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

Pistons and Crankshaft
Removal (cont'dl
6. Remove the bolts. To prevent warpage, unscrew the
bolts in sequence 1/3 turn at a time; repeat the
sequence until all bolts are loosened.
Remove the rod caps/bearings and main caps/bear-
ings, Keep all caps/bearings in order
Lift the crankshaft out of the engine. being careful
not to damage the journals.
7.
7-10
9.
10.
Remove the upper bearing halves from the connecting
rods, and set them aside with their respective caps.
Reinstall the main caps and bearings on the engine
in proper order.
lf you can feel a ridge of metal or hard carbon
around the top of each cvlinder, remove it with a
ridge reamer. Follow the reamer manufacturer's
instructions. lf the ridge is not removed, it may
damage the pistons as they 8re pushed out.
12.
11.
14.
Use the wooden handle of a hammer to drive the
pistons out.
13.Reinstall the connecting rod bearings and caps after
removing each piston/connecting rod assembly.
To avoid mixup on reassembly, mark each piston/
connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indi-
cates the rod bore size.
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PistonsCrankshaft
Installation
1. Apply a coat of engine oil to the ring grooves andcylinder bores.
It the crankshaft is already installed.
2. Set the crankshatt to BDC for each cylinder.3. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of theconnecting rod bolts.
4. lnstall the ring compressor, and check that the bear-ang is securely in place.
5. Position the piston in the cylinder, and tap it in usingthe wooden handle of a hammer. Maintain down-ward force on the ring compressor to prevent ringstrom expanding before entering the cylinder bore.6. Stop after the ring compressor pops free, and checkthe connecting rod-to-crank journal alignmentbefore pushing piston into place.
7. Install the rod caps with bearings, and torque theNUIS IO:
31 N.m (3.2 kgf.m,23 tbf.ft)
Apply engine oil to the bolt threads.
lf the crankshaft is not installed:
2. Remove the rod caps and bearings, and install theflng compressor.
3. Position the piston in the cylinder, and tap it inusing the wooden handle of a hammer. Maintaindownward force on the ring compressor to prevent
rings from expanding before entering the cylinderoore,
4. Position all the pistons at top dead center.
The arrow must facethe timing belt sideof the engine.
CONNECTING ROOOIL HOLE
RUBBER HOSES
7 -20
\-\
3.
4.
1.
6.
Installation
Apply a coat of engine oil to the main bearings androd bearings.
Insert the bearing halves in the cylinder block andconnect|ng rods.
Hold the crankshaft so the rod journals for cylindersNo.2 and No. 3 are straight down.
Lower the crankshaft into the block, seating the rodjournals into connecting rods No.2 and No.3.Install the rod caps and nuts finger tight.
outward.
Rotate the crankshaft clockwise, and seat the jour
nals into connecting rods No. 1 and No. 4, Install
the rod caps and nuts finger-tight. Install the capsso the bearing recess is on the same side as therecess an the rod.
Check the rod bearing clearance with plastigage(see page 7 8). then lorque the capnuts.
Torque:
3l N.m 13.2 kgf.m, 23 lbt.ftl
Apply engine oil to the bolt thleads.
5.
7. Install the thrust washers on the No. 4 journal.
Line up the mark wheninstalling connecting rodcap.
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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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8. Install sth gear using the special tools and a press.
PRESS
I
DRIVER, 40 mm l.D.
07715 - 0030300
ATTACHMENT,30 mm LD.077,16 - 0030300
LInstall the needle bearing using the special tools
and a press, then installthe bearing outer race
PRESS
I
DRIVER. 40 mm l.D.077{6 - 0030100
ATTACHMENT,30 mm l.D.07746 - 0030300
NEEDLEBEASING
10. Install the ball bearing using the special tools and a
press.
PRESS
I
DRIVER. 40 mm LD.07746 - 0030100
ATTACHMENT,30 mm LD.077a6 - 0030300
11.Securely clamp the countershaft assembly in
bench vise with wood blocks.
LOCKNUTReplace.
Install the spring washer.
Install the new locknut to the correct torque, then
stake the locknut tab into the groove.
Torque: 127 + 0 + 127 N.m 113 - 0 +13 kgf.m,
94+0-94|bf.ft)
12.
wooD slocKs
13-35
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Power Steering Gearbox
Reassembly (cont'dl
58. Installthe cylinder lines A and B
Note these items during reassembly:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by hand first, then tighten the flare
nuts to the soecified torque.
CYLINDEF LINE A
Grease the sliding surface of the rack guide, and
install it onto the gear housing.
For'97 model, apply a thin coat of grease to the new
O-ring, and install it on the rack guide screw.
