Use engine oil HONDA CR-V 2000 RD1-RD3 / 1.G Workshop Manual

Emission Group ldentification
(1999 model)
Example:
50 state TLEV + NLEV {Unrestricted}
THIS VEHICLE CONFORMS TO U.S. EPA NLEV
REGULATIONS APPLICABLE TO 1999 MODEL YEAR
NEW TLEV LIGHT DUTY TRUCKS ANO CALIFORNIA
REGULATIONS APPLICABLE TO 1999 MODEL YEAR
NEW LIGHT DUTY TRUCKS.
'.WNEN AOO NG OR CNANGINC THE COOLANT. USE @SOLU I ON Of FONOA U-ECo-q.NOEDImcrtniuvcoourr mo wlttt NEVEF oILLJTE THE CooLANT,0RTHE LIFE 0F TNE
"Eifil:$o""niii?i,THffi ffi'"R @ M LEs lmo rhl, wNrcHEVEn coMEs
i'lrt^t orrrr, ^,r*a, rurr"* os @ M LEs 1@ kmr wNICHEVER coMEs
}CNECK OR ADD COOLANT AT THE RESER!'E TAN( NOT IHE NADIATOSDFOfi fWTHEF NFORMATION ON THE COOL NC SYSTEM READ THE OWNER'S MANUAL'' CHECK WIIH YOUS HONOA OEALER.
GD
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFOAMSTOU. S EPA NLEVFEGULANONS APPLICCBLI TO 1999 MOD€LYEA8 NEW TIEV LIGHT DUTY ]nUCKS ANDCALIFORNIA REGULATIONS APPLICASLE IO 19S9MOOEL YEAR NEW TLEV LIGHT DUTY IFIJCKS,,|F --'-
Ll: .-.-,1
I rFrll\=#_H*
CATALYST
VALVE IASN lN:010r0.02 mmlCoLDj EX 0131002 mmSPA8K PLUG GAP 10- l l nmIDLE SPEED 130 t 5{ rPmOBDIICERT]ATD
201
TUNE I]PCONDIIIONS INGINEAT NOBTEI\'PERATUR€ ATL ACCESSOS ES TLJRNFAN OFf IRANSMSSION N NEL]TMLNO OINER ADJUSTMTNTS NEEOEO.
JL
Iooro nr tist rc orn svtncrE MUsT BE coMoufitooNArounwNEElDslvE SPEEDiitriunor mo ovuvo uenn orr Enw sE a NoN.loaDE D rEsr PRoCE ouRE MU sT 8E Pf Rr-
Engine and Evaporative Families
Engine Family:X HNX T02,O UA2
Model Year
X:1999
Manutao{urer Subcode
HNX: HONDA
Family Type
V: LDV
T: LDT
Displacoment
Saquence Charactors
Evaporative Family:X HNX EOO8OAAB
Model Yoal
X:1999
Manutacturar Subcode
HNX: HONDA
Family Typo
E: EVAP
R: EVAP/ORVR
Canbter Work Capacity
S€quonce Chartsters
1-17
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MEASUREMENTSTANDAFD INEWISERVICE LIMIT
lgnition coilRated voltage VPrimary winding resistance 0 at 68'F (20'C)120.63 0.77
lgnition wireBesistance at 68"F (20 C) ktl25 max.
Firing order1 3 4-2
Spark plugTypeGapSee Section 41.0 - 1.1 (0.039 - 0.043)
lgnition timingAt idle BTDC161 2 {Red)
Alternator belt*rDeflection with 98 N {10 kgf, 22 lbf)8.5 11.510.33 0.45)with used belt5.5 - 8.0 (0.22 - 0.31) with new belt
Belt tension N {kgf, lbt)Measured with bek tension gauge340 - 490 {35 - 50, 77 110) with used belt690 880 (70 90, 150 - 200i with new belt
AlternatorOutput A (at 13.5 V, hot and 6,000 alternator rpm AIIM/IBrush length
959010.5 (0.41)1.5 (0.06i
Staning motorOutput kW A/fMica depth MfiCommutator runoutCommutator O.D.Brush lengthBrush spring tension N (kgf, lbf)
1.11.00.5 - 0.8 {0.02 - 0.03)0,0.02 (0 0.0008)27.9 28.0 (1.0984 1.1024)14.0 14.5 (0.55 0.57)13.7 - 17.7 (1.40 - 1.80,3.09 - 3.97)
0.2 (0.008)
0.0s (0.002)
27.0 (1.06)
9.0 (0.35)
Standards and Service Limits
Engine Electrical - Section 4
'1 When using a new belt, ddiust deflection to new value. Run the engine for 5 minutes then turn it of{. Beadiust deflection to used belt value.
