air con HONDA CR-V 1997 RD1-RD3 / 1.G Workshop Manual

CAUTION: lf either end ot the special tool issetover an
area of the spring retainer which is unsupported by the
return spring, the retainer may be damaged. B€ sure the
special tool is adiusted to have lull contact with the
spring retainer.
SPRING RETAINER
4. Compress the return spring.
Do not s6t h6re.
5. Remove the snap ring, Then remove the special tools,
spring retainer and return spring.
Wrap a shop rag around the clutch drum, and apply
air pressure to the ATF passage to remove the pis-
ton.
Place a finger tip on the other end while applying
arr pressure.
OSHA.APPROVED
SPRIlIG RETAINER
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49. Set the control shaft to E position, and install the
A,/T gear position switch on it.
CONTROL SHAFT
l( ((,,, ,.
*
$*\.t+-
NN
6x1.0mm12 N.m 11.2 kgt.m,8.7 tbf.ftl
6xl.0mm12 N.m 11.2 kgf'm,
8,7
'gtt - 00 MoDELS{6 position3}T
Install the A/T gear position switch cover, then
install the harness clamps of the AviT gear position
switch harness on the end cover and the transmis-
sion housing.
50.
CONTROL SHAFT
HARNESS CLAMP
HARNESS CLAMP
Clean the areas where the transfer assembly con-
tacts the transmission with solvent or carburetor
cleaner, dry with compressed air, then coat the con-
tact areas with ATF. (4WD)
Install the transfer assembly with a new O-ring. Do
not allow dust or other foreign particles to enter the
transmission. {4WD)
O.RINGReplace-
10 r 1.25 mma,a N'm 14.5 kgt'm, 33 lbf'ftl
54.
55.
lnstall the cooler lines with the line bolts and new
sealing washers.
TOROUE: 28 N.m 12.9 kgif'm. 21 lbf'ft)
Install the ATF dipstick.
lnstall the breather cap on the breather pipe so its
arrow points to the transmission hanger.
TRANSMISSION
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Transmission
Installation (cont'dl
8. Install the transmission housing mounting bolts.
TRANSMISSION HOUSING MOUNTING BOLTS12 x 1.25 mm54 N.m 16,5 kgf.m, a7 lbtftl
9. Remove the transmission jack.
10. Attach the torque convener to the drive plate witheight bolts. Rotate the crankshaft as necessarv totighten the bolts to 'll2 of the specified torque, thento the final torque, in a crisscross pattern. Aftertightening the last bolt. check that the crankshaftrotates freelv.
6x1.0mln12 N.m (1.2 tgt m,8.t lbf.frl
6x1.0mm12 N.m {1.219{.m,8.7 tbtft,
12 x t.25 mm34 N.m 13.5 kgf.rn,25 lbf.ft)
8 x 1.25 mm2a N.m 12.5 kgf'm,18 tbt.ftl
DRIVE PLATE
STIFFENER
44 N.rn (4.5 kgt m, 33 lbtftl
11.
12.
Install the torque convener cover and the rear stiff_ener.
Tighten the crankshaft pulley bolt as necessary (seesection 5).
14-260
13. Connect the ATF cooler hoses to the ATF coolerlines (see page 14-266).
. ATF COOLERLINE
'i 'l'r',:,.) -
10 x 1.25 mm44 N.m (4.5 kgf.m,33 tbtftl
CLAMP
12 x 1.25 mm64 N.m 16.5 kg{.m,a7 tbt.ftlFRotrtT
15.
16.
't 4.
SET RINGReplace.
MOUNT/ARACKET
Install the right front mounvbracket.
Install new set rings on the ends of the intermediateshaft and the driveshaft.
Clean the areas where the intermediate shaft con_tacts the transmission {differential) with solvent orcarburetor cleaner, and dry with compressed air.Then install the intermediate shaft in the differen_tial, While installing the intermediate shaft, be surenot to allow dust or other foreign panicles to enterthe transmission.
l0 x 1.25 mm39 N.m 14.0 kgt.n,29 tbf.ftl
INTERMEDIATE SHAFT
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17. Install the right and left driveshafts (see section 18).
While installing the right driveshaft in the differen-
tial, be sure not to allow dust or other foreign parti-
cles to enter the transmission.
NOTE:
. Clean the areas where the right driveshaft con-
tacts the transmission (differential) with solvent
or carburetor cleaner, and dry with compressed
air.
. Turn the right and left steering knuckle fully out-
ward, and slide the right driveshaft into the dif-
ferential until you feel its spring clip engage the
side gear. Slide the left driveshaft into the inter-
mediate shaft until you feel the spring clip of the
intermediate shaft engage the left driveshaft,
18. Install right damper fork, then install the right and
left ball joints on each lower arm with the castle
nuts and new cotter pins (see section 18).
