1997 HONDA CR-V Washer

Fuel Tank
Replacement
1. Relieve the fuel pressure (see page 11-178).
2. Fold the left rear seat cushion forward, and remove the base frame cover {see section 20).
3. Remove the access panel from the floor.
4. Disconnect the 5P connector 1C562) and 6P connector (C580) ('98-00 models)'
5. Disconnect the fuel return hose and quick-connect fittings {see page 11-175}
6. Jack up the vehicle, and support it with jackstands.
7. Remove the middle floor beam.
8. Remove the drain bolt, and drain the fuel into an approved contaaner.
g. Disconnect the hoses (see page 11-173, 174). slide back the clamps. then twist hoses as you pull, to avoid damaging
them.
10. Place a jack, or other suppon, under the tank
11. Remove the strap nuts, and let the straps fall free
12. Remove the fuel tank. lf it sticks on the u ndercoat applied to its mount, carefu lly pry it off the mount,
'13. lnstallthe drain bolt with a new washer, then coat the drain bolt with Noxrust 1248'
Allow the Noxrust to dry for 20 minutes.
14. Install parts in the reverse order of removal.
'97 modol:AOCESS PANEL
CONNECTOR
@ Do not smoke while working on fuol systam Keep open flame away from your work area'
DRAIN EOLT49 N.m15.0 kgf'm,36 rbt frl
(cont'd)
1 1-191
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Pressure Plate
Removal/lnspection
1.Check the diaphragm spring fingers for height using
the special tools and a feeler gauge.
Standard lNewl: 0.6 mm {0.02 in) max.
Service Limit: 0.8 mm (0.03 in)
HANDLE07936 - 3710100
CLUTCH ALIGNMENT DISCOTJAF - PM7O11A
CI.UTCH ALIGNMENT SHAFT07NAF - PR30100
FEELER GAUGE
lf the height is more than
the pressure Plate.
the service limit, replace
2. lnstall the sDeciallools as shown.
RING GEAR HOLDER ADJUSTER NUT
ENGINE BLOCKADJUSTER BOLT
BOLT
NUT WASHER
To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps. then remove the pressure plate.
4. Inspect the pressure plate surface for wear, cracks,
and burning.
5. Inspect the fingers of the diaphragm spring for wear
at the release bearing contact area.
Inspect for warpage using a straight edge and feeler
gauge. Measure across the pressure plate.
Standard lNew): 0.03 mm 10.001 in) max.
Service Limit: 0.15 mm (0.006 inl
6.
FEELER GAUGE
lf the warpage is more than the service limit,
replace the pressure plate.
PRESSURE PLATE
PRESSURE PLATE
12-7
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Flywheel
Inspection
2.
3.
Llnspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the fly-
wheel for wear, cracks, and burning
Measure the flywheel runout using a dial indicator
through at least two full turns. Push against the fly-
wheel each time you turn it to take up the crank-
shaft thrust washer clearance.
NOTE: The runout can be measured with engine
installed.
Standard (Newl: 0.05 mm (0.002 in) max.
Service Limit: 0.15 mm {0.006 inl
lf the runout is more than the service limit, replace
the flywheel and recheck the runout
Turn the inner race ot the flywheel bearing with your
finger. The bearing should turn smoothly and qui-
etly. Check that the bearing outer race fits tightly in
the tlywheel. lf the race does not turn smoothly, qui-
etly, or fit tight in the flywheel, replace the bearing.
FLYWHEEL
RING GEAR
FLYWHEEL
L
2.
Replacement
Installthe special tool as shown.
Remove the flywheel mounting bolts in a crisscross
pattern in several steps, and remove the flywheel.
MOUNNNGBOLTS
FLYWHEEL
(cont'd)
12-9
RING GEAR HOLDER07LAB - PV00r00ol07924 - PD20003
3. Remove the ball bearing from the flywheel.
BALL BEARING
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MaintenanceBack-up Light Switch
Transmission Fluid
NOTE: Check the fluid with the engine OFF and vehicle
on level ground.
1. Remove the filler plug. then check the level and
condition of the fluid.
FILLER PLUG44 N.m {4.5 kgf.m. 33 lbf ftl
ll
Ptopet Level
\--ril /
HllllllTl /
Hllllrlll /_rf-F{--rno."."
ll| | Replaco.
The fluid level must be up to the filler hole. lf it is
below the hole, add fluid until it runs out. then rein-
stall the tiller plug with a new washer.
lf the transmission fluid is diny, remove the drain
plug and drain the fluid.
