1997 HONDA CR-V seat

Fuel Supply System
Fuel Gauge
Tssting
NOTE: Refer to section 23 for the fuel gauge system cir-cuit diagram.
'1. Check the No. 25 METER (7.5 A) fuse in the under-dash fuse/relay box before testing.
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 from the fuel pump.
5. Measure voltage between the 5P connector termi-nals No.2 and No. 5 with the ignition switch ON ( ).There should be between 5 and 8 V.
FUEL PUMP5P CONNECTOR
tc56al
a
a
Wire side of female t€rminals
lf the voltage is as specified, go to step 6.lf the voltage is not as specified, check for:- an open in the YEUBLK or BLK wrre.- poor ground (c552).
11-184
7.
Turn the ignition switch OFF.
Attach a jumper wire between the No. 2 and No. 5terminals, then turn the ignition switch ON fll).
Check that the pointer of the fuel gauge starts mov-ing toward the "F" mark. Turn the ignition switchOFF before the pointer reaches "F" on the gauge
dial. Failure to do so may damage the luel gauge.
NOTE: The fuel gauge is a bobbin (cross-coil) type,hence the fuel level is continuously indicated evenwhen the ignition switch is OFF, and the pointer
moves more slowly than that of a bimetal type.
. lf the pointer of the fuel gauge does not move atall. replace the gauge.
. lf the gauge is OK, inspect the fuel gauge send-ing unit.
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Fuel Gauge Sending Unit
Tgsting
@ Do not smoke while working on tho fuel
systom. Keop open flamo 8waY from your work araa.
1. Fold the left rear seat cushion forward, and remove
the base frame cover (see section 20).
2. Remove the access panel.
3. With the ignition switch OFF. disconnect the 5P con-
nector from the fuel pump.
4. Relieve fuel pressure (see page 11-178).
5. Disconnect the fuel lines.
6. Remove the fuel pump,
7. Measure the resistance between the No. 2 and No. 5
terminals at E (EMPTY), 1/2 (HALF FULL) and F (FULL)
by moving the float.
lf you do not get the above readings, replace the
fuel pump.
11-185
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Fuel Supply System
Low Fuel Indicator System
Indicator Light Testing
NOTE: Refer to section 23forthe lowfuel lndicator circuit
clragram.
1. Check the No. 25 METER (7.5 A) fuse in the under-
dash fuse/relay box before testing.
2. Park the vehicle on level ground.
@ Do not smoke while working on the
fuel system. Keep open flame away trom the work
aroa. Drain fuel only into an approved container.
Drain the fuel into an aoDroved container. Then
install the drain bolt with a new washer.
Add less than 8 f (2.1 U.S. Gal. 1.8 lmp. Gal) of fuel,
and turn the ignition switch ON {ll). The low fuel indi-
cator light should come on within four minutes.
INDICATON LIGHT
. lf the light comes on within four minutes, go tostep 8.
. lf the light does not come on within four min-
utes. go to step 5.
Remove the seat cushion (see section 20).
Remove the fuel tank access panel from the floor,
and disconnect the 5P connector from the fuel pump,
Connect the No. 1 and No. 2 terminals with a jumper
wire.
. lf the lightcomeson, checkthe sending unit.. lf the light does not come on, check for:- an open in the GRN/yEL wire between thefuel unit and fuel gauge assembly.- blown bulb.- poor ground (G552).
FUEI- PUMP 5P CONNECTOR (C562)
JUMPER WIRE
IGRN/YEL}
7.
1 1-1 86
Wire sid€ ol tem€le terminals
8. Add 4 / of fuel (1.1 U.S. Gal, 0.9 lmp. Gal). The light
should go off within four minutes.
. lJ the light does not go off, check for:- a short in the GRNA/EL wire between the fuel
gauge sending unit and fuel gauge assembly.- faulty gauge assembly.
. lf the light goes off, the low fuel indicator light is
oK.
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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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Tapered Roller Bearing Preload Adiustment
lf any oJ the items listed below were replaced, the tapered
roller bearing preload must be adjusted.
. Transmission housing
. Clutch housing
. Differential carrier
o Tapered roller bearing and bearing outer race
. Thrust shim
. 75 mm sham
1. Remove the bearing outer race and thrust shim
from the transmission housing (see page 13-40)'
NOTE:
. Do not reuse the thrust shim if the bearing outer
race was driven out.
. Let the transmission cool to room temperature il
the bearing outer race was removed by heating
the clutch housing.
2. Do not use more than one thrust shim to adjust the
tapered bearing preload. First try the same size
thrust shim that was removed. There are no shims
used on the clutch housing side
SHIMTHRUST
/A
After installing the thrust shim, install the bearing
outer race in the transmission housing (see page
13-40).
With the mainshaft and countershaft removed,
install the differential assembly, and torque the
clutch housing and transmission housing.
NOTE: lt is not necessary to use sealing agent be-
tween the housings.
TOBOUE; 8 x 1.25 mm: 27 N'm(2.8 kgf'm, 20 lbt'ftl
Rotate the differential assembly in both directions
to seat the tapered roller bearings.
Measure the tapered roller bearing preload at nor-
mal room temperature. Measure the starting torque
of the differential assembly in both directions with
the special tool and a torque wrench.
STANDAFD: 1.4 - 2.5 N'm
{1/r - 26 kgf'cm, 12 - 23 lbf in)
(cont'd)
4.
5.
