damper HONDA CR-V 1998 RD1-RD3 / 1.G Workshop Manual

Engine RemovaUlnstallation
OOI{TROL PI
Removal (cont'dl
31. Remove the shift cable. Take care not to bend the
cable when removing it. Always replace any kinked
cable with new one (Afl-).
SNAP PIN
sHtFT CABttOOVEB
8 x 1.25 mmt2 N.m 12.2 lgtr'l'',,16 tbf.ftl
Remove the right damper fork (see section 18).
Disconnect the suspension lower arm ball joints (see
section 18),
Remove the driveshafts (see section t6). Coat allprecision-finished surface with clean engine oil. Tieplastic bags over the driveshaft ends.
5-8
34.
Make marks on the transfer companion flange andpropeller shaft as shown. Use these marks to set thepropeller shaft in the proper position when rein-
stalling (4WD).
Remove the four bolts securing the propeller shaft,then separate the propeller shaft from the transfer
companion flange (4WD).
E x 1.25 mm32 N.m 13.3 lgt.m, 24 lbt'ftlRepl€ce.
37. Lower the hoist,
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FUEL PRESSUREREGULATORTesting, page 11-181Replacement, page 11 181
FUEL PUMPTesting, page 11 183Replacement, page 11 183FUEL GAUGE SENDING UNITTesting, page 11 185
'97 model:
'98 model:
FUEL PULSATION DAMPER
EVAPORATIVE EMISSIONIEVAP) CONTROL CANISTERTroubleshooting. page 1'l-205
FUEL FILTERReplacement, page 11 182
FUEL INJECTORSReplacement, page 1 1-179
FUEL FEED PIPEFUEL VAPOR PIPE
FUELFITTINGS
FUEL FILLCAP
EVAPORATIVE EMISSION
IEVAPI TWO WAY VALVETesting, page 11 224
TANKReplacement, page 11 191
-CONNECT
Precautions, page 1 1-175Disconnection, page 11 175Connection, page 1 1-176
FUEL FILTERReplacement, page 11 182
FUEL FEED PIPEFUEL VAPOR PIPE
FUEI- TANKReplacement,page 1l 191
FUEL TUBE/OUICK.CONNECTFITTINGSPrecautions, page 11 '175
Disconnection, page 11 175Connection, page 11 176
FUEL PUMPTesting, page 11 183Replacement, page 11 183FUEL GAUGE SENDING UNITTesting, page 1l'185
FUEL FILL CAP
FUEL TANK PRESSURESENSORTroubleshooting, page 1 l-209
FUEL PULSATION DAMPER
EVAPORATIVEEMTSSTONIEVAPICONTROLCANISTERVENTSHUT VALVETroubleshooting,page 11'213
EVAPORATIVE EMISSIONIEVAPI CONTROL CANISTERTroubieshooting, page 1 1 -213
FUEL RAIL
FUELFeplacement, page 1 1-179
FUEL PRESSURENEGULATORTesting, page 11-181Replacement, Page 11 181
EVAPORATIVE EMISSION{EVAP) EYPASSSOLENOID VALVETroubleshooting, page 1 1'213
€VAPORATIVE EMISSION{EVAP) TWO WAY VALVETesting, page 11 224(cont'd)
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Gomponent Locations
Index lcont'd)
'99 - (X) modols:
FUEL TANKReplacement,page 11-191
FUEL FEED PIPE
FUEL FILTERReplacement, page 11 182
FUEL VAPOR PIPE
FUELFITTINGS
FUEL PUMPTesting, page '11 183Replacement, page 1 1_183FUEL GAUGE SENDING UNITTesting, page 11-185
FUEL FILL CAP
EVAPORATIVE EMISSIONIEVAP) CONTROLTroubleshooting, page 1 1-213
FUEL PULSATION DAMPER
FUEL RAIL
FUELReplacement, page 1 1-179
