Ac lines HONDA CR-V 1999 RD1-RD3 / 1.G Repair Manual

Steering
Special Toofs ............. 17-2
Component Locations
Index ................ ....... 17-3
Troubleshooting
General Troubleshooting ................ 1 7-4
Noise and Vibration ......................... 17-8
Fluid Leaks ............. 17-10
Inspection and Adiustment
Steering Operation .......................... 17-12
Power Assist Check
With Vehicle Parked ....................
Steering Linkage and Gearbox .......
Pump Belt
Rack Guide Adjustment ...................
Fluid Rep|acement ...................,,.,....
Pump Pressure Check .................,,...
*Steering Wheel
Removal ................. 17-18
*Steering Column
Removal/lnstallation ................ ....... 17 -2O
lnspection .............. 17-21
Steering Lock Replacement ............ 17 -22
Power Steering Hoses, Lines
Ffuid Leakage Inspection ................. 17 -23
Repfacement .......... 17-23
Power Steering Pump
Repfacement .......... 17-24
Disassembly ...........17-25
fnspection .............. 17-26
Reassembly ............ 17-28
Power Steering Gearbox
Removal ................. 17-31
Disassembly ........... 17-34
Reassembly ............ 17-40
Ball Joint Boot Replacement .......... 17-50
Installation ............. 17-51
17-12
17-13
17-14
l7-15
17-15
17-16
Disassembly/Reassembly............... 17-18
4'%/b.......... -r'-7--a/
SUPPLEN\EN AL RES\RA(N SYSTES{ (SRS\
This model has an SRS which includes a driver's airbag in the steering wheel hub. a passenger's airbag in the dashboardabove the glove box ('97 - 00 models), and seat belt tensioners in the seat belt retractors ('98 - 00 models). Informationnecessary to safely service the SRS is included in this Service Manual. ltems marked with an asterisk (*) on the contentspage include, or are located near, SBS components. Servicing. disassembling or replacing these items will require specialprecautions and tools, and should only be done by an authorized Honda oearer.
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontalcollision. allSRS service work must be performod by an authorized Honda dealer.lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniurycaused by unintontional deployment of th€ airbags {'97 - 00 models), and seat belt tensioners ('98 - 00 modelsl.Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when theignition switch is ON (lll.
SRS electrical wiring harnesses are identitied by yellow colof coding. Ralated components are located in the steeringcolumn, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box. Do not use elec-trical test equipment on these cilcuits,
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Component Locations
lndex
Note these items during disassembly:' lf an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur-ing transit, storage or service. it should be deployed (see section 24),a Before removing the gearbox, remove the driver.s airbag assembly and steering wheel.. After installing the gearbox, check the wheel alignment and adjust if necessary.
SRS components are located in this area. Review the SRS component locations, precautions, and procedures an the SRssection (24) before performing repairs or servrce.
STEERING WHEELRemoval, page 17,18Disassembly/Reassembly, page 1?,18Installation, page 17-19DRIVER'S AIRBAG ASSEMBLYRemoval/lnstallation, see section 24
STEERING GEARBOXRack Guide Adjustment, page 17-15Removal, page 17-31Disassembly, page 17-34Reassembly, page 17,40Installation, page 17,51VALVE BODY UNITOverhaul, page 17-38
STEERING COLUMNRemoval/lnstallation. page 17-20Inspection, page l7 21Steering Lock Replacement, page 17 22CABLE REELRemoval/lnstallation, see section 24tcNrnoN swtTcHSee s€ction 23
STEERING HOSES, LINESReplacement. page l7-23
Pump Belt Inspection andAdjustment, pag€ t7-14Pump Pressure Check, page 17-16 ot 17-1jReplacemont, page 17-24Disassembly, pa96 17,25Inspection, page 17-26Reassembly. page17-28
RESERVOIRFluid R6placement. page 17 15Fluid Leakage lnspection, page 17-23
END BALL JOINTBallJoint Boot Replacement, page 17-50
17-3
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Troubleshooting
General Troubleshootin g
Check the following before you begin:
. Has the suspension been modified in a way that would affect steering?
