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

Uneven or rough steering.Ad,ust the rack gu ide (see page 17- 15).
ll the problem is not corrected byadjusting the rack guide, replacethe gearbox.
Adjust the belttension. Replace thebelt, if necessary (see page 17-14).Belt slipping on pulley.
lf the engine stalls when thewheel is turned while the vehicleis stopped or moving at lowspeed, adjust the idle speed (seesection 111.
ldle speed low or erratic.
Check power steering lluid level. lfthe level is excessively low checkfor leaks in the system. Add fluidto the specified level.
Air in reservoir, or check powersteering tluid level.
lf fluid level is OK, check O-ringsand seals on both ends of thepump inlet hose, and the P/Spump housing mating surlacesand drive shaft oil seal for suction leaks. Check the reservoir forcracks, Replace parts as neces-
Pump belt slipping on pulley(pump stops momentarily).Adjust the belt tension (see page17-14) or replace belt.
Check if pump pressure is normaland the gauge needle travel is 500kPa (5 kgl/cm,, 71 psi) or less.Check the flow control valve if theneedle travel exceeds 500 kPa (5kgflcm', 71 psi). lI the flow controlvalve is normal, replace the pumpas an assembly,
Install the power steering pres-sure gauge, Close the pressurecontrol valve and shut off valve (if
so equipped) fully and measurethe pump pressure (see page 17-16ot 17 17).
Steering wheel kicks backduring wide turns.
7-7
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Pump noiseGrating nois€trom pump
Pump noise
Raftle or chattering
Check the fluid lev€1.lt low, fill the reservoir to theproper level. and check for leaks.Tighten or roplace as necessary,
Cavitation caused by air bubblesin the fluid.
Check for a crushed inlet hose ora loose hose clamp allowing airinto the suction side of the system. Check the reservoir forcracks. Tighten or replace as nec-
Check the drive shaft oil seal.
Pump noise up to 2 - 3 minutesafter starting in cold weather isnormal, Compare pump noise atoperatrng temperature to anothervehicle.
ll pump noise is abnormally loud,remove and inspect the pump forwear and damage (see page 17-251.
Tighten or replace the pulley.lI shaft is loose, replace thepump.
17-9
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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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Steering Wheel
Removal
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
1. Align the front wheels straight ahead. then remove
the driver's airbag assembly (see section 24) from
the steering wheel.
2. Disconnect the horn connector and cruise control
switch connectors.
CONTROLSWITCHES CONNECTOR
3. Loosen the steering wheel bolt, then install a steering
wheel puller on the steering wheel and remove it.
Note these items when removing the steering wheel:
. Do not tap on the steering wheel or the steering
column shaft when removing the steering wheel.
. lf you thread the puller bolts into the wheel hub
more than five threads, the bolts will hit the cable
reel and damage it. To prevent this, install a pair
of jam nuts five threads up on each puller bolt.
STEERING WHEEL BOLT39 N.m 14.0 kgt.m,29 lbtftl
STEERING WHEEL EOLT
Disassembly/Reassembly
EOSS COVER PLATE
_^M
STEERING WHEEL
WHEEL BODY COVER
17-18
@,
ACCESS PANEL
h"\
BODYCOVER CAP
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lnstallation
1. Before installing the steering wheel, make sure the
front wheels are aligned straight ahead, then center
the cable reel. Do this by first rotating the cable reel
clockwise until it stops. Then rotate it counterclock-
wise approximately two turns. The arrow mark on
the cable reel label should point straight up.
ARROW MARK
2. Install the steering wheel on to the steering column
shaft, making sure the steering wheel shaft engages
the cable reel and canceling sleeve. Do not tap on
the steering wheel or steering column shatt when
instailing the steering wheel
HOLE
Install the steering wheel bolt, and tighten it to 39
N.m (4.0 kgf.m, 29 lbf.ft).
Connect the horn connector and the cruise control
switch connectors,
Install the driver's airbag assembly, and confirm
proper system operation (see section 24).
CABLE REEL
17-19
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Steering Column
Removal/lnstallation
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
Note these items when removing the steering column:. Before removing the steering column, remove thedriver's airbag assembly and cable reel (see section24).
. Before removing or installing, set the column shaft inthe neutral position by pulling up the steering columnto uppermost position, then lower it 8 mm (5/16 in).Tighten tilt lever.
FULL STROKE:23 mm 10.9 in)
MAXIMUM UPPER8 mm (5/16)
POSTTTON
Remove the steering wheel (see page 17-18).
Remove the driver's side dashboard lower cover
and knee bolster (see section 20),
Remove the column covers.
With A"/T, move the shift lever to the E position,
and remove the shift cable from the column. andset it aside (see section 14).
