Building the Ultimate Honda CR-V: K-Swap Gets Complicated

With the Honda K24a2 hanging in the engine bay, now it's time for everything else, starting with the cooling and fuel systems along with a custom exhaust system.

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This transcript follows a major engine-swap project on a high-mileage 2000 Honda CR-V. Instead of repairing the failed automatic transmission after 400,000 km, the builders decide to transform the CR-V with a more powerful modern drivetrain. 

Core Build Overview

The project involves:

• • Swapping in a 200-horsepower Acura TSX K-series engine
  • Pairing it with a manual AWD 5-speed transmission from a newer CR-V
  • Using swap components from  Hasport and K-Tuned

The creators explain that physically mounting the engine was relatively easy, but making everything function properly as a reliable daily driver became highly complex. 

Cooling System Challenges

A stock CR-V radiator would not fit because the hose locations interfered with the new engine accessories. They solve this by:

• • Installing a K-swap radiator from Coyo Radiator
  • Customizing brackets and fan placement
  • Testing intake manifold fitment to maximize clearance

They compare two intake manifold options:

• • RBB manifold for low/mid-range torque
  • RBC manifold for better top-end power

The RBC manifold ultimately provides better clearance and becomes the preferred solution. 

Custom Plumbing & Accessories

A large part of the episode focuses on adapting:

• • Radiator hoses
  • Heater hoses
  • Intake routing
  • Power steering lines

The builders use a mix of:

• • K-Tuned components
  • Custom AN fittings
  • Vibrant Performance hoses
  • Parts from their “stash” of leftover components

They also relocate and redesign the power steering plumbing because the K-series engine layout differs from the original B-series setup. 

Manual Transmission Conversion

Since the CR-V started as an automatic:

• • The team must install a clutch pedal
  • Remove the column shifter
  • Modify pedal assemblies
  • Adapt a clutch master cylinder
  • Install a K-swap shifter setup

The shifter installation requires:

• • Tunnel cutting
  • Fabrication
  • Spacers
  • Custom trim adjustments

In the end, they manage to create a setup that looks nearly OEM while maintaining good ergonomics. 

Drivetrain & Exhaust Issues

The AWD layout creates several unexpected complications:

• • The stock driveshaft is slightly short, but they determine it still has enough travel to work safely.
  • Standard K-swap headers interfere with the AWD drivetrain.
  • They resort to a stock TSX exhaust header for clearance reasons.

The exhaust system ultimately requires:

• • Full custom fabrication
  • Re-routing around the driveshaft
  • A custom 3-inch exhaust system
  • A high-flow catalytic converter to keep the vehicle emissions-friendly

The builders describe the exhaust fabrication as an all-day process involving heavy trial and error. 

Overall Tone & Conclusion

The episode emphasizes:

• • Problem-solving
  • Fabrication work
  • Trial-and-error engineering
  • Making a modern drivetrain work in a 25-year-old platform

By the end:

• • Major mechanical systems are installed
  • The custom shifter and drivetrain are functioning
  • The exhaust is completed
  • The next phase will involve creating a custom air-conditioning setup for the K-swapped CR-V

The project is portrayed as an ambitious but rewarding transformation of an aging SUV into a more modern, engaging, manual AWD performance daily driver.

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