5 - Honda CR-V Owners Club
Contents
1. Transfer the plastic insulator and the clamp to the new clutch line A PLASTIC INSULATOR Transfer from the old line NEW CLUTCH LINE A NX OLD CLUTCH an LINE A Discard CLAMP Transfer from the old line 21 Remove and discard clutch line B from the slave cylinder to the mounting bracket then install the new clutch line B Do not tighten the line fitting yet 22 Install the new flexible clutch hose with the white band toward clutch line B NEW FLEXIBLE CLUTCH HOSE NEW CLUTCH LINE B eo QO 23 Install the new clutch line A Do not tighten the fittings yet 24 Install the new clutch line A mounting bracket with the bolts you retained in step 16 Torque the mounting bolts to 9 8 N m 7 2 lb ft 25 Reinstall the air duct tube and torque the bolts to 9 8 N m 7 2 lb ft 26 Torque all clutch line fittings to 15 N m 11 lb ft 01 101 27 28 29 30 31 32 01 For vehicles equipped with ABS Reconnect the orange 2P and 10P connectors and attach the connectors to their mounting brackets UNDERHOOD ABS FUSE RELAY BOX Detach harness clips ORANGE 10P K CONNECTOR g A ORANGE 2P CONNECTOR Reinstall the engine harness and starter wire clips onto the shock tower and thermostat mounting brackets Reinstall the fuel filter and mounting bracket Refer to page 11 184 of the service manual Attach the clutch master cylinder reservoir to the bul2. HONDA Service Bulletin 01 101 DO Applies To 1998 01 CR V ALL with Manual Transmission December 18 2001 Selecting Gears Is Difficult at Times SYMPTOM REPAIR PROCEDURE Intermittently selecting any gear with the clutch pedal 1 Record the radio station presets and the anti theft fully depressed is difficult This condition may be worse code then disconnect the negative battery cable daring weduantusaga Suen asim siop and ga anie 2 Remove the clutch master cylinder Refer to page 12 5 of the 1997 2001 CR V Service Manual PROBABLE CAUSE NOTE Do not disconnect the reservoir from the The driver may be resting his or her foot on the clutch clutch master cylinder at this time pedal preventing the fluid from returning to the clutch 3 Disconnect the switches then remove the clutch master cylinder reservoir This prevents the clutch from pedal upper mounting bolt Remove the pedal disengaging or engaging properly assembly SWITCHES UPPER CORRECTIVE ACTION MOUNTING Ke om J Bout PARTS INFORMATION Clutch Kit P N 06469 S10 305 H C 6828180 Replace the clutch pedal the clutch master cylinder 7 g and the clutch lines with improved parts WR Q Sy REQUIRED MATERIALS Honda DOT 3 Brake Fluid P N 08798 9008 H C 4423802 CLUTCH PEDAL ASSEMBLY WARRANTY CLAIM INFORMATION In warranty The normal warranty applies Operation Number 211105 Flat Rate Time 1 7 hours Failed Part P N 46920 S10 C01 H C 5751219 D
3. clutch line A from the white clip in the center of the bulkhead and the black clip under the battery support then remove it from the bolted clamp on the right frame rail WHITE 01 101 15 Disconnect the flexible clutch hose from clutch line B short steel line at the bracket where it attaches to the transmission CLUTCH BRACKET LINE B S FLEXIBLE 6 CLUTCH HOSE A y 240 Eby CLUTCH LINE B FLEXIBLE CLUTCH HOSE radiator hose CLUTCH LINEA MOUNTING SNORKLE TUBE BRACKET Unbolt and pull away 16 Remove the mounting bolts for the air snorkel tube then remove the bolts for the mounting bracket that attaches clutch line A to the flexible hose Retain the mounting bolts 3 of 5 17 For vehicles equipped with ABS Disconnect the orange 2P and 10P connectors and detach the connectors from their mounting brackets Detach the harness clip on the ABS motor harness then route the harness under clutch line A UNDERHOOD ABS FUSE RELAY BOX Detach harness clips ORANGE 10P CONNECTOR Detach and disconnect ORANGE 2P CONNECTOR Detach and disconnect A 18 Detach the engine harness and starter wire clips from the shock tower mounting bracket then detach the engine harness clip from the thermostat mounting bracket Detach harness clips THERMOSTAT MOUNTING BRACKET 19 Remove clutch line A from the engine compartment as an assembly 4of5 20