EVAPORATIVEEMtSStON
IEVAP)CONTROLCANISTERVENTSHUT VALVETroubleshooting,page 11-213FUEL TANK PRESSURESENSORTroubleshooting, page 1'l'208
EVAPORATIVE EMISSION{EVAP) TWO WAY VALVETesting, page 11-224
FUEL PRESSUREREGULATORTesting, page 11-181Replacement, page 11 181,CONNECT
PrecaLrtions, page 1 1-175Disconnection, page 1 1-175Connection, page 176
EVAPORATIVE EMISSION{EVAPI BYPASSSOLENOID VALVETroubleshooting, page 11 213
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System Description
I
I
I
Vacuum Connections (cont'dl
'98 model:
C PRIMARY HEATEO OXYGEN SENSOR (PRIMARY HO2S,
SENSOR 1)(, SECONDARY HEATEO OXYGEN SENSOR ISECONDARYHO2S, SENSOR 2)(!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR
G) ENGINE COOLANT TEMPERATUBE (ECT) SENSOR
O INTAKE AIR TEMPERATURE {IAT} SENSOR
@ CRANKSHAFT SPEED FLUCTUATION (CKFI SENSOR
O IDLE AIR CONTROL (IAC) VALVE
@ FAST IDLE THERMO VALVE (A/T)
O THROTTLE BODY (TBI(0) FUEL INJECTOR.1' FUEL PULSATION DAMPER.14 FUEL FILTER(i FUEL PRESSURE REGULATOR14 FUEL PUMP(D FUEL TANK@ FUEL TANK EVAPORATIVE EMISSION {EVAPI VALVE
C] AIR CLEANER(O RESONATOR1iC POSITIVE CRANKCASE VENTILATION (PCV) VALVE
6 \$REE$IN gN NL$\C CON\ER\ER (TNC\
ti q rpos,xr E qN
ssros \E aP cqN\RoLcaNtsr€R
@ EVAPORATIVE EMISSION IEVAP) PURGE CONTROL
SOLENOID VALVEq3 EVAPORATIVE EMISSTON IEVAP} CONTROL CANISTER
VENT SHUT VALVE
@ EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE
€i EVAPORATIVE EMISSION {EVAP) BYPASS SOLENOID
VALVE
€9 FUEL TANK PRESSURE SENSOROi EVAPORATIVE EMISSION {EVAP) THREE WAY VALVE
Qd PURGE JOINT
G/T only)
f
-i*'";-t
COOLANT Jt
U
11-12
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System Description
Vacuum Connections (cont'dl
'99 - q) models:
ENGINECOOLANT
t
o
o
o@
o@@@@@@@@@(t
PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S,SENSOR 1lSECONDARY HEATED OXYGEN SENSOR {SECONDARYHO2S. SENSOR 2lMANIFOLD ABSOLUTE PRESSURE (MAPI SENSORENGINE COOLANT TEMPERATURE IECN SENSORINTAKE AIR TEMPERATURE IIATI SENSORCRANKSHAFT SPEED FLUCTUATION {CKF) SENSORKNOCK SENSOR (KS}
IDLE AIR CONTROL IIACI VALVEFAST IDLE THERMO VALVE {A/T}THROTTLE BODY (TB}
FUEL INJECTORFUEL PULSATION DAMPERFUEL FILTERFUEL PRESSURE REGULATORFUEL PUMPFUEL TANKFUEL TANK EVAPORATIVE EMISSION (EVAPI VALVE
AIR CLEANERRESONATORPOSITIVE CRANKCASE VENTILATION (PCV} VALVETHREE WAY CATALYTIC CONVERTER ITWCIEVAPORATIVE EMISSION {EVAPI CONTROL CANISTEREVAPORATIVE EMISSION IEVAPI PURGE CONTROLSOLENOID VALVEEVAPORATIVE EMISSION {EVAPI CONTROL CANISTEFVENT SHUT VALVEEVAPORATIVE EMISSION IEVAPI TWO WAY VALVEEVAPONANVE EMISSION {EVAPI AYPASS SOLENOIDVALVEFUEL TANK PRESSURE SENSOBEVAPORATIVE EMISSION IEVAPI THREE WAY VALVEPURGE JOINT
@@@@@@
@
@@
@@@
11-14
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12. Disconnect the heated oxygen sensor (HO2S) con-
nector, then remove the exhaust pipe A.
