Fluid HONDA CR-V 2000 RD1-RD3 / 1.G Owners Manual

20. Press the new bearing into the valve housing with
the stamped letter facing up using a hydraulic press
and soecialtool.
ATTACHMENT,32x35mm07746 - 0010100
- ROLLER BEARINGLetter stamped face
21. Apply vinyl tape to the pinion shaft, then coat the
vinyltape with power steering fluid.
Sealing lip tace.VALVE OIL SEAL
VALVE HOUSING
SHAFT
SLEEVE SEAL
PINION
E
22, Insert the pinion shaft into the valve housing. Be
careful not to damage the valve seal rings.
23. Remove the vinyl tape from the pinion shaft, then
remove any residue from the tape adhesive.
8e sure that theseal rings are notturned up, theninstall.
DRIVER
24. Press the pinion shaft/sleeve using a hydraulic
press. Check that the pinion shaft/sleeve turns
smoothly by turning the pinion shaft,
(cont'd)
17-43
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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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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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't 4.
15.
Center the steering rack within its stroke.
Install the steering joint, and reconnect the steering
shaft and pinion shaft.
NOTE: Make sure the steering joint is connected as
follows.
a. Insen the upper end of the steering joint onto the
steering shaft (line up the bolt hole with the flat
on the shaft).
UPPER JOINT BOLT22 N.m12.2 kgf.m, 16lbl.ft,
STEERING JOINT
COLUMNSHAFTLOWER JOINT BOLT22 N.m12.2 kgf.m, 16lbtftl
UPPER JOINT BOLTBolt must line upwith tlat on shatt.
LOWER JOINT BOLTBolt must line up withgroove around on shaft.
PINIONSHAFT
b, Slip the lower end of the steering ioint onto the
pinion shaft.
c. Install the lower joint bolt (line up the bolt hole
with ths groove around the shaft). Be sure that
the lower joint bolt is securely in the groove in
the pinion shaft.
d. Pull on the steering joint to make sure that the
steering joint is fully seated.
e, Install the upper joint bolt,
Reinstall the steering wheel {see page'17-19).16.
17-53
17. Wipe off any grease contamination trom the ball
joint tapered section and threads then reconnect the
tie-rod ends to the steering knuckles. For'97 - 98
models; torque the castle nut to the lower torque
specification, then tighten it only far enough to
align the slot with the pin hole. Do not align the nut
by loosening. Install new cotter pins.
CAST1T NUT(9t - 98modol!)
HEX NUTl'g!t - 00 modeb)il:l N.m14.4 ksl.m,32 tbf.f0
39 - iU N'm
lil.o - 4.8 kgl.m,
29 - 35 tbf.ftl
18.
19.
20.
21.
22.
23.
'99 - lD modeb:
COTTER PINRePlace.on reassembly, bendthe cotter Pin as shown.
With 4WD, connect the propeller shaft and transfer
assembly (see section 16).
Connect the shift linkage to the transmission (M/T:
see section 13, A,/T; see section 14).
Installthe Twc (see section 91.
lnstall the front wheels,
Fill the system with power steering fluid, and bleed
air from the system (see page 17-15).
After installation. perform the following checks.
. Start the engine, allow it to idle, and turn the
steering wheel from lock-to-lock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-23).
. Adjust the front toe (s€e section 18).
. Check the steering wheel spoke angl€. Adjust by
turning the right and left tie-rods equally, if nec-
essary.
TIE.ROO END
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Gomponent Locations
lndex
ERAKE SYSTEM INOICATORCircuit Diagram, page't9-8
PARKING BRAKEAdjustment, page 19-6Parking Brake Switch Test, page '19-8
PARKING BRAKE CABI..EInspection and Replacement,page 19-23
BRAKE BOOSTERBrake Booster Inspection, page 19-15
Removal/lnstallation, page 19 13
MASTER CYLINDER
Inspection, pago 19-16Brake Shoes Replacement,page 19-18Wheel CylinderReplacement, page 19-20
REAR DRUM BRAKE
Removal/lnstallation, page 19-13lnspection/Disassembly.page 19-14Pushrod Clearance Adjustment,page 19 ldBrake Fluid LevelSwitch Test,page 19-8
Inspection/Torque Specification, pag€'19-21
Hose Replacement, Page 19-22
Front Brake Pads, page 19-9Front Brake Disc. page 19-11Front Brake Caliper, page 19-12
)i't ' -"''
/'"''t,'..,1 ...,. , \,,,.
i ,.'
