.0 kg{.m,7.2lbt.trl
8 x 1.25 mm24 N.m {2.4 kgf.m,17 tbt.ftl
7 -22
,'t ./o,DowEL PtN
// |
16.Apply liquid gasket on
cover matrng areas.
CYLINDERBLOCK
the oil pump and right side
Apply liquid g€sketto these pornts.
17. Install the oil pan gasket and oil pan. Wait no
than five minutes after applying liquid gasket.
OIL PAN
OIL PANGASKETReplace.
Apply liquid gasketto these pornts,
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Oil Seals
18. Tighten the bolts and nuts finger tight at six points.
Tighten all bolts and nuts, starting from nut O. clock-
wise in three steps. Excessive tightening can cause
distortion ot the oil pan gasket and oil leakage.
Torque: 12 N.m (1.2 kgt.m,8.7 lbtft)
19.
1.
lnstallation
Dry the crankshaft oil seal housing.
Apply a light coat of grease to the crankshsft and to
the lips of the seals.
Using the special tool, drive in the timing pulley-end
seal until the driver bottoms against the oil pump.
When the seal is in place, clean any excess grease
off the crankshaft and check that the oil seal lip is
not distorted,
SEAL DRIVEROTLAD - PT3O1OAlnstall sealwith theparts number sidefacing out.
(cont'd)
7-23
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