front mount HONDA CR-V 1998 RD1-RD3 / 1.G Owner's Manual

'1.
Lower Ball Joint Replacement
Remove the knuckle (see page 18-10).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage. and
replace it if necessary.
lnstall the special tools on the ball joint, and tighten
the castle nut.
BAII JOINT BEMOVER BASE07JAF - SH2oe00
Position the special tools over the ball joint as
shown. then set the assembly in a vise. Press the
ball joint out of the knuckle.
Place the ball joint in position by hand.
Install the special tools over the ball joint as shown,
then press the balljoint in.
BAII JOINT INSTAL1IR BASE
7.
8AI.I JOINT REMOVEN/INSTALLER
BALL JOINT HOUSING SURFACE
18-15
8. Install the ball joint boot and set ring using the spe-
cial tool {see page 18-16}.
Install the knuckle in the reverse order of removal.
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
toroue values.
a Torque the castle nuts to the lower torque speci-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. Install new cotter pins on the castle nuts after
IOrqurng.
Avoid twisting the sensor wires when installing
the wheel sensor.
Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
Before installing the wheel. clean the mating sur-
face of the brake disc and the inside of the wheel.
Check the front wheel alignment, and adjust it if
necessary (see page 18-4).
o
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Front Damper
Reassembly
1. Install the damper unit on a spring compressor.
STRUT SPflNG COMPBESSOR:lcomm.rcillly .vrilrble)BRANICKC T/N MST.sEOAor Mod.l 7200or oquivtla
SPRING LOWER SEAT
Assemble the damper in reverse order of removal
except the damper mounting washer and self lock-
ing nut. Align the bottom of the damper spring and
the spring lower seat as shown.
Position the damper mounting base on the damper
unit as shown.
Compress the damper spring,
Install the damper mounting rubber, damper mount-
ing washer, and a new 10 mm self-locking nut.
SELF-LOCKING NUT10 x 1.25 mmZt N.m 13.0 kgf.m, 22 lbf.ft)Replace.
Hold the damper shaft, and tighten the
locking nut.
DAMPERMOUNfING WASHER
18-18
10 mm self-
1.
lnstallation
Loosely install the
aligning tab facing
two flange nuts.
damper on the frame with
inside, then loosely install
FLANGE NUT
the
tne
-__---a-"- 10 x 1.25 mmg*- 59 N.m {5.0 kgt m, 43 tbf.ftl
| -,./.46- --...
./ -4 A-
DAMPERASSEMBLY
ALIGNINGTAB
2, Install the damper fork over the driveshaft and onto
the lower arm. Install the front damper in the
damper fork so the aligning tab is aligned with the
slot in the damDer fork,
3. Loosely install the damper pinch bolt on the top of
the damper fork.
4. Looselv install the damper fork bolt and a new self-
locking nut on the bottom of the damper fork.
5. Raise the knuckle with a floor iack until the vehicle just
lifts off the safetv stand.
The lloor iack must b€ socurely posi-
tioned or personal iniury may result.
6. Tighten the damper pinch bolt.
7. Tighten the damper fork bolt and self-locking nut.
8. Tighten the flange nuts on top of the damper.
9. Install the brake hose mounts with the brake hose
mounting bolts.
10. Installthe front wheel.
10 x 1.25 mmil3 l+m
{4.4 kgf'm,
Replace.
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Front Brake Disc
Disc Runout Inspection
l.Loosen the front wheel nuts slightly, then raise the
vehicle, and make sure it is securely supported.
Remove the front wheels.
Remove the brake pads {see page 19-9).
Inspect the disc surface for damage and cracks.
Clean the disc thoroughly, and remove all .ust.
Use wheel nuts and suitable plain washers to hold
the disc securely against the hub, then mount a dial
indicator as shown, and maasure the runout at
10 mm (0.4 in) from the outer edge of the disc.
