Interior HONDA CR-V 1999 RD1-RD3 / 1.G Workshop Manual

Intermediate Shaft
Reassembly
Note these items during reassembly:
. Clean the disassembled parts withparts with solvent.
. Be careful not to damage the metal
solvent, and dry them thoroughly with compressed
rings on the intermediate shaft during reassembly.
air. Do not wash the rubber
BEARING SUPPORT RING
INTERNAL CIRCLIP
Press the intermediate shaft bearing into the bear-ing support using the special tools and a press.
EXTERNAL CIRCLIP
DOWEL EOLT10 x 1.25 mm39 N.m 14.0 kg't m, 29lbf.ft)
Press
I
W--
L!
Pack the interiorof the outer seal.2.0 -3.5 g {0.07 -0.r2 oz}
'L
BEARING SUPPORTOUTER SEA-Replace.
Seat the internal circlip in the groove of the bearingsupport.
INTERMEDIATE SHAFT
ATTACHMENT.35 mm l.D.07746 - 0030400
Press the intermediate shaft into the shaft
using the special tools and a press.
ATTACHMENT,52x55mm07746 - 0010400
INTERMEDIATE SHAFT RING
Prcss
t
16-20
bearing
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4. Seat the external circlip in the groove of the inter-
mediate shaft.
Press
+ DRNER07749 - 0010000
Pack the interiorof the outer seal.2.0- 3.5 9 {0.07 - 0.12 oz)
OUTER SEAL
ATTACHMENT,52x55mm07746- 0010400
ATTACHMENT.40 x 50 mm l.D.07LAD - PW50601EXTERNALCIRCLIP
6.
Install the outer seal into the bearing support using
the special tools. The seal should be flush with the
bearing support.
Install the new set ring in the intermediate shaft
groove.
lnstallation
1. Clean the areas where the intermediate shaft con-
tacts the transmission (differential) thoroughly with
solvent or carburetor cleaner, and dry with com-
pressed air. Insen the intermediate shaft assembly
into the differential. Hold the intermediate shaft hor-
izontal to prevent damage to the differential oil seal.
2. Install the three dowel bolts, then torque them.
OOWEL BOLTS10 x 1.25 mm39 N.m {4.0 kgf.m, 29 lbtftl
INTERMEOIATE SHAFT
16-21
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Power Steering Gearbox
Reassembly (cont'd)
74. Connect the air tube between the right and left
boot,
CYLINDERLINE A
75. Install the clips on the cylinder lines, then clamp theair tube with the clips.
76. Apply vinyl tape to around the pinion shaft, andcoat the surface of the tape with grease.
DUST COVER
Vinyl Tsp€
VALVE OIL SEAL
VALVE BODY UNIT
Pack the interior of the dust cover and lio withgrease, then install dust cover on the valve bodv unit.
Remove the vinyl tape f.om the pinion shaft.
77.
CYLINDER LINE
17-50
SET RING
't.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot inslalla-
tion section with graase.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ballpin. then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation section and
the tapered section of th€ ball pin.
. Do not allow dust, dirt, or other to.eign materi-
als to enter the boot.
EALL PIN TAPEREDSECTIONWipe olf the grease.
BOOT INSTALLATIONSECTIONWipe offthe grease.
B(X)T IT{STALLATIONsEclroNWipe off the grease.
ADJUSTING BOLTAdiust the depthby turning the bolt.
Install the boot in the groove of the boot installation
section securely. then bleed air.
Adjust the special tool with the adjusting bott untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
I|on.
CAUTION: After installing the boot, chock the batlpin lapered section for grease contamination andwipe it it n€cessary.
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Front SuspensionFront Damper
Ball Joint Boot Replacement
1.
BALL PIT{ TAPEFEO S€CTION
B{rcY HSISECTIO BOOT |NSTSECTIONwip6 off tho gr6aso.Wipo otf th6 grors€.
Wipe the grease off the sliding surface of the ball
pin, and pack it with fresh greass. Keep grease off
the boot installation section and the taoered section
of the ball pin.
Do not allow dust, dirt, or other foreign materials to
enter the boot.
Install the boot in the groove of the boot installation
section securelv, then bleed air.
Install the upper and lower ball joint boot set rings
using the special tools as follows:
Lower ball joint: Adjust the special tool with the
adjusting bolt until the end of the tool aligns with
the groove on the boot. Slide the set ring over the
tool and into oosition.
Upper ball joint: Hold the tool over the ball joint,
then slide the set ring over the tool and into position.
EAII JOINTAD'USN G BOLTAdjust th6 depth byturning the bolt.
Remove the set ring and the boot.
Pack the interior of the boot and lip with grease. Do
not contaminate the boot installation section with
grease.
B(X)T CUPGUttrE
UPPER BAI.IJott'tr Boor:07GAG - SO407q)LOWEF BATIJOIIYI EOOTI0t97il - SA507lXl
After installing the boot, check the ball pin tapered
section for grease contamination, and wipe it if nec-gssary.
18-16
Removal
1, Remove the front wheels (see page 18-10).
2. Remove the damper pinch bolt from the top of the
damper fork.
