Head removal HONDA CR-V 1999 RD1-RD3 / 1.G User Guide

Gylinder Head
Removal (cont'dl
'11. Remove the brake booster vacuum hose. fuel return
hose, and vacuum hose.
'97 - 98 modsls:
VACUUMHOSE
BRAKE BOOSTEBVACUUM HOSE
6-18
BRAKE BOOSTER
12. Remove the breather hose and oositive crankcase
ventilation (PCV) hose,
'97 - 98 models:
BREATHEBHOSE
PCV HOSE
'99 - 00 models:
BREATHERHOSE
PCV HOSE
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Cylinder Head
Removal (cont'dl
Remove the timing belt (see page 6-10).
Remove the camshaft pulleys and back cover.2't.
BACK COVER
6-20
22. Bemove the exhaust manifold
ing nuts.
'97 - 98 U.S. modsls (Californial:
GASKETReplace.
SELF.LOCKING NUT54 N.m {5.5 kgf.m, .{) lbf.ftlReplace.
'97 - 98 U.S. models {Excepi Calitornia}:'99 - 0O modeb:
GASKETSReplace.
bracket and self-lock-
'r
EXHAUST MANIFOLDBRACKET
10 x 1.25 mm44 N.m 14.5 kgf,m,33 rbf.ft)
SELF.LOCKING NUT10 x 1 .25 mm54 N.m {5.5 kgt.m, 40 lbtft}Replace.
10 x 1.25 mm4il N.m (4.5 kgf.m,33 tbf.ftl
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Valve Guides
Replacement (cont'dl
5.
Working from the camshaft side, use the driver andan air hammer to drive the guide about 2 mm (O.l
in) towards the combustion chamber. This willknock off some of the carbon and make removaleasier. Hold the air hammer directly in line with thevalve guide to prevent damaging the driver.
CAUTION: Always wear satety goggles or a faceshield when driving valve guidss.
Turn the head over and drive the guide out towardthe camshaft side of the head.
li a valve guide won't move, drill it out with a 8.0mm (5/16 in) bit, then try again. Dritt guides onty inextreme cases; you could damage the cylinder headif the guide breaks.
Remove the new guide(s) from the freezer, one at atlme, as you need them.
6.
7.
6-26
'o C'
8. Apply a thin coat of clean engine oil to the outsideof the new valve guide. Install the guide from thecamshaft side of the head; use the special tool todrive the guide in to the specified installed height. lfyou have all 16 guides to do, you mav have toreheat the head.
Valve Guide Installed Height:
Intake: 13.75 - 1i1.25 mm
{0.5,[1 - 0.561 in)
Exhaust: 15.75 - 16.25 mm(0.620 - 0.640 inl
ATTACHMENT
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Cylinder Head
Installation
Installthe cylinder head in the reverse order of removal:
1. Clean the cylinder head and block surfaces.
2. Clean the oil control orifice. Install the cylinder headgasket, dowel pins and the oil control orifice on thecylinder block. Always use a new cylinder head gas-ket.
CYLII{DER HEADGASKETR€place.
DOWEL PIN
O.RINGRoplace.
DOWELPIN
OIL CONTBOLORIFICEClean.
Apply clean engine oil to the bolt threads and underthe bolt heads.
4. Tighten the cylinder head bolts in two steps. In thefirst step tighten all bolts, in sequence, to about 29
N.m {3.0 kgf.m,22 lbf.ft); in the finat step, tighten inthe same sequence to 85 N.m (8.7 kgf.m,63 lbf.ft).
Use a beam-type torque wrench. When using a pre-
set-type torque wrench, be sure to tighten slowly
and do not overtighten.
lf a bolt makes any noise while you are torquing it,loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Tighten the intake manifold mounting bolts (see
page 6-21).
Install the exhaust manifold bracket. and tighten thenew self-locking nuts (see page 6-20).
6-30
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Glutch Master Cylinder
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage
the paint; if brake tluid does contact the paint. wash
it off immediately with water.
. Plug the end ol the clutch line and leservoir hose
with a shop towel to prevent brake tluid trom coming
out.
The brake fluid may be sucked out through the top
of the master cylinder reservoir with a syringe.
Disconnect the clutch line and reservoir hose from
the clutch master cylinder,
't.
9.8 N.m 11.0 kst m,7.2 tbf.ftl
CLUTCH LINE
19 N'm 11 9 kgJ m'
14 lbf.frl
Remove the reservoir from the engine compartment
bulkhead.