Brake Di3c Runout:
Service Limit: 0.10 mm {0.00,0 in)
WHEEL NUT ANDPLAIN WASHER108 N.m {11 kg{ m, 80 lbf.ft)
lf the disc is beyond the service limit, refinish the
brake disc with an on-car brake lathe. The Kwik-
Lathe produced by Kwik-way Manufacturing Co.
and the "Front Brake Disc Lathe" offered by Snap-
on Tools Co. are approved for this operation.
M8x. Rofinish Limit: 21.0 mm l0.8il in)
NOTE: A new disc should bs refinished if its runout
is greater than 0.10 mm (0.004 in).
Disc Thickness and Parallelism
Inspection
1.Loosen the front wheel nuts slightly, then raise the
vehicle, and make sure it is securely supported.
Remove the front wheels.
Remove the brake pads (see page 19-9).
Using a micromater, measure disc thickness at eight
points, approximately 45'apan and 10 mm (0.4 in)
in from the outer edge of the disc. Replace the brake
disc if the smallest measurement is less than the
max. refinishing limit.
Brake Disc Thickness:
Standard:'97 - 98 modsls:
22.9 -23.1mm {0.90 - 0.91 inl'99 - 00 mod€ls:
23.6 - 23.8 mm {0.93 - 0.94 in}
Max. Refinishing Limit:21.0 mm (o.txl in)
Brake Disc Parallelism: 0.015 mm {0.0006 in} max.
NOTE: This is the maximum allowable difference
between the thickness measurements,
lf the disc is beyond the service limit for parallelism,
refinish the brake disc with an on-car brake lathe.
The Kwik-Lathe produced by Kwik-Way Manufac-
turing Co. and the "Front Brake Disc Lathe" offered
by Snap-on Tools Co. are approved for this opera-
tron.
NOTE: See section 18 for brake disc replacement.
19-1 1
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Master Cylinder/Brake Booster
Removal/lnstallation
1, Disconnect the brake fluid level switch connectors.
2. Remove the reservoir cap from the master cylinder.
3. Remove the brake fluid from the master cvlinder
reservoir with a syringe.
4. Disconnect the brake lines from the master cylinder.
To prevent spills, cover the line joints with rags or
shop towels.
5. Remove the master cylinder mounting nuts and
wasners.
6. Remove the master cylinder from the brake booster.
CAUTION: Be careful not to bend or damage the
brake lines when removing the master cylinder.
Do not spill brake fluid on the vehicle; it may dam.
age the paint; it brake fluid does cont.ct the paint,
wash it oft immediately with water.
7. Disconnect the vacuum hose from the brake booster.
8. Remove the cotter pin and clevis pin from the clevis.
Do not disconnect the clevis by removing it from
the operating rod of the brake booster. lf the clevis
is loosened, adjust the pushrod length before
installing the brake booster (see page 19-15).
To Front Caliper (Without ABS)
\\
15 N.m {1.5 kgtm, vAcuuM HosE
r r rbf.ft) |
/ | BRAKE FLUTD LEvEL
/l /
swrrcHcoNNEcroRs
/ I I I COTTER PIN
I I / neotace
l,/-- ro Rear wheet cylinders / | I
h ./-''' /. I I IYli //*s (.S
I /r:
9. Remove the four booster mounting nuts.'10. Pull the brake booster forward until the clevis is
clear of the bulkhead.
11. Remove the brake booster from the enqine com-
panment.
12. Install the brake booster and master cylinder in the
reverse order of removal, and note these items:
. When connecting the brake lines, make sure that
there is no interference between the brake lines
and other parts.
. Be careful not to bend or damage the brake lines
when installing the master cylinder.
. lf replacing the master cylinder or brake booster,
check and adjust the pushrod clearance before
installing the master cylinder (see page 19-14).
Fill the master cylinder reservoir, and bleed the
brake system (see page 19-7).
After installation, check the brake pedal height and
brake pedal free play (see page 19-5), and adjust if
necessary.
13 N.m 11.3 kg{.m,I rbf.ft)
13.
14.