Remove the combination switch assembly from thesteering column shaft by disconnecting the connec-
tors, and removing the two screws.
Disconnect the steering joint from the engine com-panment.
Remove the steering column by removing theattaching nuts and bolts.
7.
1.
MAXIMUM LOWERPOSTTTON
SHAFT CENTER
111 mm 100 mm5mm
JOINT COVERBOOT BAND
9,8 N.m l r .0 kgf.m, 7 lbf.fO
JOINT DUST SEAL
22 N.m (2.2 kgl.m, 16lbtftl
TILT LEVER
UPPER ATTACHING NUTS16 N.m lr.6 kgf.m, 12 lbf.ftl
UPPER COLUMN COVER
COMAINANON SWITCH ASSEMBLY
JOINT
COLUMN BMCKET
LOWER ATTACHING BOLTS39 N.m lir,o kgf.m, 29 lbf.ft)
17-20
LOWER COLUMN COVER
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Disassembly
Note these items during disassembly:
. The power steering components are made of aluminum, Avoid damaging the components during assembly.
. 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 recommended power steering fluid to the parts indicated in the assembly procedures.
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.
. Replace the pump as an assemblyif the parts indicated with asterisk(*) areworn ordamaged.
FLANGE BOLTS20 N.m 12.0 kgt'm,
1a tbf,ft)
.PUMP COVER
ROLLER
PUMP COVER SEAL
*PUMP HOUSING
5l x 2.4 mm O-RINGRepiace.
13 x 1.9 mm O-RINGReplace.
INLET JOINT
*OUTER SIDE PLATE
.PUMP CAM RING
PUMP SEAL SPACER
PUMP DRIVE SHAFT
FLANGE BOLTS11 N.m 11.1 kgt m,8 tbf.ft)
PULI.-EY NUTfl N.m (6.5 kgf.m,/r7 lbf.ftl
(cont'd)
17 -25
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Power Steering Pump
Disassembly (cont'dl
1.
7.
9.
10.
Drain the fluid from the pump.
Hold the steering pump in a vise with soft jaws.
hold the pulley with the special tool, and remove
the pulley nut and pulley. Be careful not to damagethe pump housing with the jaws of the vise.
UNIVERSAL HOLDER07725 - 0030000
Loosen the flow control valve cap with a hexwrench, and remove it.
Remove the O,ring, flow control valve and spring.
Remove the inlet joint and O-ring.
Remove the pump cover and pump cover seal.
Remove the outer side plate, pump cam ring, pump
rotor, pump vanes, side plate and O-rings.
Remove the snap ring, then remove the sub-valvefrom the pump housing.
Remove the circlip, then remove the pump driveshaft by tapping the shaft end with the ptastic ham-mer.
Remove the pump seal spacer and pump seal.
17-26
Inspection
Flow Control Valve
1. Check the flow control valve for wear, burrs, and
other damage to the edges of the grooves in thevalve.
'97 model:
FLOWCONTROL VALVE
Check fordamage to edges.
'98 - 0O mod€ls:
FLOW CONTBOL VALVE
Check for damageto edges.
Insp€d the bore of the flow control valve tor scratchesor wear.
Slip the valve back in the pump, and check that itmoves in and out smoothly. lf OK, go to step 4; ifnot, replace the pump as an assembly. The flowcontrolvalve is not available separately.
CONTROL VALVE
4. Attach a hose to the end of the valve as shown.
FLOW CONTROL VALVE HOSE
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Power Steering Pump
Reassembly
'1.Align the pin of the sub-valve with the oil passage
in pump housing, and push down the sub-valve.
Install the snsp ring properly.
OIL PASSAG€Align the pin of
the oil passage.
#q
;1..*
\SNAP RINGPUMP HOUSING
Install the new pump seal (with its grooved side fac-
ing in) into the pump housing by hand, then install
the pump seal spacer.
Position the pump drive shaft in the pump housing,
then drive it in using a 29 mm socket as shown,
BALL BEARfNG grlu,e un.t
/ /ffi\
1 / t\v4
t/ Y
# I F
PUMP SEALSPAC,ER
ry^
i- d
,O mm CIRCLIP
Hgo
/= PUMP DRIVE SHAFT
@.--#$i":*'
4,
PUMP HOUSING
Install the 40 mm circlip with its radiused side fac-
Ing out.
29 mm SOCKET
17 -2A
7.
5. Coat the pump cover seal with power steering fluid,
and install it into the groove in the pump cover.
OUTER SIDE PLATE
5 mrh ROLLER
lnstall the oute. side plate over the two rollers.
PUMP CAM RING
ROLLER SET HOLES
ROLLERS
Set the pump cam ring over the two rollers with the"' " mark on the cam ring upward.
ROLLER SET HOLES
PUMP COVER
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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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