Power steering rack HONDA CR-V 1997 RD1-RD3 / 1.G User Guide

Inspection and Adjustment
Pump Belt
When using a new belt. first adjust the deflection or ten-
sion to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after
running engine for five minutes.
Inspection
Note these items during inspection:
a lf there are cracks or any damage evident on the belt,
replace it with a new one.
. Follow the manufacturer's instructions lor the tension
gauge.
'1. Remove the P/S reservoir from the bracket, and set
it aside.
2. Attach the belt tension gauge to the belt with the
gauge face toward the engine, and measure the ten-
sion of the belt.
Remove the belt tension gauge carefully to avoid
hitting the gauge reset lever.
Tension:
Used Belt: 390 - 540 N {40 - 55 kgf, 88 - 121 lbf)
New Belt: 7,[0 - 840 N (75 - 90 kgf, 165 - 198 lbf)
CRANKSHAFT PULLEY
17-14
Measurement without Belt Tension Gauge:
Apply a force ot 98 N (10 kgf,22 lbt) and measure the
deflection between the power steering pump and the
crankshaft oullevs.
Deflection:
Used Belt: 11.0 - 1i1.5 mm {0.'(l - 0.57 in)
New Belt: 7.5 - 10.0 mm {0.30 - 0.39 in)
CRANKSHAFT PULLEY
Adiustment
'1. Loosen the power steering pump mounting bolt
and pump lock bolt.
PUMP MOUNNNG BOLT24 N'm (2.4 kgf'm, 17 lbf ftl
PUMP LOCK BOLT24 N.m 12.4 kgf.m, 17 lbf.ftl
Adjust the belt tension by moving the power steer-
ing pump with a 1/2" drive breaker bar to obtain theproper belt tension, then retighten the mounting
bolt and lock bolt.
Start the engine and turn the steering wheel from
lock-to-lock several times, then stop the engine and
recheck the deflection of the belt.
Measure here.
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Rack Guide Adjustment
1.
6.
7.
5.
4.
Set the wheels in the straight ahead position.
Loosen the rack guide screw locknut with the spe-
cialtool, then loosen the rack guide screw.
For'98 - 00 models, remove the rack guide screw.
Remove the old sealant from rack guide screw
threaded section, and apply new sealant to the first
three threads. Loosely install the rack guide screw
on the steering gearbox.
RACK GUIDE SCREW
LOCKNUT25 N.m
12.5 kgt m, 18lbtftl
Tighten the rack guide screw to 25 N.m (2.5 kgf'm,
18 lbf.ft), then loosen it.
Retighten the rack guide screw to 3.9 N'm (0.4
kgf.m, 2.9 lbf.ft), then back it off to specified angle.
Specified Return Anglo:
37 model: 10 r 5"'98 - 00 modeb: 20' Max
Tighten the locknut while holding the rack guide
screw.
Check for tight or loose steering through the com-
plete turning travel.
Perform following inspections:
. Steering operation (see page 17-12).
. Power assist with vehicle parked
Fluid Replacement
Check the reseryoir at regular intervals, and add the rec-
ommended fluid as necessary.
CAUTION: Always use Gsnuine Honda Power Steering
Fluid-V or S. Using any other type of power steering
tluid or automatic transmission fluid can cause increassd
wear and poor steering in cold w3athel.
SYSTEM CAPACITY:
0.85 liter {0.90 US. qt. 0.75 lmp.qtl
at disasssmbly
RESERVOIR CAPACITY:
0.,1 liter (0.42 US. gt, 0.35 lmp.qi)
UPPEN LEVEL LINE
LOWER LEVEL LINE
1.Raise the reservoir. then disconnect the return hose
to drain the reservoir. Take care not to spill the fluid
on the body and parts. Wipe off any spilled fluid at
once.
2, Connect a hose of suitable diameter to the discon-
nected return hose, and put the hose end in a suit-
able container.