To Master Cylinder(Without ABS)To Modulator Unit(with ABs)@-\
\
^ To Front Caliper
9i\.
-#qCLEVIS PIN
):-,/
PROPORTIONING CONTROL VALVE
MASTER CYLINDER
15 N.m (1.5 kgf.m, 11 lbl.ftl
BRAXE BOOSTER
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Doors
Component Location Index
Front Door:
NOTE: Refertothe 1997 Series Honda CR-V Body Repair Manual (P/N 61S1030) forfrontdoor removat.
ffi
*Y
lPOWER DOOR LOCKCONTROL UNIT
t\q
efl-Nr2
/ *-8
ARMREST
OOOR CHANNEL TAPE
INNERW€ATHERSTRIP
v
MIRROR MOUNTCOVER
----s-re
"\-,-.*
€fl
FRONT DOORPosition Adjustment,page 20-22
FRONT DOOR PANELRemoval and lnstallation, page 20,7
OUTER MOLDING
PLASTICCOVER
,.r=R
\//
::r
HINGE
20-2
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Doors
Front and Rear Door Glass
Adiustment (cont'dl
6. Check for water leaks.
Spray water over the roof and on the sealing area
as snown.
NOTE:
. Adjust the water pressure as shown.
. Do not soueeze the tio of the hose.
12 mm {0.47 in.l
#
(r\"1
HOSE
-"'*r"i
,'r)"f
tl
0.5 m (1.6 ftl
7. Attach the plastic cover, then install the door panel
(see pages 20-7, 'l 1),
20-22
..-
300 mm 111.8 in.)
Front and Rear Door Position
Adjustment
NOTE: Place the vehicle on a firm, level surface when
adiusting the doors.
After instailing the door, check for a flush fit with the
body, then check lor equal gaps between the front, rear.
and bottom door edges and the body. The door and
body edges should also be parallel. Adjust at the hinges
as shown.
CAUTION: Placa a shop towel on the iack to prevent
damage to the door when loosening the door and hinge
mounting bolts lor adiustment.
DOOR MOUNTING BOLTSI x 1.25 mm28 N.m 12.9 kgtr.m, 21 lbI.ftlLoosen the door mounting bolrs slighrlyto movethe door lN or OUT untilit's flush with the bodv. lf necessary,you can installa shim behind onehinge to make the door edgesPARALLEL with the bodv.
HINGE MOUNTING BOLTS8 x 1.25 mm28 N,m 12.9 kgt.m. 21 lbl.ftlRemove the inner fender,loosen the hinge mountingbolts, and move the doorBACKWARD or FORWARD,UP or DOWN as necessaryto equalize the gaps.
Lower the glass.
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Front Grille
Replacement
CAUTION: When prying with a flat-tip screwdriver,
wrap it with protective tape, and apply protective tape
around the related parts to prevent damage.
NOTE: Take care not to scratch the front orille and front
oumper.
1. Remove the front grille emblem cover. Loosen and
remove the grille mounting screws. and remove the
front grille by pulling it forward.
>: Screw locationsa>,5s>,2
@-l @,"l
NOTE: Insert a Phillips screwdriver through theholes in the front grille, then loosen the screws.
2. Installation is the reverse of the removal procedure.
20-77
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Frame Repair Chart
(cont'd)
Side view:
Unit: mm (in.)
0: Inner diamete.
POINT d3
o15 {0.591 For Trensmission Mount
d15 10.591 For Trrnsmi3donMount
POINT d1
t13 10.5'll For Transmb3ionMount
POINT el
613 10.51) For TransmirsionMouni
z
t13 {0,511 For Engin6 Mount
M10 x Pl.25
t13 10.51) For Uppcr Arm
.25
POINT,1710.67)Fof Re.r Beam
o12 (0.,171 For Right Front Stop
POINT c1
o16 10.631 Locate Hole
612 {0.47} For Left Front Stoo
b2
r12 {0.47) For Left Front StoD
t5011.97| Locrt. Hol.