. Are tire sizes, tire variety and air pressure correct?
. ls the steering wheel original equipment or equivalent?
. ls the power steering pump belt properly adjusted?
. ls steering fluid reservoir filled to proper level?
. ls the engine idle speed correct and steady?
Hard Steering (Check the power assist, see page 17-12. lf the force is over 29 N (3.0 kgl 6.6 lbfl, proceed with this troubleshooting.i
Abnormalthiidpressure (Iluidpressure is toohigh)
Relief pressuretoo low
Faulty valve body unit
Abnormal
Check the teed and return circuit lines and hosebetween the gearbox and pump for clogging anddeformation.
Normal line and hose
Check the pump fluid pressure(see page 17-16 or 17-17).Measure steady state lluid pres-
sure at idle with the pressure con-trol valve and the shut-off valve (it
so equipped) fully open.The fluid pressure should be 1,500kPa (15 kgf/cm,,213 psi)or less.
Normal
Check the flow control valve (see page 17 26).. Check the valv€ lor smooth movement in the hous-ing.. Check the relief valve for leaks.
Check the pump fluid pressure(see page 17-16 or l7-17).Measure pump relief pressure atidle with the pressure controlvalve and the shut'off valve lil soequipped) fully closed.The fluid pressure should be 6,9007,800 kPa (70 - 80 kgflcm,, 1,000- 1,140 psi).
Normal relief pressure
17-4
Go to page 17 5Faulty pump assemblyFaulty flow control valve
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Abnormal
Not deformed
Deformed
Faulty cylinder lines
Readjust the rack guide(see page 17-15)
Bent
IFaulty steering gearbox
Compair the steering to anotheralike vehicle.
(cont'd)
17-5
Adjustment OK
Check the force required to turnthe wheel lsee page 17 12).Start the engine and measure theforce required to turn the wheelto the right and left. Difference ofthe force required to turn thewheel to the right and to the leftshould be 2.9 N (0.3 kgf,0.7 lbt)or less,
Normal
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Troubleshooting
General Troubleshooting (cont'dl
Assist (excessively light steering) athigh speed.
Shock or vibration when wheel isturned to full lock.
Steering wheel will not returnsmoothly.
lf the problem is not corrected byadjusting the rack guide, adjustthe front wheel alignment (see
section 18).
Check the rack guide for proper
adjustment (see page 17-15).
Check the rack guide for properadjustment (see page 17'15).
Adjust the rack guide.
Rack guide is adiusted properly.
lf the problem is not corrected byadjusting the rack guide, replacethe gearbox.Check the belt for slippage andadjust as necessary (see page 17-14).
A and B cylinder lines are normal, check wheel alignment (see
section 18).
Wheel alignment is abnormal,adjust as needed.
Wheel alignment is normal.Check the steering wheel opera-tion and power assist check (seepage 17-121.
lf the measurements are out ofspecifacations, adjust the rackguade.
lf the problem is not corrected byadjusting the rack guide, replacethe gearbox,
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Power Steering Hoses, Lines
Fluid Leakage Inspection
HOSES and LINES
. lnspect hoses for damage. leaks. interference and twisting
. Inspect fluid linesfor damage, rusting and leakage.
. Check for leaks at hose and line joints and connections.
FEED HOSE37 N.m 13.8 kgf.m, 27 lbtft)RETURN LINE JOINT28 N.m (2.9 kgf.m.21 lbf.ftl
CYLINDER LINES17 N.m (1.7 kgf.m. 12 lbf.ftl
FOWER STEERING PRESSURE SWITCH12 N.m (1.2 kgf.m,8.7 lbtft)
26 N.m (2.7 kgf.m, 20 lbf.ft)
GEARBOX .nd VALVE BODY UNllCheck for leaks at the mating surfaceand flare nut connections.
CYLINDER
FEED HOSE11 N.m('1.1 kgt.m, 8 lbf.ftl
SUCTION HOSE
PUMP ASSEMBLYCheck for leaks atthe pump
seal. inlet and outlet fittings.