Cylinder Head/Valve Train - Section 6
MEASUREMENTSTANDARD {NEW} SERVICE LIMIT
Compression250 rpm and Nominalwide open throttle MinimumkPa (kgflcm', psi) Maximum variation
1 ,230 i'12 .5 , 11Al930 (9.s, 135)200 12.0,2al
Cylinder headWarpageHeight131.95 - 132.05 {5.195 - 5.199)0.05 {0.002)
CamshaftEnd playCamshaft to hoider oil clearanceTotal runoutCam lobe height '97,'98 models lNEX'99,'00 models lNEX
0.05 0.1s (0.002 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 {0.001)max.33.204 \1.3072133.528 {1.3200)33.1 16 \1 .321 4)33.528 {'1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
Valve clearance (Cold)* lNEXValve stem O.D. lNEXStem'to-guide clearance lNEX
0.08 - 0.12 (0.003 0.005)0.16 0.20 (0.006 - 0.008)6.580 - 6.590 (0.2591 0.2594)6.550 - 6.560 (0.2579 0.2s83)0.02 - 0.05 {0.00t 0.002)0.05 - 0.08 (0.002 0.003)
u* to.rutt6.52lO.257l0.08 {0.003i0.'1t (0.004)
width tNEXStem installed height lNEX
1.25 - 1.55 (0.049 - 0.061)1.25 1.55 (0.049 - 0.061)40.765 - 41.235 {1.6049 1.6234)42.765 - 43.235i'1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 {1.6333}43.485 {1.7120i
Valve springFree length lNEX42.36 (1.668i
44.32 t1 .1 451
Valve guideI,D, INEXInstalled height tNEX
6.61 6.63 10.260 - 0.261)6.61 6.63 {0.260 - 0.261i13.75 - 14.25 10.541 0.561i15.75 - 16.25 {0.620 0.640i
6.6510.26216.65 (0.262i
*: Measured between the camshaft and rocker arm,
2-2
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Standards and Service Limits
Automatic Transmission (cont'dl - Section 14
Differential (4WDl * Section 15
MEASUREMENTSTANOABD {NEW'
SteeringSection 17
* When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.Readjust dellection or tension to used belt values.
MEASUREMENTSTANDARO INEWI
Wire Dia.o.D.Fiee LengthNo. of Coils
SpringsRegulator valve spring ARegulator valve spring BStator reaction springModulator valve springTorque convener check valve spring'97 model'98 - 00 modelsCooler relief valve springRelief valve spring2nd orilice control valve spring1-2 shitt valve spring2 3 shift valve spring3-4 shift valve spring1st accumulator spring4th accumulator spring B4th accumulator spring A2nd accumulator spring A3rd accumulator spring A2nd accumulator spring B3rd accumulator spring I3rd sub accumulator spring2nd accumulator spring CLock-up shift valve springLock-up timing valve springLock'up control valve spring3'4 orifice control valve springServo control valve springCPB valve spring4th exhaust valve spring
1.8 10.071)1.8 i0.071)4.5 (0.177)
1.4 {0.055)
1.1 (0.043)
1.2 (0.047)
1.0 (0.039)
1.1 (0.043)
0.7 (0.028)
0.9 (0.035)
0.9 (0.035)
0.9 (0.03s1
2.1 (0.083)
2.3 (0.091)
2.6 (0.102)
2.410.094)2.8 (0.110)
1.6 (0.063)
2.1 (0.083)
2.7 {0. r06)2.2lO.OA7)0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
0.6 (0.024)
1.0 (0.039)
0.9 (0.035)
0.9 (0.035)
14.7 (0.579)
9.6 (0.378)
35.4 {1.394}9.4 (0.370)
8.4 (0.331)
8.4 (0.331)
8.4 (0.331)
8.6 (0.3391
6.6 (0.260i
7.6 {0.299}7.6 {0.299)7.6 {0.299)16.0 (0.630)
10.2 to.402l17.0 (0.669)
29.0 \1.1421'r7.510.689)
9.0 (0.354)
31.0 (1.220)17.0 (0.669)
14.510.571)7.610.299i8.1 {0.319}6.6 (0.260)
6.6 (0.260i
8.1 (0.319)
8.1 {0.319)6. t (0.240)
87.8 (3.457)
44.011.132130.31r.193)35.0 {1.378)
36.4 {1.433)32.4 tl.216J33.8 {r.331)37.1 (1.461)
34.8 (1.370)
41.3 (1.626)
57 .0 (2.2441
57 .0 12.244189.1 (3.508)
51.6 (2.031)
88.4 (3.480)
39.011.s35)94.313.713)20.7 10.8r5)38.2 (1.504)
39.0 (1.535)
68.0 (2.677)
73.7 12.902)8r.4 (3.205)
38.0 fl.496)37.9 (1.492)
52.1 (2.051)
41 .2 t .A5Al36.4 (1.4331
r 1.01.910.9
12.O12.78.213.422.0
26.426.8
13.814.22.915.9
2.66.3
32.047.A
20.8'18.3'19.5
Capacity f (US qt, lmp ql)1.2 (1.3, 1.1) at overhaul1.0 (1.1, 0.91 at fluid change
MEASUREMENTSTANDARD INEWI
Steering wheelRotational play at steering wheel circumferenceStaning load at steering wheelcircumferenceN {kgf, lbl) Engine running
0- 10 (0 - 0.39)
29 (3.0,6.6)
GearboxAngle of rack$uide-screw loosened lrom locked position'97, '98 models'99, '00 models10" 1 5"20" MAX.
