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

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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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
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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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 (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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Power Steering Gearbox
Reassembly (cont'd)
74. Connect the air tube between the right and left
boot,
CYLINDERLINE A
75. Install the clips on the cylinder lines, then clamp theair tube with the clips.
76. Apply vinyl tape to around the pinion shaft, andcoat the surface of the tape with grease.
DUST COVER
Vinyl Tsp€
VALVE OIL SEAL
VALVE BODY UNIT
Pack the interior of the dust cover and lio withgrease, then install dust cover on the valve bodv unit.
Remove the vinyl tape f.om the pinion shaft.
77.
CYLINDER LINE
17-50
SET RING
't.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot inslalla-
tion section with graase.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ballpin. then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation section and
the tapered section of th€ ball pin.
. Do not allow dust, dirt, or other to.eign materi-
als to enter the boot.
EALL PIN TAPEREDSECTIONWipe olf the grease.
BOOT INSTALLATIONSECTIONWipe offthe grease.
B(X)T IT{STALLATIONsEclroNWipe off the grease.
ADJUSTING BOLTAdiust the depthby turning the bolt.
Install the boot in the groove of the boot installation
section securely. then bleed air.
Adjust the special tool with the adjusting bott untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
I|on.
CAUTION: After installing the boot, chock the batlpin lapered section for grease contamination andwipe it it n€cessary.
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Power Steering Gearbox
Installation (cont'd)
8, Install the left front mount. Tighten the mountingbolts in order: A and B.
LEFT FRONT MOUNT
B-12 x 1,25 mm59Nm(6.0 kgtm,,€ lbl.ftlReplaca.
9. Instsll the right front mount, Tighten the mountingbolts in order: A and B.
B-12 x 1.25 mm59 N.m16.0 ks[.m, ,|:| lbf.ftlReplace.
A-10 x 1.25 mm4,1 N.mla.s kgt m, 33 lbf.ft)
A-10 x 1.25 mma,a N.m
10. Remove the vinyl type from the side frame (both
sides).
17-52
11. Installthe return hose joint by tightening the 16 mmflare nut.
AD.'USTAB[T HOSE CLAMP(For installationreter to page 17,23)
RETURN HOSE JOINT:16 mm FLARE NUT28 N.m12.9 kg{.m.21 lbt{t)
14 mm FLARE NUT37 N.m(3.8 ksf.m, 27 lbl'frl
't2.
13.
Connect the return hose securely. and tighten theadjustable hose clamp.
Connect the pump outlet hose, and tighten the l4mm flare nut.
NOTE: Make sure that there is no interferencebetween the fluid lines, the rear beam or any otherparts.
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Diagnostic Trouble Code (DTC)
Diagnostic Trouble Gode IDTCI Indication
NOTE: This operation can also be done with the Honda pGM Tester.
1. Connect the SCS service connector to the service check connector (2P) located on the passenger's side of the centerconsote.
2. Turn the ignition switch ON (ll).
NOTE; Do not press the brake pedal whenturningthe ignition switch.
3 Record the blinking frequency of the ABS indicator. The brinking frequency indicates the DTc.
4. Turn the ignition switch OFF. and remove the SCS service connector.NOTE: The Malfunction Indicator Lamp (MlL) will stay on after the engine is startsd if the SCS seryica connecror rsconnected.
5. Erase the DTC.
Conditions for DTC indication. The vehicle is stopped.. The SCS service connector is connected before the ignition switch is turned ON flt).. The brake pedal is released.. The SCS service connector remains connected during this procedure.
The DTC indication stops and the ABS control unit axecutos tha softwaro lunction if at least one of tho following condi-tions i3 satisfiod:
. The vehicle is not stoooed.. The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda pGM Tesrer.. The SCS service connector is disconnectod during this procedure.
NQTE: The illustration of gauge assembly shows the '97 - 98 models. The '99 - oo models are similar.
SEFVICE CHECKCONNESTOR I2P}
GAUGE ASSEMBLY
A8S II{DEATOR
u.s.A.
@
CANADA
@
19-38
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Heater Control PanelBlower Unit
Replacement
'1.Remove the center panel together with the heater
control panel and the audio unit (see section 20).
Remove the self-tapping screws and the heater con-
trol panel from the center panel.
3. lnstall in the reverse order of removal.
CENTER PANEL
22-46
1.
Replacement
Bemove the evaporator (see page 22-48),
Disconnect the connectors from the blower motor,
the blower motor high relay, the power transistor
and the recirculation control motor. Remove the
wire harness clio from the recirculation control
motor, and release the wire harness from the clamp
on the blower unit. Remove the mounting bolts, the
mounting nut and the blower unit.
6x1.0mm9.8 N.m (r,0 kgf.m, 7.2 lbl.ftl
9.E N.m 11.0 kgf.m,7.2lbtftl
lnstall in the reverse order of removal. Make sure
that there is no air leakage.
6x1.0mm
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}-Overhaul
1. Remove the filter lid. then pull out the A/C filter
assembly.
Pull out the evaporator temperature sensor from
the evaporator fins.
Remove the self-tapping screws and the clamps
from the housings.
Carefully separate the housings, then remove the
evaporator.
lf necessary, remove the expansion valve When
loosening the nuts of the expansion valve, use a sec-
ond wrench to hold the expansion valve or the evapo-
rator line. Otherwise, they can be damaged.
6. Reassemble the evaporator in the reverse order of
disassembly. Make note of these items.
. Replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them. Be sure to use the right O-rings
for HFC-'134a (R-134a) to avoid leakage.
. Install the expansion valve capillary tube with
the capillary tube in contact with the outlet line
directly, and wrap it with electricaltape.
. Reinstall the evaporator temperature sensor to
its original location.
. Make sure that there is no air leakage.
ELECTRICAL TAPEReplace.Make sure there is no foreign matter stuck between
the capillary tube and outlet line.
CAPILLARY TUAE
EXPANSION VALVE
4.
TEMPERATURESENSORlest, page 22-41
,m
\!{
YFILTER LID
;
I-OWER HOUSINGA/C FILTER ASSEMBLY
22-49
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