07HAJ - PK4020'1
13-41
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Transfer Assembly
Inspection
NOTE: To prevent damage to the transfer housing,
always use soft jaws or equivalent materials between
the transfer housing and the vise.
Transter Gaar (Hypoid goar) Backlssh M€asurement
1. Set a dial indicator on the companion flange asshown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.002 - 0.006 in}
Total Sta.ting Torquo Msasuremont
3. Rotate the companion flange several times to seatthe tapered roller bearing.
4. Measure the starting torque (companion flange
side) using a torque wrench.
STANDARD:
2.68 - 3.47 N.m
{27.3 - 35.4 kgf.cm.23.7 - 30.7 tbt.in)
DIAL INDICATOR
COMPANION FLANGE
13-46
Transfer Gear lHypoid gearl Tooth Contaqt Insp€ction
5. Remove transfer cover B, then apply Prussian Blueto both sides of the transler gear teeth lightly andevenlv.
Rotate the companion flange in both directions untilthe transfer gear rotates one full tuln in both direc-tions.
Check the transfer gear tooth contact pattern.7.
lf the measurements or the tooth contact Datternare not within the standard. disassemble the trans-fer assembly, replace worn or damaged parts, andreassemble it.
TRANSFER DRIVE GEAR
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TOROUE WRENCH
10. Hold the transfer shaft with a 14 mm Allen wrench
clamped in a bench vise.
lil mm ALLEN WRENCH
Tighten the transfer shaft locknut.
NOTE:
. The transfer shaft locknut has left-hand threads,
. Do not stake the locknut in this step.
TOROUE: 118 N.m (12.0 kgf.m,86.8 lbf.ft)
Temporarily install the transfer cover A without the
O-ring.
11.
rl0ustNG
TRANSFER COVER A
8xL25mm24 N.m (2.4 kgt.m. 17 lbnftl
'14.
Rotate the companion flange several times to seat
the tapered roller bearing.
Set a dial indicator on the companion flange, then
measure the transfer gear backlash.
STANDARD: 0.06 - 0.15 mm 10.002 - 0.006 in)
COMPANION FLANGE
lf the measurement is not within the standard,
remove the transfer shaft locknut and replace the 25
mm thrust shim. Select and install a new 25 mm
thrust shim. then recheck the measurement. Do not
use more than one 25 mm thrust shim to adjust the
transfer gear backlash,
THRUST SHlM,25 mm
DIAL INDICATOR
Shim No.Part NumbelThickness
I2941r - P1C - 0001.70 mm 10.067 in
229412-PlC-000'L73 mm (0.068 in
329413-P1C-0001.76 mm (0.069 in
29414-PlC-0001.79 mm (0.070 in
529415-P1C-0001.82 mm (0.072 in
629416-PlC-0001.85 mm (0.073 in
7294'17-PrC-0001.88 mm (0.074 in
8294'18-P1C-0001.91 mm (0.075 in)
29419-PlC-0001.94 mm (0.076 in)'1029420-P1C-0001.97 mm 10.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
1229422 -P1C - 0002.03 mm (0.080 in)
1329423-P1C-0002.06 mm (0.081 in)
l429424-P1C-0002.09 mm (0.082 in)
29425-P'tC-0002.12 mm (0.083 in)
1629426-P1C-0002.15 mm (0.085 in)
1729427 -P1C-0002.18 mm {0.086 in)'1829428-P1C-0002.21 mm {0.087 in)
1929429-P1C-0002.24 mm 10.088 in)
(cont'd)
13-55
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Transfer Assembly
Reassembly (cont'dl
26. Secure the transfer housing in a bench vise with
soft jaws.
COMPANION FLANGE HOLDER07RAB - 002tD00
27. Install the special tool on the companion flange.
then tighten the transfer driven gear shaft locknut
while measuring the starting torque of the transfer
driven gear shaft.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 1i1.2 kgf.cm, 8.68 - 12.3 lbf in}
TIGHTENING TOROUE:
132 - 216 N.m
(13.5 - 22.0 kgf.m, 97.6 - 159 lbf.ft)
NOTE:
. Rotate the companion flange several times to
seat the tapered roller bearing, then measure the
startrng torque.
. lf the starting torque exceeds 1.39 N.m (14.2
kgf.cm, 12.3 lbf.in), .eplace the transfer spacer
and reassemble the parts. Do not adjust the
torque with the locknut loose.
. lf the tightening torque exceeds 216 N.m (22.0
kgf.m, 159 lbf'ft), replace the transfer spacer and
reassemble the parts.
. Write down the measurement of the starting
torque: it is used to measure the total starting
torque.
28. Stake the locknut into the transfer driven oear shaft
using a 3.5 mm punch.
0.7 - 1.2 mm(0.03 - 0.05 inl
Point to bestaked.
Install the transfer shaft assemblv in the transfer
housing, then install the tapered roller bearing,
transfer shaft collar, 25 mm thrust shim, transfer
drive gear, conical spring washer, and transfer shaft
locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut and transfer shaft
with MTF before installing the locknut.
. lnstall the conical spring washer in the direction
snown.
TMNSFER SHAFTASSEMBLY
TRANSFER HOUSING
TAPERED ROLLERBEARING
TRANSFER SHAFTCOLLAR
TRANSFER DRIVEGEAR
PUNCH3.0-3.5 mm10.12 - 0.1a inl
THRUST SHIM, 25 mmSelective part
CONICAL SPRINGWASHEBReplace.
LOCKNUTReplace.
29.
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