3. Stan the engine. let it run at idle, and turn the steer-
ing wheel from lock-to-lock several times. When
fluid stops running out of the hose, shut off the
engine. Discard the fluid.
4. Beinstallthe return hose on the reservoar.
5. Fill the reservoir to the upper level line,
6. Start the engine and run it at fast idle. then turn the
steering from lock-to-lock several times to bleed air
from the system.
7. Recheck the fluid level and add some if necessary.
Do not fill the reservoir beyond the upper level line.
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Power Steering Pump
Replacement
1.Place a suitable container under the vehicle.
Drain the power steering fluid from the reservoir.
Remove the belt by loosening the pump mountingbolt and pump lock bolt.
PUMP MOUNNNG BOI.T24 N.m 12.4 kgt m, 17 lbl.ftl
PUMP LOCK BOLT24 N.m (2.4 kg{.m, 1, tbfttl
Cover the IVC compressor with several shop towelsto protect it from spilled power steering fluid.Disconnect the pump inlet hose and pump outlethose from the pump, and plug them. Take care notto spill the lluid on the body or parts. Wipe off anyspilled fluid at once.
Remove the pump mounting bolt and pump lockbolt, then remove the pump. Do not turn the steer-ing wheelwith the pump removed.
Cover the opening of the pump with a piece of tapeto prevent foreign materialfrom entering the pump.
PUMP OU'I.TT HOSE
11 N.m (1.1 kgf.m,E rbf.ti)
17-24
7.Connect the pump inlet hose and pump outlet hose.Tighten the pump fittings securely.
Loosely install the pump in the pump bracket withthe mounting bolt and lock bolt.
Install the pump belt.
Note these items du.ing belt instsllation:. Make sure that the power steering belt is proper-
ly positioned on the pulleys.
. Do not get power steering fluid or grease on thepower steering belt or pulley faces, Clean off anyfluid or grease before installation
FOWER STEER G EELT
PUTrlY
Adiust the pump belt (see page 17-141.
Fill the reservoir to the upper level line (see page't7 -151..
10.
'l l.
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Power Steering Gearbox
Removal
Note these items during removal:
. Using solvent and a brush, wash any oil and dirt off
the valve body unit its lines, and the end if the gear-
box. Blow dry with compressed air.
. Be sure to remove the steering wheel before discon-
necting the steering joint. Damage to the cable reel
can occur.
. With 4WD. tilt the engine with a jack to expand the
clearance between the transfer assembly and rear
beam when removing the steering gearbox from the
rear oeam.
Do not remove the steering gearbox by removing the
transfer assembly from the transmission.
1. Drain the power steering fluid as described on page'17-15.
Raise the vehicle, and suppon it on safety stands in
the proper locations (see section 1).
Remove the front wheels,
Remove the drive/s airbag assembly {see section 24).
Remove the steering wheel {see page 17-18).
Remove the steering joint bolts, then disconnect the
steering joint by moving the joint toward the column.
UPPER JOINT BOLT
LOWER JOINT BOLT
13.
7. Remove the cotter pin from the nut, and remove the
castle nut {'97 - 98 models) or hex nut ('99 - 00
models).
COTTER PINReplace.
Install the 10 mm hex nut on the ball joint. Be sure
that the 10 mm hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
might be damaged by the special tool. Refer to sec-
tion 18 for ball joint remover usage instruction, Be
careful not to damaging the ball joint boot.
Separate the tie-rod ball joint and knuckle using the
special tool.
Remove the right and left tie-rod ends, then extend
the rack all the way to the right.
Remove the TWC (see section 9).
Disconnect the shift linkage from the transmission
(M/T: see section 13, A/T: see section 14).
With 4WD. separate the propeller shaft and transfer
assembly (see section 161.
10.
11.