PumpPump pressure with shut off valve closedkPa (kgvcm,, psi)6,900 - 7,800 (70 80,995 1,138)
Power steeringfluidRecommended tluidFluid capacity For overhaulI {US qt, lmp q0 For reservoir
Honda power steering fluid.0.85 (0.90,0.75)
0.4 {0.42,0.35)
Power steeringbelt*Deflection with 98 N {1O kgl,22lht)between pulleys11.0 14.5 (0.43 0.57)with used belt7.5 - 10.0 (0.30 0.40) with new belt
Belt tension N {kgt, lbf}Measured with belt tension gauge390 - 540 (40 - 55, 88 - 121) with used belt740-880 (75 90, 165 198)with new belt
2-10
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to
l
SuspensionSection 18
BrakesSec'tion 19
Air ConditioningSection 22
* When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
Readjust deflection or tension to used belt values.
o
Unit of length: mm {in)
MEASUREMENTSTANDARD {NEW)
WheelalignmentCamber FrontRearCaster FrontTotaltoe FrontnearFront wheel turning angle Inward wheelOutward wheel
0"00' 1 1'- 1"00' 1 1'2"10' ! 1"0J3(011/8)rN 2 ri (1/161 1/r6)37"00' ! 231'30'(Referencei
Wheel bearingEnd playFrontRear0 - 0.05 {0- 0.002}0 - 0.05 (0 0.002i
Rim runout Aluminum wheel AxialBadialSteelwheel AxialRadial
STANOARD (NEW)SERVICE LIMIT
0 - 0.7 (0 0.03)0,0.7 (0 - 0.03)0 1.0 (0 - 0.04)0 - 1.0 {0 - 0.04)
2.0 (0.08)'r.5 {0.06)2.0 {0.08)1.s (0.06)
MEASUREMENTSTANDARD INEWI
Parking brakeleverPlay in stroke at 196 N (20 kgf,44lbf)lever force
To be locked when Dulled: 2 - 6 notches
Foot brake pedalPedal height (with tloor mat removed)
Free playNT
155 (6 1/8)161 (6 5/16)1 5 (1/16 - 3/16)
Master cylinderPiston-to-pushrod clearance0 - 0.4 (0- 0.02)
Disc brakeDisc thickness Front '97, '98 models'99, '00 modelsDisc runoutDisc parallelismPad thickness
FrontFrontFront
STANDARD {NEW'SERVICE LIMIT
22.9 - 23.1 (0.902 - 0.909)23.6 23.8 (0.929 - 0.937)
10.5 - 11.5 (0.4't 0.45)
21.0 (0.83)
21.0 (0.83)
0.10 {0.004)0.015 (0.0006)
1.6 (0.06)
Rear brake drumLD.Lining thickness
2r9.9 220.0 (8.657 - 8.661)3.9 - 4.5 (0.15 - 0.18)221.O 8.70112.0 (0.08)
MEASUREMENTSTANDARD {NEWI
Air conditioningLubricant type:KEIHIN SP 10 (P/N 38897 - Pl3 - A01AH or 38899 -
Pl3 - A01)Lubricant capacity Condensermf {floz, lmp oz) EvaporatorLine or hoseReceiver
25 (5/6,0.9)
40 {1 1/3, 1.4)10 {1/3,0.4)10(.]/3,0.4)
Compressor(KEIHIN)Lubricant type: SP 10Lubricant capacity ml ({l 02, lmp oz}Stator coil resistance at 68'F (20"C) OPulley-to-pressuae plate clearance
130'3'{4 1fi'3o, 4.6;"}3.05 - 3.350.51 0.15 (0.02 1 0.006)
Compressor belt*Deflection with 98 N (10 kgl,22lblibetween pulleys7.5 - 10.5 {0.30 - 0.41) with used belt5.0 - 7.0 (0.20 - 0.28) with new belt
Belt tension N (kgf, lbf)Measured with belt tension gauge390 - 540 (40 55,88-120)withusedbelt740 - 880 {75 90, 170 - 200) with new belt
2-11
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Lubrication Points
For the details of lubrication points and type of lubricants to be applied. refer to the illustrated index and various work pro-
cedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
Recomm6nded Engine OilEngine oil viscosity for ambient temperature ranges
100'F
-30 -20 .10 0 10 20 30 40'c
r1: Always use Genuine Honda Manual Transmission Fluid {MTF). Using motor oil can cause stiffer shifting because it
does not contain the orooer additives.*2: Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect
shift qualitv.+3r Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the
life of the system.*4: Always use Genuine Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmis-
sion fluid can caused increased wear and poor steering in cold weather.