POINT
t17 10.671 Fo. R..r
r'17 10.671 For Rcar Bo.mt12 {0.47} For Right Front Stop
POINT c2
130POINT h1
DamperLower BushingPoint
o11 (0.{31 For Engine Mount
20-108
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A/C System Torque Specifications
EVAPORATOR
SUCTION LINE
SUCTION HOSE
RECEIVER LINE ARECEIVEN LINE B
RECEIVER/ORYER
O Discharge hos€ to the compressor {6 x 1.0 mml.... 9.8 N.m 11.0 kgrf.m.7.2lbtftl
@ Condenser line to the condenser (6 x 1.0 mm)
@ Condensor line to the receiver/dryer {6 x 1.0 mm) ........9.8 N.m {1.0 kgf.m, 7.2 lbt.ft)
O Receiver line A to the receivor/dryer (6 x 1.0 mm) ...... ....................... 9.8 N.m {1.0 kgf.m.7.2 lbf.ft}
@ Receiver line B to th€ receive. line A
O R€ceiver tine C to the receivor line B
@ Recoiver line C to the evaporator (6 x 1'0 mml9.8 N'm (1.0 kgf.m,7.2lbtftl
O Sustion line to the evaporatot 16 x 1.0 mml
@ Sustion line to the suction hose...... 31 N.m (3.2 kgl.m, 23 lbf.ft)
@ Sucion hose to the qompressor (6 x 1.0 mm) .....'...' 9 8 N'm (1 0 kgt'm, 7'2 lbf'ftI
@ Compressor to the compressor bracket {8 x 1.25 mm) ... 24 N.m l2.il kgf'm, 17 lbf'ft}
@ Compressor bracket to the cylindsr block (10 x 1.25 mm) ................ ......... il,t N'm (4.5 kgt'm, 33 lbf'ft)
@ ldler pulley bracket to the compressor bracket (10 x 1.25 mm)..................... ,14 N.m (/r.5 kgf'm, 33 lbf'ft)
@ Lock nut of the sdiusting boh to the compressor bracket ......................... 24 N'm (2./t kgt'm, 17 lbf'ft)
@|d|erpu||eytotheid|orpu||eybracket.....'..........................'....\
.'.....'........'....44N.m(4.5kg''m'33|bf.f)
@ compressor bracket to the left front mount (12 x 1.25 mml ................... ............................ 59 N'm (6.0 kgt'm, /l:| lbf'ft1
22-55
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Compressor
Replacement
lf the compressor is marginally operable. run the
engine at idie speed, and let the air conditioner
work for a few minutes. then shut the engine off.
Disconnect the negative cable from the battery.
Recover the refrigerant with a recovery/recycling/
charging station (see page 22-59).
Disconnect the condenser fan connector. Remove
the compressor clutch connector and the wire har-
ness clip from the condenser fan shroud, then dis-
connect the compressor clutch connector. Remove
the mounting bolts and the condenser fan shroud,
CONDENSER FANCONNECTOR
6x1.0mm7 N.m 10.7 kg{.m, 5 lbl.ftl
'L
2.
5. Remove each bolt, then disconnect the suction and
discharge lines from the compressor. Plug or cap
the lines immediately after disconnecting them to
avoid moisture and dust contamination,
6x1.0mm9.8 N.m 11.0 kgf.m,7.2 lbf.ft)
DISCHARGE LINE
Remove the power steering pump belt (see section
17t.
Loosen the pivot bolt of the idler pulley bracket and
the adiusting bolt, then remove the Ay'C compressor
belt from the pulleys. lf necessary, remove themounting bolts from the left front mount, thenremove the A,/C compressor belt through the gap
between the bodv and the left front mount.
6.
7.
PIVOT BOLT10 x 1.25 mmAIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftlt€FTFRONTMOUltlT
10x 1.25 mm COMPRESSOR/t4 N.m (4.5 kgl.m,33 lbtftl BELI
LINE
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