4. efect Code 031 Contention Code B99 Template ID 01 101A Skill Level Repair Technician Out of warranty Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office You must request consideration and get a decision before starting work 2001 American Honda Motor Co Inc All Rights Reserved ATB 23216 0112 1of5 Skil Level CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment R and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an REPAIR authorized Honda automobile dealer Remove and discard the adjusting bolt from the new clutch pedal assembly then transfer the switches from the original pedal assembly to the new one Do not tighten the locknuts for the switches yet NEW CLUTCH PEDAL ASSEMBLY Transfer the old switches leaving the locknuts loose ADJUSTING BOLT Discard Install the new clutch pedal assembly and attach it to the bulkhead with the upper mounting bolt Do not tighten the bolt yet Transfer the clutch master cylinder reservoir and bulkhead gasket to the new master cylinder Attach the r
5. eservoir hose to the master cylinder with the clamp ends toward the front of the master cylinder CLUTCH PEDAL ASSEMBLY MASTER CYLINDER NEW CLUTCH RESERVOIR BULKHEAD MASTER AND HOSE co S GASKET CYLINDER Clamp end should face forward Install the new master cylinder and loosely attach it to the bulkhead with the mounting nuts Do not tighten the mounting nuts yet 2of5 10 11 12 13 Under the dashboard install the pedal pin from the right side and install the lock pin on the left side from the bottom NOTE Do not adjust the length of the clutch master cylinder pushrod it is factory set Torque the clutch master cylinder mounting bolt and nuts to 13 N m 9 4 Ib ft Relieve the fuel pressure Refer to page 11 180 of the service manual Remove the lower fuel line from the fuel filter then remove the two mounting bolts from the fuel filter bracket Refer to page 11 184 of the service manual Remove the intake air duct and air cleaner housing Refer to step 5 on page 5 2 of the service manual Remove the brake booster hose the cruise control vacuum line the throttle cable and the cruise control actuator cable from the bulkhead mounting bracket Remove the mounting bolt free clutch line A long steel line from the bracket and remove the bracket CRUISE CONTROL VACUUM CLUTCH SS NEA CRUISE BRACKET CONTROL ACTUATOR lia CABLE THROTTLE CABLE 01 101 14 Remove
6. icle Check for proper clutch operation and make sure that the cruise control is cancelled by depressing the clutch pedal Enter the customer s anti theft code and radio station presets Reset the clock 5 of 5
7. khead Tighten the bolts to 9 8 N m 7 2 lb ft Install clutch line A into the bulkhead mounting bracket then attach the bracket to the bulkhead with the mounting bolt Torque the bolt to 9 8 N m 7 2 lb ft Reattach the brake booster hose the cruise control vacuum line the throttle cable and the cruise control actuator cable to the bulkhead mounting bracket CRUISE CONTROL BRAKE BOOSTER HOSE CLUTCH LINE A VACUUM LINE ES CRUISE SOS ACTUATOR CABLE THROTTLE CABLE 101 33 34 35 36 37 38 39 40 41 Fill the clutch master cylinder reservoir with Honda DOT 3 brake fluid and bleed the system Refer to step 4 on page 12 6 of the service manual Reinstall the air cleaner housing and intake tube Torque the mounting bolts to 9 8 N m 7 2 Ib ft Reconnect the negative battery cable to the battery Adjust the clutch pedal position switch While pulling the clutch pedal toward you adjust the switch until the threaded body of the switch contacts the pedal then turn the switch in a 1 4 turn more and lightly tighten the locknut CLUTCH PEDAL be Pedal in contact with switch CLUTCH PEDAL Pull toward you Depress the clutch pedal until it is 15 to 20 mm from the floor and hold it there Adjust the clutch interlock switch so that the engine will start with the clutch pedal in this position Torque the locknuts on both switches to 9 8 N m 7 2 lb ft Test drive the veh
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