API SERVICE LABEL
/,.*-G\
/.'z-\e\t/6AE\ll-;-1 5w-30 /---l
w
API CERTIFICATION SEAL
ffi-20 0 20
NO.LUBRICATION POINTSLUBRICANT
EngineAPI Service Grade: Use SJ "Energy Conserving" grade oil. The oilcontainer may also display the API Certitication seal shownbelow. Make sure it says "For Gasoline Engines." SAE vjscosity:See chart below.
2
TransmissionManualGenuine Honda MTF*1
AutomaticGenuine Honda Premium Formula Automatic Transmission Fluid(ATF)*'
3Rear differentialGenuine Honda CVT Fluid
4Brake line (includes ABS line)Genuine Honda DOT 3 Brake Fluid*3
5Clutch LineBrake fluid DOT 3 or DOT 4*3
6Shift lever pivots (Manual transmission)Grease with molybdenum disultide
1Release fork (Manual transmission)LJrea Grease UM264 P/N 4'1211 - PYs - 305
IPower steering gearboxSteering grease P/N 08733 - B070E
Throttle cable end {Dashboard lower panel holelSilicone grease
10l112
14
Throttle cable end (Throttle link)Brake master cylinder pushrodPedal linkageBattery terminalsFuelfill lidClutch master cylinder pushrod
Multi purpose grease
1617181920
Hood hinges and hood lockTailgate hingesHatch glass hingesDoor hinges, upper and lowerDoor opening detent
Honda White Lithium Grease
21
22
Caliper Piston seal, Dust seal,Caliper pin, PistonShilt cable and select cable {Manual transmission)Silicone grease
23Brake line ioints (Front and rear wheelhouse)Rust preventives
24Power steering systemGenuine Honda Power Steering Fluid-.
25Air conditioning compressorCompressor oil: SP 10 lP/N 38897 - P13 - A0lAH or38899-P13-A01)For Refrigerant: HFC 134a (R,134a)
3-2
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22. Remove the radiator caP.
!@ use care when removing the radiatol
cap to avoid scalding by hot coolani or steam.
23. Raise the hoist to full height
24. Remove the front tires/wheels.
25. Remove the guard bar and splash shield.
8 x 1.25 mm2,1 N.m {2.4 kgf,m, 17 lbl ft)6x1.0mm9.8 N.m {1.0 kgf.m, GUARD BAR7.2 tbf.rr)
Loosen the drain plug in the radiator. Drain the
engine coolant (see page 10-51.
Drain the transmission oil or fluid. Reinstall the drain
plug using a new washer lsee section 13 (M/T) or sec-
tion 14 (ly'T)].
Drain the engine oil. Reinstall the drain bolt using a
new washer {see page 8-4).
Bemove the A,/C compressor. Do not disconnect the
!y'C hoses.
SPLASH
26.
27.
28.
29.
ER
lCEB
30. Disconnect the primary heated oxygen sensor (prl-
mary HO2S) connector. then remove exhaust pipe A
'97 - 98 U.S. models (Cslifornia):
PRIMARY HO2SCONNECTOR
GASKETReplace.
SELF-LOCKING NUT8 x 1.25 mm22 N.m 12.2 kgf.m,16 lbf.ftlReplace.
8 x 1.25 mm16 N.m {1.6 kgf.m.12 tbt.ftlReplace.
SELF.LOCKING NUT10 x 1.25 mm54 N.m 15.5 kgf.m,.() tbf.frlReplace.
NUT
'97 - 98 U.S. mod€ls {Except California):'99 - 00 models:
PRIMARY HO2SCONNECTORGASKETSReplace.