DAMPER PINCH BOLT10 x 1 .25 mm43 N.m 14.{ kgf.m,32 rbr.ftl
DAMPERFORX
SELF.LOCKING NUT12 x 1,25 mm6/t N m (6.5 kg{.m, a7 lbtft)Replace.
Replace.
CASTLE12 x 1.25 mm49 - 59 N.m15.0 - 6.0 kgl m, 36 - {3 lbtftl
19, Install the propeller shaft to the transfer assembly
by aligning the reference marks (4WD).
20.
8 x 1.25 mm32 N.m (3.3 kgt'm,2ir blft)
Feplace.
\
@_
PROPELLER SHAFT
lnstall the shift cable.
4WD:
Install the shift cable with the control pin, then
secure it with the snap Din. Do not bend the shift
cable excessivelv.
CONTROLLEVER
SHIFT CAALECOVER
8 x 1.25 mm22 N.m 12.2l'gl m,16 rbt.ftl
(cont'd)
REFERENCE MARKS
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26. Connect the vehicle speed sensor (VSS). the coun-
tershaft speed sensor. and the A,/T gear position
switch connectors,
VEHICLE SPEEO
SPEED SENSOACO'{NECTOR
Connect the lock-up control solenoid valve connec-
tor, then install the harness clamp on the clamp
bracket.
HARNESS CI-AMP
27.
RADIATOR HOSECLAMP
TRANSMISSIONGROUND CAB1ITERMINAL
LOCK-UP OONTROLSOLENOID VALVECONNECTOR
6x1.0mm12 N'm (1.2 kgi.m,8.? tbtftl
28.
29.
Instail the transmission ground cable terminal on
the transmission hanger, and install the radiator
hose clamp on the transmission hanger,
Connect the starter cables to the starter, and install
the harness clamD on the clamD bracket. Make sure
the crimped side of the starter cable ring terminal is
facing out.
STARTEBCABLE
STARTER CAAtf,
Install the air cleaner housing assembly and the
intake air duct.
Refill the transmission with ATF (see page 14-161).
Connect the battery positive terminal and negative
terminal.
Set the parking brake, Start the engine, and shift the
transmission through all gears three times.
Check the shift cable adjustment (see page 14-271]-.
Check the tront wheel alignment and adjust it if
needed (see section 18).
Let the engine reach normal operating temperature
(the radiator fan comes on) with the transmission in
E or N position, then turn it off and check the ATF
level {see page 14-160).
Perform a road test (see page 14-157 and 14-158).
30.
31.
34.
CLAMP BRACKET
37.
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Transmission
Cooler Flushing
@@ To prevent in;ury to face and eyos, atwayswear safety glasses ot a face shield when using thetlansmission flusher.
This procedure should be performed before reinstallingthe transmission.
2.
LCheck equipment for wear and cracks before using.Replace any worn or cracked components.
Using the measuring cup. fill the tank with 21 ounces{approximately 213 lull) ol biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontaaner.
Secure the flusher filler cap, and pressurize theflusher with compressed air to 550 - 829 kpa (5.6 _
8.45 kgf/cm,, 80 - 120psi). The air line should beequipped with a water trap to ensure a dry air sys-tem.
Hang the flusher under the vehicle.
Attach the flusher discharge hose to the return lineof the transmission cooler using a clamp.
Connect the drain hose to the inlet line on the trans-mission cooler using a clamp.
IMPORTANT:
Securely clamp the opposite end ofthe drain hose to abucket or floor drain.
DISCHARGEHOSE
tAirlp Water
TnAI{SrfiSStoN coot"€RFLUSHER{Comm.rcidly.v.il.bt.lK.r -Moor. J38,t{15.Aor aquival.nt
5.
14-264
7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)
10.
8.
1'I.
Turn on the water valve for 1O seconds. lf waterdoes not flow through the cooler, it is completelyplugged, cannot be flushed, and must be replaced.
Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.
While flushing with the water and flushing fluid fortwo minutes, turn the air valve on for five secondsevery 15 - 20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgf/cmr, t20 psi)
Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps 8 through 10.
Release the trigger, and rinse the cooler with wate.for one minute.
Turn the water valve off, and the water supply off.
Turn the air valve on for two minutes, or until nomoisture is visible leaving the drain hose. Residualmoisture in the cooler or lines can damage thetransmission.
Remove the flusher from the cooler line. Attach thedrain hose to a container.
Install the transmission, and leave the drain hoseattached to the cooler line.
12.
13.
14.
to.
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17.Make sure the transmission is in E position.
Fill the transmission with ATF, and run the engine
for 30 seconds or until approximately 0.951 {1.0 US
qt., 0.8 lmp qt.) is discharged.
Remove the drain hose, and reconnect the cooler
return hose to the transmission (see page 14-266).
Refill the transmission with ATF to the proper level
(see page l4'161 ).
18.
19.