GASKETReplace.
HO2S CONNECTOR
NUTReplace.
EXHAUST
SELF.LOCKINGReplace.
GASKETReplace.
Mark reference marks on the joint of the transfer
and the propeller shaft.
8 x 1.25 mmReplace.
Separate the propeller shaft from the transfer
assemDly.
REFERENCE MABKS
14.
15. Remove the cotter pins, and castle nuts. then sepa-
rate the ball ioints from the lower arm (see sectlon
18).
OAMPER PINCH BOLT
CASTLE NUTNUTReplace.
17.
16.
DAMPER FORKFOFKEOLTReplace.
Remove the right damper tork bolt, then separate
right damper fork and damPer.
Pry the right driveshaft out of the differential, and
pry the left driveshaft out of the intermediate shaft
(see section 18).
Pull out the inboard ioint, and remove the right and
left driveshaft (see section 18).
Tie plastic bags over the driveshatt ends. Coat all
precision finished surfaces with clean engine oil
18.
19.
\
{cont'd}
13-9
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Countershaft Assembly
Index
NOTE:
3
The 3rd, 4th. and sth gear are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd,
4th, and sth gears, however. should be installed with a press before lubricating them.
LOCKNUT Replace.127-o-127N.m
113-0- 13kstmi
\94-0- 9.trbtft /
IST/2ND SYNCHRO HUBInspection, page 13 36
Check lor wear anddamage.
THRUST WASHERInspection, page 13-29
DAMPER
WASHER
AEARINGCheck for wear and ooeration.
BEARINGCheck for wear andoperation.
GEAR
4TH GEAR
3RD GEAR
GEAR
SPNING
DOUBI.f CONE
Inspection, page 13-37
1ST GEARInspection, page 13 29,37
BEARINGCheck tor wear and operation.
Inspection, page 13-30, 37
NEEDLE BEARINGCheck for wear and oPeration
SPACERSelection, page 13-30
DAMPERCheck for wear and damage.
DOUBLE CONE
Inspection, page 13-37
SPRING
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Disassembly
1.
2.
Securely clamp the countershaft assembly in a
bench vise with wood blocks.
SPRIiIG WASHEF
BETICHvtsE
W(X)D BLOCKS
Raise the locknut tab from the groove in the coun-
tershaft, then remove the locknut and the spring
washer.
Remove the ball bearing using a press as shown.
CHISEL
4. Remove the Jriction damper from the spacer using a
press and a socket.
Support lst gear on steel blocks, and press the
countershaft out of 3rd gear.
PRESS
t
5.
PRESS
I
3RD GEAR
1ST GEAR
FRICTION DAMPERInspect lor wear and damage.
13-31
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Reassembly
Note these items during reassembly:
. Press the 3rd, 4th, and sth gear on the countershaft
without lubrication.
. When installing the 3rd, 4th. and sth gears, suppon
the shaft on steel blocks and install the gears using a
press.
. Refer to page 13-28 for reassembly sequence.
1. Install the thrust shim, needle bearing, 1st gear, and
friction damper.
NOTE: Reassembly the friction damper on the lst
gear before installation.
rnrcrroru orn,leen ----.-4O)
lST GEAR
NEEDLE BEARING
THRUST SHIM
2. Install the double cone synchro.
3. Install the 1sv2nd synchro hub by align the friction
damper fingers with 1svznd synchro hub grooves.
(cont'd)
OUTER
lST/2ND
13-33
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Countershaft Assembly
Reassembly (cont'dl
4. Reassembly the friction damper on the spacer using
the sDecialtools and a Dress.
PRESS
t
ATTACHMENT,U2t 47 mfi07716 - 0010300
FRICTION DAMPERInspect for wear anddamage.
Install the 2nd gear by align the
fingers with 2nd gear grooves.
synchro cone the
GROOVE
13-34
6. Support the countershaft on a steel block as shown
and install 3rd gear using the special tools and a
press.
3RO GEAR
7. lnstall 4th gear using the special tools and a press.
PRESS
I
PRESS
t
ATTACHMENT,35 mm LD.07746 - 0030,100
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