For'98 - 00 models. remove the old sealant from
the threads of the rack guide screw. then apply new
sealant to the first three threads.
-6rO-RING
nlcr cutDE R"Pl""u'
SCREW
LOCKNUT
37 model:
60.
ot.
38 model:
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17,15). After
adjusting, check that the rack moves smoothly by
sliding the rack right and left.
17 N.m 11.7 kgd.m, 12lbf.ttl
26 N.m {2.7 kgl.m, 20
RACK GUIOE
17-48
STEERING RACK
(
63. Install the new lockwasher in the groove in the
steering rack.
LOCK WASHERReplace.
STEERING RACK ENO54 N.m (5.5 kgf.m,40 lbtftl
64.
STEERING
Screw the rack ends into the rack.
Hold the steering rack with a wrench ('98 - 00 mod-
els: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
wrench.
After tightening the rack ends, stake the four sec-
tions of lock washerwith a drift and a mallet.
. Place the wood block on the press table, then set
the lock washer section of the rack end on the
wood block securely.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing.
. Stake the lock washer in the center of the flat
section of the steering rack end,
ROLL PIN PUNCH
lCommorcially.Y.il.blelSnap-On No. PPR8 or oquival.nt.
NOTE: This drift has a flatshoulderto preventpuncturing of metal washer.
WOODEN BLOCK
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Rear Damper
Disassembly/lnspection
Disassembly
L Compress the damper spring with the spring com-
pressor according to the manufacturer's instruc-
tions, then remove the self-locking nut. Do not com-
press the spring more than necessary to remove the
self-locking nut.
SELF-LOCKING NUT10 x 1.25 mmReplace.
STRUT SPRINGCOMPRESSOR:lCommercirlly avaihblo)BRANICKO I/N MSI-580Aor Mod6l/7200 or equivalent
2. Release the pressure from the spring compressor,
then disassemble the damper as shown on page 18-
25.
Inspection
1. Reassemble all parts, except the spring.
2. Push on the damper as shown.
3.
WOODEN ELOCK
Check for smooth operation through a full stroke,
both compression and extension. The damper
should move smoothly. lf it does not (no compres-
sion or no extension), the gas is leaking, and the
damper should be replaced.
Check for oil leaks, abnormal noises, or binding dur-
ino these tests.
4.
SELF-LOCKING NUT10 x 1.25 mm
OAMPERMOUNTINGWASHER
29 N.m {3.0 kgf.m, 22 lbf.ft)Beplace.
OAMPER MOUNTINGRUBBERCheck fordeteriorationano oamage.
DAMPER MOUNTINGCOLLAR
DAMPERMOUNTING BASE
DAMPER MOUNTINGRUBBERCheck fordeteriorationano oamage.
'"dd"^.s"'
//F,
DAMPERCheck for weakness,compressron
DUST COVER PLATE
DUST COVERCheck for bendingand damage.
SPRING MOUNTINGRUBBERCheck Ior deteriorationand damage.
BUMP STOPCheck for weaknessano oamage.
DUST COVEN BOOTCheck for deterioralionano oamage.
BUMP STOP PLATE
DAMPER
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Glass
Windshield Replacement
CAUTION:
. Put on gloves to protect your hands.
. Use seat covers to avoid damaging any surfaces.
1. To remove the windshield, first remove the:
. Rearview mirror (see page 20-28)
. Sunvisors and holders (see page 20-44l'
. Ceiling light (see section 23)
. Grab handle (see page 20-44)
. Front door trim (see page 20-41)
. Front pillar trim (see page 20-41)
. Windshield wiper arms and cowl cover (see page
20-98)
2. Remove the molding and glass brackets.
NOTE: lf removing the molding is difficult, cut the
moldlng with a utility knife.
MOLDING
3. Pull down the front Dortion of the headliner (see
page 20-44).
CAUTION: Take care not to bend the headliner
excessivsly, or you may break it.
WINDSHIELD
20-30
4. Apply protective tape along the edge ot the dash-
board and body as shown. Using an awl, make a
hole through the rubber dam and adhesive from
inside the vehicle. Push a piece of piano wire
through the hole, and wrap each end around a
piece of wood.
PROTECTIVETAPE
WINDSHIELD
ADHESIVE
PIANOWIRE
PROTECTIVETAPE
WINDSHIELO
PROTECTIVETAPEDASHBOARD
ADHESIVELOWER RUBBERDAM
CAUTION: Hold the piano wire as close to the wind-
shield as possible to prevent damage to the body
and dashboard.
5. With a helper on the outside, pull the piano wire
back and fo(h in a sawing motion, and carefully cut
through the rubber dams and adhesive around the
entire windshield.
6. Carefully remove the windshield.
UPPER RUBBER
PIANO
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