(cont'd)
17-31
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Power Steering Gearbox
Removal (cont'dl
24. Remove the mounting brackets.
25.lvlove the steering gearbox to the right so the
rack end clears the rear beam, then place the
rack end below the rear beam.
left
left
Move the steering gearbox to the left, and tilt the
left side down to remove it.
With 4WD. remove the steering gearbox through
the clearance between the transfer assembly and
propeller shaft.
MOUNTING BRACKETS
STEEBING GEARBOX
17 -34
4. Pull the boots away from the ends of the gearbox.
Disassembly
Steering Rack Disassembly
Note these items when disassembling:
. Before disassembling the gearbox, wash it off with
solvent and a brush.
. Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox (see page 17-31).
2. Remove airtube and clips.
3. Remove the boot bands and tie-clips.
AIR TUBE
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Power Steering Gearbox
Disassembly {cont'd}
12. Drill a 3 mm (0.12 in) diameter hole approximately
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the staked
point on the cylinder. Do not allow metal shavings
to enter the cylinder housing. After removing the
cylinder end, remove any burrs at the staked point.
D.oth: 2.5 - 3.0 mm 10.10 - 0.12 inl
CYUNOER
Hold the gearbox using using a C-clamp as shown,
Loosen and remove the cvlinder end.
13.
17-36
14, Assemble a 12 x 1.25 mm flange nut onto a '12 x 175
mm grade 10 flange bolt as shown, Wrap the flange
portion of the bolt with vinyl tape to protect the
cvlinder,
VINYL TAP€ tp/N 90177 - SLO - OOOI 12mmFLANGENUT
Install the flange bolt into the end of the steering
rack until it bottoms in the hole. then back the
flange bolt out 1/4 turn. Hold the flange bolt, and
tighten the flange nut against the rack by hand.
Install the bearing separator on the gearbox housing
as snown.
15.
BEARING SEPARATOR0 - 1112'(Commercially available)
17.
STEERING RACK
CYLINDER €ND
Set the gearbox in a press so the lelt side points
upward, then press the cylinder end seal and steer-
ing rack out of the gearbox. Hold the steering rack
to keep it from falling when pressed clear. Be care-
ful not damage to inner surface of the cylinder
housing with the flange bolt.
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Power Steering Gearbox
Reassembly
Note these items during reassembly
. Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly.
. Apply the recommended power steering fluid to the parts indicated in the assembly procedures.
. Do not allow dust. dirt, or other toreign materials to enter the power steering system.
. Use the appropriate specialtools where necessary.
FLANGE BOLTS20 N.m (2.0 kgl.m, 14lbtftl
CYLINDER LINE AFLARE NUTS17 N.m 11.712 rbl.ftl
VALVE HOUSING
CYLINDER END SEALReplace.
VALVE OIL SEALBeplace.
ROLLER BEARING
CIRCLIPReplace.
BA.KUP RING
\/^"
WAVE WASHERBACKUP RINGReplace.97 model:HOUSING
VALVE SEAL RINGReplace.
O.RINGReplace.
32 mm SHIMS'97 mod6l only:
RACK GUIDE SCREW
O-RINGReplace.
@---r-ocxr'rur
'97 model:
'98 model:
'99 - 0O mod6ls:'9? model only:
CYLINDER END69 N.m (7.0 kgf.m, 51 lbf.ft)'98 - (x) models:
PISTON SEAL RINGReplace.
17-40
STEERING RACK
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Power Steering Gearbox
Reassembly (cont'dl
Stecring Rack R8assembly
25. Coat the piston seal ring guide with power steering
fluid, then slide it onto the rack, big end first.
26. Position the new O-ring and new piston seal ring on
the sDecial tool, then slide them down toward the
big end of the tool.
Note these items during reassembly:
a Do not over expand the resin seal rings. Install
the resin seal rings with care so as not to dam-
age them. After installation, be sure to contract
the seal ring using the special tool (sizing tool).
a Replace the piston's O-ring and seal ring as a set.