TOOL MAINTENANCE
1. €mpty and rinse the flusher after each use. Fill the
flusher with water and pressurize it, then flush the
discharge line to ensure that the unit is clean.
2. lf discharge liquid does not foam, the orifice may be
blocked.
3. To clean, disconnect the large coupling nut from the
flusher.
FILTER
\-0--D
I
IO.RING
Remove the in-line filter from the discharge side and
clean it if necessary.
The fluid orifice is located behind the filter.
Clean it with the pick stored in the bottom of the
tank handle, or blow it clean with air.
Reassemble all parts.
COUPLINGNUT
II
-@q
\ORIFICE
4.
5.
6.
FILLER CAP
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Shift Lever
Removal/lnstallation
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vrce.
1. Remove the instrument panel lower cover and the
column covers (see section 171.
2. Shift to N position, then remove the lock pin from
the cable adjuster.
3. Separate the shift cable from the cable adjuster, Do
not bend the shift cable excessively.
ADJUSTER ROD
SHIFT CABLE
22 N.m (2.2 kgf.m, 16 lbt.ftl
7.
Remove the flange nuts and bolts securing the
steering column, then lower the steering column.
FLANGE NUTS16 N m (1.6 kgl m, 12 lbt'ftl
Disconnect the shift lock solenoid and the park pin
switch connector.
Remove the bolts securing the shift lever assembly,
then remove the shift lever assembly.
lnstall the shift lever assembly in the reverse order
of removal.
NOTE;
. Make sure the lock pin is seated securely in the
cable adjuster.
. Replace the lock pin if it does not snap over the
cable adjuster securely.
Check the cable adjustment after installing the shift
lever (see page 14-27'l).
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Shift Lever
Disassembly/Reassembly -'97 - 98 Models
SRS components are located in this area. Review the SRS component locations. precautions. and procedures in the SRS
section (24) before performing repairs or service.
Apply silicone grease to these parts'
. Movable parts of the shift lever,
. Movable parts of the shift lock mechanism.
. Sliding surfaces on the detent of the control checker and detent guide.
SHIFT LOCK SOLENOIDSPRING
SCREW
SHIFT LOCK2.5 N.m {0.25 kgtm, 1.8 lbtftl
SCREW2.5 N.m {0.25 kg{.m,1.8 rbf.ft)
SHIFT LOCK SOLENOIDPLUNGER
SHIFT LOCKEXTENSION
DETENT SPFING
SHIFT LEVER
PARK PIN SWITCHCONNECTOR
SHIFT LOCKRELEASE LEVER
CONTROL BRACKET
STOP
DETENT GUIDE
9.3 N.m 10.95 kgtm,6.8 tbrft)
SPRING
9.3 N.m {0.95 kgf.m,6.8 tbf.ftl
SHIFT LEVERLINK
9.3 N.m (0.95 kgt.m,6.8 tbf.ftl
SHIFT CAALE
KNOBI N.m 10.9 kgt.m,7 rbf.ftl
14-268
7 N.m {0.7 kgf.m.5 tbt.fr}
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Disassembly/Reassembly -'99 - 00 Models
SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS
section (24) before performing repairs or service.
Apply silicone grease to these parts:
. Movable parts of the shift lever.
. Movable parts of the shift lock mechanism.
. Sliding surfaces on the detent of the control checker and detent guide.
NOTE: Adjustthe clearance between the O/D switch wires and the edge ofthe shift lever control bracket after reassembly(see page 14-270).
SHIFT LOCKRELEASE LEVERSHIFT LOCK SOLENOIDSPRING
SCREW2.5 N.m {0.25 kgf.m, 1.8lbtft)SHIFT LOCK SOLENOID
SCREW2.5 N.m (0.25 kgl.m, 1.8 lbl.ft)
SHIFT LOCK SOLENOIOPLUNGER
DETENT SPRING
SHIFT LEVER CONTROLBRACKET
PARK PIN SWITCH _
o/D swtTcHCONNECTOB
SHIFT LOCK EXTENSION
STOP
DETENT GUIDE
9.3 N.m {0.95 kgf.m, 6.9 lbl.ftl
SCREW2.5 N.m {0.25 kgt m,1.8 tbf.ftl
SHIFT LOCK BELEASELEVER SPRING
9.3 N.m {0.95 kgl.m,6.9 lbtfr)
HARNESS CLAMPERACKET
PARK PINswrTcH
SCREW2.5 N.m {0.25 kgf.m,1.8 tbl.f0
9.3 N.m 10.95 kgtm,6.9 tbf.ft)CONTROL CHECKER
SHIFT LEVER KNOB6- 12 N.m{0.6 - 1.2 kgt'm,4 - 8.7 tbnft)LOCKNUT7 N.m {0.7 kgl.m,5 tbf.ftl
SHIFT LEVERBUSHING
o/D swtTcH
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