1999 HONDA CR-V Ac lines

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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Valve Body Unh Roa$embly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl tape with
the power steering fluid.
Vinyl tape(Stopp6d portion)
VALVE OIL SEALReplace.Make sure the spring isseated in the oil seal.
Serling
E
7.
PINION SHAFT
BACKUP RING137 modell
WAVE WASHER{'98 - 00 modelsl
Install the backup ring {'97 model) or wave washer
('98 - 00 models).
Coat the inside surface of the new valve oil seal
with power steering fluid.
Install the valve oil seal with its grooved side facing
opposite the bearing, then slide the valve oil seal
over the pinion shaft, being careful not to damage
the sealing lip.
Apply vinyl tape to the splines and stepped ponion
of the shaft, and coat the surface of the vinyl tape
with the power steering fluid.
Vinyl trp€
O.RINGReplace.Do not twist.R€place-Do not over-expand.
Fit the new O-ring in the groove of the pinion shaft.
Then slide the new valve seal ring over the shaft
and in the groove on the pinion shaft,
Remove the vinyl tape from the pinion shaft.
\/
PINION SHAFT
8.Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
Apply power steering fluid to the inside of the spe-
cial tool. Set the larger diameter end of the special
tool over the valve seal ring.
VALVE SEAL RINGSIZNG TOOL07NAG - SR309q'ot07NAG - SR3oltoA
Mak€ the valve seal ringfit snugly in the pinion
shatt using th6 other end{smaller diameter end) otthe special tool.
10.
11.
12.
Move the special tool up and down several times to
make the valve seal ring fit in the pinion shaft,
Remove the soecial tool.
Turn the special tool over, and set the smaller diam-
eter end of the specisl tool over the valve seal ring.
Move the special tool up and down several times to
make the valve seal ring fit snugly in the pinion
shaft.
(cont'd)
lrr.rj1
tffifrE-rr.]
r\-''] 7
Usg th6 larg€r diameterend of the specialtoollirst to maketh€ valve seal ringtit in the pinion
shaft.
17-41
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Power Steering Gearbox
Reassembly (cont'dl
58. Installthe cylinder lines A and B
Note these items during reassembly:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
material,
. lnstall the cylinder lines A and B by tightening
the flare nuts by hand first, then tighten the flare
nuts to the soecified torque.
CYLINDEF LINE A
Grease the sliding surface of the rack guide, and
install it onto the gear housing.
For'97 model, apply a thin coat of grease to the new
O-ring, and install it on the rack guide screw.
For'98 - 00 models. remove the old sealant from
the threads of the rack guide screw. then apply new
sealant to the first three threads.
-6rO-RING
nlcr cutDE R"Pl""u'
SCREW
LOCKNUT
37 model:
60.
ot.
38 model:
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17,15). After
adjusting, check that the rack moves smoothly by
sliding the rack right and left.
17 N.m 11.7 kgd.m, 12lbf.ttl
26 N.m {2.7 kgl.m, 20
RACK GUIOE
17-48
STEERING RACK
(
63. Install the new lockwasher in the groove in the
steering rack.
LOCK WASHERReplace.
STEERING RACK ENO54 N.m (5.5 kgf.m,40 lbtftl
64.
STEERING
Screw the rack ends into the rack.
Hold the steering rack with a wrench ('98 - 00 mod-
els: left end only), and tighten the rack ends. Be
careful not to damage the rack surface with the
wrench.
After tightening the rack ends, stake the four sec-
tions of lock washerwith a drift and a mallet.
. Place the wood block on the press table, then set
the lock washer section of the rack end on the
wood block securely.
. Be sure the tool is aligned with the flat sections
of the steering rack end before pressing.
. Stake the lock washer in the center of the flat
section of the steering rack end,
ROLL PIN PUNCH
lCommorcially.Y.il.blelSnap-On No. PPR8 or oquival.nt.
NOTE: This drift has a flatshoulderto preventpuncturing of metal washer.
WOODEN BLOCK
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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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