27. Pull rhe O-ring off into the piston groove, then pull
the piston seal ring off into the piston groove on top
of the O-ring.
Coat the piston seal ring and the inside of the spe-
cial tool with power steering fluid.
07GAG - SO4O200 orOTGAG - SD'()2OA
Carefully slide the tool onto the rack and over thepiston seal ring.
Move the special tool back and fonh several times
to make the piston seal ring fit snugly in the piston.
24.
PISTONReplace
E
30.
PISTON
17-44
31. Wrap vinyl tape around the rack teeth and rack end
edges, then coat the surface of the tape with the
power steering fluid. Make sure that the vinyl tape
is wrapped carefully so that there is no stepped por-
tion.
Coat the inside surface of the new cvlinder end
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston. When
installing the cylinder end seal, be careful not dam-
age the sealing lip face of the seal with the edges or
teeth of the steering rack.
CYLINDER END SEAL
Make sure thespring is in lhe cylindereno seal
Remove the vinyl tape from the steering rack, then
remove any residue from the tape adhesive.
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35. Install the new backup ring on the steering rack,
then place the cylinder end seal against the piston.
BACKUP RINGReplace.
Grease the steering rack teeth, then insert the steer-
ing rack into the gearbox housing, Be careful not to
damage to inner surface of the cylinder wall with
the rack edges.
to.
GEARBOX HOUSING
Prers
37. Install the flange bolt into the end of the steering
fack until it bottoms in the hole, then back the
flange bolt out 1/4 turn. Hold the flange bolt and
tighten the flange nut against the rack by hand.
12 x'175 mm FLANGE BOLT
lP/N 90177 - SLo - 0001
12 mm FLANGE NUT
38.
CYLINDER END SEALReplace.
Install the cylinder end seal into the bottom of the
cylinder by pressing on the bolt with a press, Do notpush on the bolt with excessive force as it may
damage the cylinder end seal.
Remove the flange bolt, and center the steering
rack.
Wrap vinyl tape around the rack end edges, and
coat the surface of the tape with the power steering
fluid. Make sure that the vinyl tape is wrapped care-
fully so that there is no stepped portion.
(cont'dl
ia
40.
17-45
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Power Steering Gearbox
Reassembly (cont'dl
4l. Coat the inside surface of the new cvlinder end seal
with power steering fluid.
CYLINDEB ENO SEALReplace.Make sure the springis in the cylinder end seal.
43.
Stakedposrtron.
Grooved side.
42. Install the cylinder end seal onto the steering rack
with its grooved side toward the piston.
Push in the cylinder end seal with your finger.
When installing the cylinder end seal, be careful not
damage the sealing face of the seal with the threads
and burrs at the staked position of the cylinder
housing.
Remove the vinyl tape from the steering rack, then
remove any residue from the tape adhesive.
Hold the gearbox using a C-clamp as shown.
GEARBOX
44.
45.
C.CLAMP
17-46
46.Grease the inside surtace of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der.
Remove the C-clamp from the gearbox.
After tightening the cylinder end, stake the point of
the cylinder shown below. Stake the cylinder in the
position opposite from where the stake was removed
during disassembly,
NOTE: For '98 - 00 models, go to step 54.
41.
48.
BUSHING
-tGCYLINDER END69 N.m (7.0 kgf.m,51 lbtft)8e careful not to damagethe bushing when insertingthe cylinder end.
49. Select the 32 mm shim(s) ('97 model onlv).
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shaft. valve housing, and gear-
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
lows.
Shim selection:
Set the four 32 mm shims on the bearing surface of the
gearbox housing. Total thickness of the four shims
should equal no more than 0.70 mm.
Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15
mm, 0.20 mm, 0.25 mm respectively)
NOTE: The four 32 mm shims do not have thickness
identification marks. Measure the thickness of each shim
using a micrometer, and mark the shim for identification.
Stake point, Depth: 1,0 mm (0.04 inl
4.0 mm {0.16 in)
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