13 N.m t1.3 kgt.m,g.il lbtft)
4. Prv out the lock pin, and pull the pedal pin out of
the voke. Remove the nuts.
NUTSI x 1.25 mm
5, Remove the clutch master cylinder.
CLUTCH MASTERCYLINDEF
Install the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system {see page
12-61.
12-5
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Steering Wheel
Removal
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-
vice.
1. Align the front wheels straight ahead. then remove
the driver's airbag assembly (see section 24) from
the steering wheel.
2. Disconnect the horn connector and cruise control
switch connectors.
CONTROLSWITCHES CONNECTOR
3. Loosen the steering wheel bolt, then install a steering
wheel puller on the steering wheel and remove it.
Note these items when removing the steering wheel:
. Do not tap on the steering wheel or the steering
column shaft when removing the steering wheel.
. lf you thread the puller bolts into the wheel hub
more than five threads, the bolts will hit the cable
reel and damage it. To prevent this, install a pair
of jam nuts five threads up on each puller bolt.
STEERING WHEEL BOLT39 N.m 14.0 kgt.m,29 lbtftl
STEERING WHEEL EOLT
Disassembly/Reassembly
EOSS COVER PLATE
_^M
STEERING WHEEL
WHEEL BODY COVER
17-18
@,
ACCESS PANEL
h"\
BODYCOVER CAP
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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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Mirrors
Rearview Mirror Replacement
CAUTION: When prying with a flat-tip screwdrivor,
wrap it whh a shop towel to prevent damage.
NOTE: Take care not to scratch the cover or tear the
headliner.
1. Remove the cover using the end of a flat-tip screw-
drtver.
Remove the rubber damper.
>: Screw locations,3
Remove the screws, then remove the rearview mir-
ror.
Installation is the reverse of the removal procedure.
20-28
HOOKS
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lnterior Trim
20-40
CARGO FRONTSPACER(see page 20 43)
FRONT PILLARTRIM(see page 20-41)
TRUNK FLOOREXTENSION(see page 20 43)
HEADLINERRemoval and lnstallation,page 20-44
Component Location Index
SRS components are located in the areas marked with an asterisk (*). Review the SRS component locations, precautions,
and procedures in the SRS section (24) before performing repairs or service.
CENTER PILLARUPPER TRIM(see page 20 41)CENTER PILLARLOWER TRIM PANEL(see page 20 41)
FRONT SIDETRIM(see page 20-41)
BEAR SIDETEIM(see page 20'41)
OUARTER PILLARTRIM PANEL(see page 20 42)
*CARPET
Replacement,page 20 45
CENTER CONSOLE IM/T}Replacement, page 20-47
CENTEN TABLE(see page 20-45)
PARKING BRAKECOVER(see page 20-45)
TRIM
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lnterior Trim
Headliner Removal and Installation
CAUTION: When prying with a tlat-tip screwdriver,
wrap it with protective tape to prevent damage.
NOTE:
. Take care not to bend and scratch the headliner.o Be careful not to damage the dashboard and other
interior trim.
1. Remove:
. Front and rear door side trim (see page 20-41). Front pillartrim (see page 20-41)
. Center pillar lower trim panel (see page 20-41). Center pillar upper trim (see page 20 41). Rear seat (one side, see page 20-63). Cargo area floor and cargo storage bin
{see page 20-43)
. Rear trim panel (see page 20-421
. Rear side trim panel (oneside, see page 20-42l,
. Rear hatch glass support strut (one side, seepage 20-78)
. Ouaner pillar trim panel {one side, see page 20-
42)
. Ceiling light, interior light and trunk light(see section 23)
. Rearview mirror (see page 20-28)
2. Remove the sunvisor and holder from each side.
>: Scaew location3, 4
I
A\"r- |Yr* || -
suNvtsoR
20-44
3. Remove the grab handles from
passenger's sides.
>r Screw locations, 6
the front and rear
ry_l
COVER
4. Remove the clips, then remove the headliner.
NOTE: An assistant is helpful when removing the
headliner.
>: Clip locations,9
HEADLINER
Pullout. OUARTERTRIMPANEL
5. Remove the headliner through the rear hatch glass
openrng.
6. Installation is the reverse of the removal procedure.
NOTE:
. When reinstalling the headliner through the rear
hatch glass opening, be careful not to fold or
bend it, Also, be careful not to scratch the body.. Check that both sides of the headliner are
securely attached to the trim.
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