Note these items during installation:
. Connect each hose to the corresponding line securely
until it contacts the stop on the line. Install the clamp
or adjustable clamp at the specified distance from the
hose end as shown.
. Check all clamDs for deterioration or deformation;
replace with the clamps new ones if necessary.
. Add the recommended power steering fluid to the
specified level on the reservoir and check for leaks.
ADJUSTABLE HOSE CLAMP: la)
. Position the adjustable hose clamps at the points
indicated by (a) in the drawing above.
. Slide the hose over the line until it contacts the stop.
HOSE CLAMP: lbl
. Position the hose clamps at the
(b) in the drawing above.
. Slide the hose over the line until
Replacement
10.01 - 0.22 in)
points indicatsd by
it contacts the stop,
2.0 - 4.0 mm10.08 - 0.16 inl2.5 - 5.5 mm{0.01 - 0.22 in}17 -23
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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
AN'USTABLE HOSE CLAMP
Removal (cont'dl
14. Loosen the 14 mm flare
pump outlet hose.
nut, and disconnect the
14 mm FLARE NUT
15. Loosen the adjustable hose clamp and disconnect
the return hose,
16. Loosen the 16 mm flare nut, and remove the return
hose joint.
17. After disconnecting the hoses and lines, plug or seal
them with a piece of tape or equivalent to prevent
foreign maisrials from entering the valve body unit.
NOTE:
. Do not loosen the cylinder line A and B between
the valve body unit and cylinder.
. With 2WD, continue to step 23.
17 -32
STOP BOLT
10 x 1.25 mm
4WD: Stepr 18-22
18. Removethe right tront mount, then apply vinyl tape
to the side frame to protect it from the transmission
cover and stop bolt.
12 x 1.25 fiiAReplace.
RIGHT FRONT MOUNT
x 1,25 mm
SIDE FRAME
'19. Remove the left front mount, then apply vinyl tape
to the side frame to protect it from the stop bolt.
Vinyltape orequivalgnt material.
Vinyltap€ orequival€nt m6terial.
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5. Hold the steering rack with a wrench {'98 - 00 mod-
els: left end onlv), and unscrew the rack end with
another wrench, Be careful not to damage the rack
surface with the wrench,
LOCK WASHER
Loosen the locknut, then remove the rack guide
screw and O-ring ('97 model).
6.
1.
LOCKNUT
Remove the spring and the rack guide from the gear-
DOX.
RACK GUIDE
9.
8. Remove cylinder lines A and B from the gearbox,
CYLINDER LINE A
Drain the fluid from the cylinder fittings by slowly
moving the steering rack back and {orth.
Remove the two tlange bolts, then remove the valve
body unit from the gearbox. (See page 17-38 for
valve body unit disassembly.)
VINYL TAPE
FLANGE BOLT
Apply vinyl tape to stepped portion of the pinion
shaft, and remove the dust cover.(cont'd)
DUST COVER
11.
17-35
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Power Steering Gearbox
Disassembly (cont'd)
Valve Body Unit Dbassembly
23. Before removing the valve housing, apply vinyltape
to solines of the Dinion shaft.
VALVE HOUSING
Separate the valve housing from the pinion shafv
valve using a press.
Check the inner wall of the valve housing where the
seal ring slides with your finger. lf there is a step in
the wall, the valve housing is worn. Replace the
valve housing.
Note these items during inspection:
o There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.
. When the valve housing is replaced, install new
shim{s) on the bearing surface of the housing to
adiust the thickness.
Check the inside ofvalve housingfor a step in the wall.
17-38
26. Check for wear, burrs and other damage to the
edges of the grooves in the sleeve.
NOTE: The pinion shaft and sleeve are a precision
matched set. lf either the oinion shaft or sleeve
must be replaced, replace both parts as a set.
SLEEVE SEAL RINGSCheck for Deel off or
27. Remove the circlip and sleeve from the pinion shaft.
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