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

Engine Removal/lnstallo cton
Installation (cont'd)
8. Tighten the nut on the right front mount.
AlTi
59 .m 16.0 tgt m, (l lbfftlReplace.
MlTi
12 x'1.25 mm59 N.m 16,0 kgt m, /(} lbt ttlReolace.
5-16
9. Perform the following checks and adjustments:. Check that the spring clip on the ends of the drive-shaft and intermediate shaft clicks into place. Usenew spring clips.. Adjust the shift cable (see section l4).. Adjust the throttle cable (see section 11).. Refill the engine with engine oil (see page g-4).
. Refill the transmission with oil or fluid (see sec-tion 13 or 14).
. Refill the radiator with engine coolant (see page
10_5).
. Bleed air from the cooling system with theheater valve open (see page l0-5).. Clean the battery posts and cable terminals withsandpaper, assemble them, then apply grease toDrevent corrosron.. Inspect for fuel leakage (see section 1l).After assembling fuel line pans, turn on the igni-tion switch (do not operate the starter) so thatthe fuel pump operates for approximately twoseconds and the fuel Iine pressurizes.
Repeat this operation two or three times, andcheck for fuel leakage at any point in the fuel line.
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Cooling
f ffustrated Index ........... ..... 1O-2
Radiator
Rep|acement ...........,....,...................... 10-4
Engine Coolant Refilling and
Bleeding ..,.,................. 10-5
Cap Testing .................... 10-7
Testing ......10-7
Thermostat
Rep|acement ....................................... 10-8
Testing ...... 10-9
Water Pump
lllustrated lndex ....,..... .. 10-10
Inspection . 10-1 1
Replacement ....................................,.. 10-1 1
Fan Gontrol
Component Location Index ............... 10-12
Circuit Diagram ............. 10-13
Fan Motor Testing ......... 10-14
Radiator Fan Switch Testing ............. 10-14
Coolant Temperature Gauge
Gauge Testing ............... 10-15
Coolant temperature Sending
Unit Testing ........,....... 10-15
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lllustrated Index
CAUTION: The system is under high pressure when the
engine is hot. To avoid danger ol releasing scalding engine
coolant, remove the cap only when the engine is cool.
Total Cooling System Capacity fincluding 0.6 I (0.63 US
qt, 0.53 lmp qt) for heater and reservoirl:
A/T: 5.9 { {6.2 US qt, 5.2 lmp qt)
M/T: 6.0 f (6.3 US $, 5.3 lmp qt)
deterioration and replace if necessar,.
Check all hose clamps and retighten if necessary.
lf any engine coolant spills on the
body, rinse it off immediately.
Check all cooling system hoses
painted portions of the
for damage, leaks or
6x1.0mm9.8 N.m 11.0 kgf.m.1.2 tbl.ftl
RADIATOREngine coolant refilling and bleeding,page 10-5Leak test, page 10 7Inspect soldered joints andseams for leaks.Blow out din from betweencore fins with compressed air.lf insects, etc., are cloggingradiator, wash them off withlow pressure water.RADIATOR CAPPressure test, page 10-7
ATF COOLERHOSEReler to section 14when installing.
LOWERcusHroN
6x1.0mm7 N.m (0.7 kgf.m, 5 lbf ftl
FAN MOTOR
10-2
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Radiator
1.
2.
3.
4.
Replacement
CONDENSERFAN,/SHROUDASSEMBLY
Drain the engine coolant.
Remove the upper and lower radiator hoses, and
ATF cooler hoses.
Disconnect the fan motor connector.
Remove the radiator upper bracket, then pull up the
raotalor,
5. Remove the fan shroud assemblies and other parts
from the radiator.
6. lnstall the radiator in the reverse order of removal.
NOTE:
. Set the upper and lower cushions securely.
. Fill the radiator with engine cooiant and bleed the air.
RADIATOR CAP
RADIATOR
6x1.0mm9.8 N.m 11.0 kgf.m,7.2 tbl.trl
6x1.0mm7 N.m (0.? kgd.m, 5 lbl.ftl
UPPER MDIATOR HOSE
Reler to section 14when installing.
DRAIN PLUG
LOWER CUSHION
LOWERTOR HOSE
RADIATORASSEMBLY
6x1.0mm7 N.|n 10.7 kgt.m,5 tbt.ftl
rriItriiii
10-4
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Engine Coolant Refilling and Bleeding
1. Slide the heater lemperature control lever to maxi
mum heat.
Make sure the engine and radiator are cooi to the
touch.
2. Remove the radiator caP.
3. Loosen the drain plug, and drain the coolant.
4. Remove the drain bolt from the cylinder block.
DRAIN PLUG
DRAIN BOLT78 N.m {8.0 ksl.m, 58 lbtft}
10-5
6.
7.
Apply liquid gasket to the drain bolt threads, then
reinstall the bolt with a new washer and tighten it
securely.
Tighten the radiator drain plug securely.
