2002 Honda CR-V ES, LX, EX, and RV-Si Shop Manual (P/N 62S9A00)

• Coverage: 2002 CR-V four-door station wagon applications identified in Honda’s VIN table, including RD5, RD6, RD7, and RD8 codes; 2WD and 4WD; left- and right-hand drive; K20A4, K20A5, and K24A1 engines; Z2M1/Z2M3 5-speed manuals and MCVA/MRVA 4-speed automatics; and Base, ES, LS, LX, EX, SE/SES, RV-i/RV-iH, and RV-Si/RV-SiH grades.
• Document set: Honda Motor Co., Ltd., Service Publication Office, First Edition 11/2001. This 28-file PDF set totals 1,976 pages, including 20 blank section-end pages. Honda’s original introduction separately states 1,834 pages.
• Engine repair coverage reaches well past routine maintenance, with engine removal and installation, compression testing, VTEC rocker-arm and VTC actuator checks, cam-chain timing service, cylinder-head and valve work, crankshaft, bearing, and piston repair, cylinder honing, oil-pump overhaul, and cooling-system testing.
• Transmission and driveline chapters cover clutch hydraulics and clutch replacement; manual-transmission teardown, shaft, synchronizer, differential, and transfer work; automatic-transmission DTC diagnosis, road, stall-speed, and hydraulic-pressure testing, valve-body and clutch service; plus the rear dual-pump differential, axles, and propeller shaft.
• Chassis procedures include power-steering pressure and leakage checks, pump and steering-gear overhaul, wheel alignment, hub and bearing service, damper and spring replacement, brake bleeding, caliper and master-cylinder overhaul, booster checks, and ABS circuit, modulator, and wheel-sensor diagnosis.
• Electrical coverage spans starting, charging, ignition, PGM-FI, VTEC/VTC, EVAP, cruise control, body multiplex, immobilizer, security, lighting, power accessories, HVAC, navigation, and SRS. Group 77 adds fuel/emissions and automatic-transmission DTC procedures that do not require a scan tool or Honda PGM Tester.

This is a global-market shop manual, not a North America-only publication. Its application tables separate market grades, engine and transmission serial ranges, Japanese- and UK-built vehicles, and the MCVA 2WD automatic from the MRVA 4WD automatic. Maintenance schedules are divided for European models, Australia/New Zealand models, and other markets. Those distinctions matter when choosing repair procedures, electrical diagrams, and test specifications.

The engine chapters document the mechanical repair sequence from removal through internal inspection and reassembly. Cylinder-head coverage includes valve-clearance adjustment, cam-chain removal and installation, VTC actuator and camshaft-sprocket service, head warpage inspection, valve-guide replacement, valve-seat reconditioning, and the factory head-bolt tightening sequence. The block section adds bearing selection and replacement, crankshaft and piston inspection, cylinder honing, ring service, and final assembly checks.

Manual-transmission coverage follows the Z2M units through removal, disassembly, mainshaft and countershaft inspection, synchronizer and shift-fork checks, thrust-clearance adjustment, differential setup, and transfer overhaul. The larger automatic-transmission section combines electronic diagnosis with mechanical repair: PCM inputs and outputs, DTC and symptom indexes, hydraulic-control descriptions, road and stall-speed tests, pressure tests, solenoid and pressure-switch checks, transmission removal, valve-body repair, clutch-pack inspection, shaft service, differential work, and transfer assembly procedures.

Factory tool information is placed with the applicable procedures. Examples include Engine Tilt Hanger Set 07KAK-SJ40101, VTEC Air Adapter 07ZAJ-PNA0101, A/T Oil Pressure Gauge Set 07406-0020004, P/S Pressure Gauge 07406-0010001, MPCS Short Connector 07WAZ-0010100, and SRS Inflator Simulator 07SAZ-TB4011A. Reference data is organized as component-specific torque tables, standards and service limits, clearances, wear limits, fluid and lubricant information, pressure-test data, wheel-alignment values, and electrical test specifications rather than isolated general notes.

Diagram coverage includes the automatic-transmission cutaway and hydraulic-flow views, PCM connector terminal locations and input/output charts, ABS and SRS circuit and connector views, and Group 78 wiring diagrams for starting/charging/ignition, PGM-FI and automatic transmission, fan controls and HVAC, multiplex functions, keyless locking and security with or without super locking, exterior lighting, navigation, and audio. Component-location indexes and exploded views connect those diagnostic references to the repair chapters.

Two cautions show why the model-specific factory procedures matter. The 4WD chapters warn that towing or wheel-rotation testing with only two wheels supported can damage the 4WD system. During automatic-transmission valve-body repair, the shift-solenoid installation order is not interchangeable; the manual flags an incorrect sequence as a risk to the hydraulic control system.

Body coverage is service-oriented: doors, mirrors, glass, sunroof, trim, dashboard, seats, bumpers, hood, tailgate, latches and openers, and frame reference points. It is not a dedicated collision-panel replacement manual. Repair work involving SRS, refrigerant, braking systems, heavy components, or a raised vehicle requires the specified precautions, tools, and test equipment.