GASKETReplace.
SELF.LOCKING8 x 'l.25 mm22 N.m (2.2 kgf m,
16 rbf.ftlReplace.
SELF.LOCKING NUT
8 x 1.25 mm16 N.m 11.6 kgf.m,12 tbt fr)Replace.
10 x 1.25 mm54 N.m 15.5 kgt.m,40 rbt.ftlReplace.
{cont'd)
5-7
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Engine RemovaUlnstallation
OOI{TROL PI
Removal (cont'dl
31. Remove the shift cable. Take care not to bend the
cable when removing it. Always replace any kinked
cable with new one (Afl-).
SNAP PIN
sHtFT CABttOOVEB
8 x 1.25 mmt2 N.m 12.2 lgtr'l'',,16 tbf.ftl
Remove the right damper fork (see section 18).
Disconnect the suspension lower arm ball joints (see
section 18),
Remove the driveshafts (see section t6). Coat allprecision-finished surface with clean engine oil. Tieplastic bags over the driveshaft ends.
5-8
34.
Make marks on the transfer companion flange andpropeller shaft as shown. Use these marks to set thepropeller shaft in the proper position when rein-
stalling (4WD).
Remove the four bolts securing the propeller shaft,then separate the propeller shaft from the transfer
companion flange (4WD).
E x 1.25 mm32 N.m 13.3 lgt.m, 24 lbt'ftlRepl€ce.
37. Lower the hoist,
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Engine Removal/lnstallo cton
Installation (cont'd)
8. Tighten the nut on the right front mount.
AlTi
59 .m 16.0 tgt m, (l lbfftlReplace.
MlTi
12 x'1.25 mm59 N.m 16,0 kgt m, /(} lbt ttlReolace.
5-16
9. Perform the following checks and adjustments:. Check that the spring clip on the ends of the drive-shaft and intermediate shaft clicks into place. Usenew spring clips.. Adjust the shift cable (see section l4).. Adjust the throttle cable (see section 11).. Refill the engine with engine oil (see page g-4).
. Refill the transmission with oil or fluid (see sec-tion 13 or 14).
. Refill the radiator with engine coolant (see page
10_5).
. Bleed air from the cooling system with theheater valve open (see page l0-5).. Clean the battery posts and cable terminals withsandpaper, assemble them, then apply grease toDrevent corrosron.. Inspect for fuel leakage (see section 1l).After assembling fuel line pans, turn on the igni-tion switch (do not operate the starter) so thatthe fuel pump operates for approximately twoseconds and the fuel Iine pressurizes.
Repeat this operation two or three times, andcheck for fuel leakage at any point in the fuel line.
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Valve Guides
Replacement (cont'dl
5.
Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (O.l
in) towards the combustion chamber. This willknock off some of the carbon and make removaleasier. Hold the air hammer directly in line with thevalve guide to prevent damaging the driver.
CAUTION: Always wear satety goggles or a faceshield when driving valve guidss.
Turn the head over and drive the guide out towardthe camshaft side of the head.
li a valve guide won't move, drill it out with a 8.0mm (5/16 in) bit, then try again. Dritt guides onty inextreme cases; you could damage the cylinder headif the guide breaks.
Remove the new guide(s) from the freezer, one at atlme, as you need them.
6.
7.
6-26
'o C'
8. Apply a thin coat of clean engine oil to the outsideof the new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified installed height. lfyou have all 16 guides to do, you mav have toreheat the head.
Valve Guide Installed Height:
Intake: 13.75 - 1i1.25 mm
{0.5,[1 - 0.561 in)
Exhaust: 15.75 - 16.25 mm(0.620 - 0.640 inl
ATTACHMENT
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Cylinder Head
Installation
Installthe cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surfaces.
2. Clean the oil control orifice. Install the cylinder headgasket, dowel pins and the oil control orifice on thecylinder block. Always use a new cylinder head gas-ket.
CYLII{DER HEADGASKETR€place.
DOWEL PIN
O.RINGRoplace.
DOWELPIN
OIL CONTBOLORIFICEClean.
Apply clean engine oil to the bolt threads and underthe bolt heads.
4. Tighten the cylinder head bolts in two steps. In thefirst step tighten all bolts, in sequence, to about 29
N.m {3.0 kgf.m,22 lbf.ft); in the finat step, tighten inthe same sequence to 85 N.m (8.7 kgf.m,63 lbf.ft).
Use a beam-type torque wrench. When using a pre-
set-type torque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Tighten the intake manifold mounting bolts (see
page 6-21).
Install the exhaust manifold bracket. and tighten thenew self-locking nuts (see page 6-20).
6-30
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