FILLEB PLUGa,a N.m 14.5 kgf..n. 33 lbt'ftl
DRAIN PLUG39 N m (4.0 kgf.m, 29 lbf'ft)WASHERReplace.
Reinstall the drain plug with a new washer. and
refill the transmission fluid to the proper level.
NOTE: The drain plug washer should be replaced at
every fluid change.
Reinstall the filler plug with a new washer.
Fluid Capacity
1.7 / {1.8 US qt, 1.5 lmp qtl at oil change
2.1 ! 12.2 US qt, 1.A lmp qtl at overhaul
Alwavs use Genuine Honda Manual Transmission
Fluid (MTF). Using motor oil can cause stiffer shift-
ind because it does not contain the proper additives.
Test/Replacement
1. Disconnect the connectors from the switch.
Terminal side oImale lerminals
BACK.UP LIGHT SWTTCHr 25 N.m 12.5 kgt m, 18 lbf.ftl
WASHERReplace.
Check for continuity between the No. 1 and No. 2
terminals.
. There should be continuity when the shift lever
tnto reverse.
. There should be no continuity when the shift
lever in position except reverse,
lf necessary, replace the switch.
13-3
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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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Transmission Assembly
Removal (cont'dl
6. Remove the cotter pins,
washers, plastic washers.
cable from the levers.
then remove the steel
shift cable, and select
1.
8.
Remove the cable bracket from the clutch housing.
Disconnect the vehicle speed sensor (VSS) connec-tor.
-------------.2
13-8
9. Remove the
bolts.
four upper transmission mou nting
10.
11.
Drain transmission fluid (see page '13-3).
Remove the guard bar and the splash shield.
MOUNNNG BOLTS
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Transmission Assembly
lllustrated Index
Refer to the drawing below for the transmission disassembly/reassembly.Clean all the pans thoroughly in solvent, and drv with comoressed air.
I LuUri""r" utt the parts with MTF before reassembly.
NOTE:
t This transmission uses no gaskets between the major housings; use liquid gasket (p/N 0g718 - 0001 or oE7l8 - 0003)(see page 13-69, 71).. Always clean the magnet @ whenever the transmissjon housing is disassembled.. Inspect all the bearings for wear and operation.
C) sHrFr FoRK ASSEMBLY.Index page, l3-21(a MAINSHAFT ASSEMBLY.Index page, 13-23(9 28 mm WASHER€) 28 mm SPRTNG WASHERO BALL BEARINGa6) OIL SEAL ReDlace.(D 14 x 20 mm DOWEL ptN
G) couNTERSHAFT ASSEMBLY.lndex page, 13-28
NEEDLE SET PLATENEEDLE BEARINGOIL GUIOE C PLATEMAGNETDIFFERENTIAL ASSEMBLY.lndex page, 13-38O-nlNG Beplace.TRANSFER ASSEMBLY.Index page, '13,44
OIL SEAL Replace.VEHICLE SPEED SENSORCLUTCH HOUSINGREVERSE LOCK CAMREVEESE SHIFT HOLDERREVERSE IDLE GEARREVERSE GEAR SHAFTTHRUST WASHER,20 x 36 x 2COLLER, 15 x 20 x 20
aol
@o@@
(D
i9
@@@(9
@@@e3@
13-12
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C) TRANSMISSION HANGER
O INTERLOCK BOLT
O 32 mm SEALING BOLT
@ STEEL BALL {5/16 in.)
€) SPRING 26.1 mm {1.03 in.l
@ wasHER Replace.
O sET BALL scREw
@ WASHER Replace.
€) FLANGE BOLT
@ oll SEAL Replace.
@ DRAIN PLUG
@ WASHER Replace.
@ FILLER PLUG
@ WASHER Replace.
(9 10 x 12 mm DOWEL PIN(D SPRING 25.6 mm 11.01 in.l
€' THRUST WASHER
@} SHIFT ARM C(3 CONICAL SPRING WASHER
@ SPECTAL BOLT
8] SHIFT ARM COVER
@ OIL SEAL Replace.
€! SHIFT LEVER
@I BREATHER CAP(2! SHIFT ARM SHAFT ASSEMBLY
@ SPRING PIN Replace.O SELECT ARM
€!} THRUST WASHER
@ sTH/REVERSE SELECTRETURN SPRING
@ SELECT RETURN SPRING
€) OIL GUTTER PLATE
@ 78 mm SHIM
@ OIL GUIOE M PLATE
@ SELECT SPRING BOLT
@ OIL SEAL Replace.
@ SELECT LEVER
O BACK.UP LIGHT SWITCH
@ WASHER Replace.OO TRANSMISSION HOUSING
13-13
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