'a.,
I
.) ..)
t ^fl)
19-3
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Inspection and Adjustment
Brake System Rubber Parts and Brake Booster
@-Brake Booster
Check brake operation by applying the brakes.
lf the brakes do not work properly, check the brake
booster. Replace the brake booster as an assembly ifit does not work properly or if there are signs of leak-
age.
@-Piston Cup and Pressure Cup Inspection. Check brake operation by applying the brakes.
Visually check for damage or signs of tluid leakage.Replace the master cylinder as an assembly if thepedal does not work properly or if there is damage orsigns of fluid leakage.
. Check for a difference in brake pedal stroke betweenquick and slow brake applications. Replace the mas-.
ter cylinder if there is a difference in pedal stroke.
(9-Brake Hoses
Visually check for damage or signs of fluid leakage.
Replace the brake hose with a new one if it is dam-
aged or leaking.
O-Caliper Piston S€al and Piston Boots
Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leakage. lf
the pedal does not operate properly, the brakes drag,
or there is damage or signs of fluid leakage, disas-
semble and inspect the brake caliper. Replace the
boots and seals with new ones whenever the brake
caliper is disassembled.
@-Wheel Cylinder Piston Cup and Dust Cover
Check brake operation by applying the brakes.
Visually check for damage or signs of fluid leakage. lf
the pedal does not operate properly, the brakes drag,
or there is damage or signs of fluid leakage, replace
the wheel cvlinder.
19-4
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Bleeding
CAUNON:
. Do not spill brake tluid on the vehicle. it may damage
the paint; if brake fluid does contaqt th€ paint, wash
it otf immodiately with water.
. Maks sure no dirt oy other forsign matter is allowsd
to contaminate the brake fluid.
NOTE:
. Do not reuse the drained fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using
a non-Honda brake fluid can cause corrosion and
decrease the life of the svstem.
. The reservoir on the master cylinder must be at the
MAX (upper) level mark at the start of bleeding pro-
cedure and checked after bleeding each brake caliper
and wheel cylinder. Add fluid as required.
1, Make sure the brake fluid level in the reservoir is at
the MAX (uDDer) level line.
MAX {UPPER) LEVELLINE
RESERVOIR
MASTER CYLINDER
2.
3.
Have someone slowly pump the brake pedal several
times, then apply steady pressu.e.
Loosen the brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securely.
Repeat the procedure for each wheel in the sequence
shown below until air bubbles no longer appear in
the tluid.
Refill the reservoir on the master cvlinder to the
MAX (upper) level line.
ALEEDING SEOUENCE:
O Front RightGt Rear Right
O Front LeflO Rear Left
NOTE: Bleed the front calipers first in the bleeding
procedure.
4.
FRONT:
BLEEO SCREW7 N.m (0.? kgf.m, 5 lbf.ftl
19-7
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Inspection and Adjustment
Brake System Indicator
Circuit Diagram lNuLR.HorJDGNrT 0llSt!ITCHUNDEB.DASHFUSE]NEtAY BOIrllA Nl] 42 4!A
PAFK NC BRA(E S\I'ICH
GBNiBEO
Io\lt j I ERAKE tuU 0 rEVEr 9!1 I(N
| oPt^r'f,'1 .r
BIKI-o-:G401
Parking Brake Switch Test
1. Remove the parking brake cover,
2. Disconnect the connector from the parking brakeswitch.
3. Check for continuity between the terminal and bodyground in each position according to the table.
Terminal
Lever Position \
Positive
TerminalBody Ground
Lever Up--o
Lever Down
NOTE (Canada): lf the parking brake switch is OK, butthe brake system indicator does not function, perform
the input test for the daytime running lights control unit(see section 23).
Brake Fluid Level Switch Test
1. Remove the reservoir cap. Check that the float
moves up and down freely; if it doesn't, replace the
reservoir cap assembly.
2. Check for continuity between the terminals in each
switch position according to the table.
- r9''r
Position12
FLOAT UP
FLOAT DOWNo
RESERVOIR CAP
GROUND
Switch contacts open atproper fluid level.
19-8
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