Remove, drain and reinstall the reservoir' Fill the
tank halfway to the MAX mark with water, then up
to the MAX mark with antitreeze.
(cont'd)
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Radiator
Engine Coolant Refilling and Bleeding (cont'dl
Mix the recommended antifreeze with an equal
amount of water in a clean container.
NOTE:
. Always use Genuine Honda Antifreeze/Coolant.
Using a non-Honda coolant can result in corro-s\on, ca
sng t\e coo\
g sys\em \o ma\lunct\on
o. fail.
For best corrosion protection, the coolant con-
centration must be maintained year-round at50% minimum. Coolant concentrations less than
50% may not provide sufficient protection against
corrosion or freezing. Coolant concentrationsgreater than 60% will impair cooling efficiency
and are not recommended.
Do not use additional rust inhibitors or anti-rustproducts; they may not be compatible with the
coolant.
Engine Coolant Refill Capacity Iincluding 0.6 / 10.63US $, 0.53 lmp qtl for hoater and ressrvoirl:
A/T: 3.9 f {4.1 US $, 3.4 lmp qtl
M/T: 1.O t 14.2 US $, 3.5 lmp qrl
10-6
9. Pour coolant into the radiator uD to the base of the
filler neck. When pouring engine coolant. do not let
coolant spill on any electrical pans or the paint. lf
any coolant spills, rinse it oft immediately.
Start the engine, and let it run until it warms up (the
radiator fan comes on at least twice).
Turn off the engine. Check the level in the radiator,
add coolant if needed.
Put the radiator cap on tightly. then run the engine
again and check for leaks.
11.
10.
12.
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Inspection
1.
2.
Remove the timing belt (see section 6)
Turn the water pump pulley counterclockwise.
Check that it turns freely.
Check for signs of seal leakage.
NOTE: A small amount ol "weeping" from the bleed
hole is normal.
BIIED HOLE
Replacement
1. Remove the timing belt (see section 6).
2. Remove the water pump by removing five bolts
3, Inspect, repair and clean the O-ring groove and the
mating surface with the cylinder block.
Replace.6x1.0mm't2 N.m 11 2 kgf m.
8.7 tbf.ftl
4. lnstall the water pump in the reverse order of removal.
- @-
I
I
10-1 1
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Fan Control
Fan Motor Testing
1. Disconnect the 2P connector.
Terminalside ofmale terminals
Test the motor by connecting battery power to theNo. 2 terminal and ground to the No. 1 terminal.
lf the motor fails to run or does not run smoothly,reptace rt.
RADIATOR FAN MOTOR
10-14
Radiator Fan Switch Testing
E@ Removing the radiator fan switch whilethe engine is hot can cause the coolant to spray out, seri-ously scalding you. Always let the enginc and radiatorcool down before removing the radiator fan switch.
1. Remove the radiator fan switch from the thermostathousing (see page 10 '10).
2. Suspend the radiator fan switch in a container ofwater as shown.
Heat the water, and check the temperature with athermometer. Do not let the thermometer touch thebottom of the hot container.
Measure the continuity between the A and B termi-nals according to the table.
Bleed the air from the cooling system after installingthe radiator fan switch (see page 10-5).
Terminal
op".*i- Tr"ip".a*" \.B
SWITCH
ON196 - 203"F
{91 - 95.C)o---o
OFF
5 - 14"F (3 - 8.C)
lower than the tem-peratu re wh en itgoes on
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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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Slave Cylinder
RemovaUlnstallation
CAUTION:
. Do nol spill brake tluid on the vehicle; itmaydamage
the paint; if brake fluid do€s contast the paint, wash
it off immediately with water.. Plug the end of the clutch line with a shop towel toprevcnt brake tluid from coming out.
.6|l,Super High Temp Urea crease (p/N 08798 -
9002).
: Brake Assembly Lube or equivalent rubber
grease.
1. Disconnect the clutch line from the slave cvlinder.
2. Remove the slave cylinder from the clutch housing.
12-6
3. Install the slave cylinder in the reverse order ot
removal.
NOTEr Make sure the boot is installed on the slave
cylinder.
CLUTCH LINE15 N.m (i.S kgf.m, lt tbf.ftl
SLAVE CYLINDER
.-lG(P/N 08798 - 90021
E x 1.25 mm22 N.m (2.2 kgt.m,16 tbtft)
(Brake AssemblyLube)
Bleed the clutch hydraulic system.
Attach a hose to the bleeder screw, and suspend
the hose in a container of brake fluid.
Make sure there is an adequate supply of fluid at
the clutch master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
Refill the clutch master cylinder with fluid whenqone.
Always use Genuine Honda DOT3 Brake Fluid.
Using a non Honda brake fluid can cause corro-
sion and decrease the life of the system.
Confirm clutch operation, and check for leaking
fluid.
7.8 N.m (0.8 kgf.m. 5.8 lbt.ft)BLEEDER SCREW
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