DAMPERPINCHBOLT'10 x 1.25
SELF.LOCKING NUT12x 1.25 fifiReplace.
Remove the damper fork bolt and self-locking nut
from the bottom of the damper fork, then remove
the damper fork.
Remove the damper by removing the two nuts.
DAMPER
DAMPER FORK
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Interior Trim
@wt we@M
REAR SIOETRIM PANELRemove the reat seat(see page 20-63).
FCONNECTOR
2
OUARTER PILLARTNIM PANELRemove the rear hatch glasssupport strut (see page20-741.
Removal and Installation (cont'd)
>i Clip loc.tionsa>,21B>,4c>, 1E>. !F >,3D>, 1
Disconnect the accessorysocket connectors,
9.8 N.m (1.0 kgf.m,1.2lbt-lrl
5x1.0mm6x1.0mm9.8 N.m (1.0 kgtm,7.2 tbf ftl
TIE DOWNHOOK
6x1.0mm
TIEoowNHOOK
v
O\A
D
REAR SEAT BELTLOWER ANCHOR EOLT7/16 - 20 UNF32 N.m {3.3 kgt.m,24 tbl.frl
9.8 N.m (1.0 kgt m,7.2 tbf.ft)
REAR TRIM PANELRemove the cargo area floorand cargo slorage bin.
20-42
REAN SEAT BELTUPPER ANCHOR BOLT7/16-20 UNF32 N.m {3.3 kgt.m,24 rbt.ft)
REAR DOOR
REAR
ffi
STRIKER
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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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Connector ldentification and Wire Harness Routing
Main Wire Harn€ss (left side of dash and floor branchesl {cont,dl
c401
c402
c403
c404
c404
c405
c406
c407
c408
c409
c410
c410
c411
c412
c413
c413
c414
c415
c416
c416
c417
c418
c419
c420
c420
c421
c422
c423
c424
c425
c42A
c426
c437
c438
c438
c439
c440
c441c442
5
20
20
24
't4
8
5
3
12
10'1
18
20'18
10
15
1
4
8
5
5
22
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dash
Under left side of dashUnder left side of dashUnder left side of dash
Under left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder middle of dashUnder middle of dashUnder middle of dashUnder middle of dashUnder middle of dash
Under left side of dashUnder left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dash
Under left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dash
Starter cut relay
Horn relay
Left side wire harness (C558)
Left side wire harness (C559)
Left side wire harness (C559)
Cruise control unitDaytime running lights control unitDaytime running lights control unitlgnition key light control unitInterior wire harness {C701)Cable reel
Cable reel
lgnition key switchlgnition key switch
Combination switch sub-harness {C753)
Combination switch sub-harness (C753)
SRS main harness (C803)
Dashboard wire harness (C503)
Dashboard wire harness (C501)
Dashboard wire harness {C501)Under-dash fuse/relay box (C922)
Under-dash fuse/relay box (C920)
Under-dash fuse/relay box (C919)
lntegrated control unit
Integrated control unitFront fog lights switchBrake switch
Interlock control unitReverse relay
Rear accessory socket relayRear accessory socket relayRear heated oxygen sensor sub-harness (C722)
Security control unitSecurity starter cut relay (for securityalarm system)
Junction connector (for interlock system)Security wire harnessSecurity wire harnessRear window wiper control unitCombination switch sub-harness (C760)
Combination switch sub-harness (C760)
Securlty indicatorSecurity valet switchClutch interlock switchClutch switch (for cruise control)
'97 model'98 - 00mooets
Canada
Canada'97 model
'97 model'98 - 00models
'97 - 98models'99 - 00
moqets
'97 model'98 - 00mooets
Optional
Optional
Optional
Optional
Optional'97 model
'97 - 98mooels'99 - 00models
OptionalOptional
Mfi
Mlr
Under left side of dashBody ground, via main wire harness
23-20
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Interior Lights
Component Location Index
SPOTLIGHTSTest, page
DRIVER'S DOOR SWITCH
LEFT REARoooR swtTcH
FRONT CEILING LIGHTTest, page 23-94
FRONT PASSENGER'SDOOR SWITCH
REAR CCILING LIGI{TTest, page 23-94
RIGHT REARswtTcH
HATCH GLASSLATCH SWITCH
TAILGATELATCH SwlTCH
23-92
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Interior Lights
Ceiling Laght Test
Front and rgar:
1. Turn the light switch OFF.
2. Pry off the lens.
3. Remove the two mounting nuts and the housing.
4. Disconnect the 3P connector from the housing.
Check for continuity between the terminals in each
switch position according to the table.
t€rmtnar
Position \
1or1'2'3'3
OFFo-Pd'l-o
MIDDLEo-/=\-o
ONo-/a\-o\:/
23-94
1 1' 3' 2'
Spotlight Test
1. Turn the spotlight switch OFF.
2. Pry off the lens.
3. Remove the two screws and the housing.
4. Disconnect the 3P connector from the housing.
Check for continuitv between the terminals in each
switch position according to the table,
Terminal
t"",rr" \12ol2'3
R
ONo-/-\--o\:./
OFFo@o
L
ONo-/a--o\:./
OFFo-(9--o
aULB(5Wx2l
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