2004 Honda Element DX 2003-06 STEERING Power Steering - Element 2003-06 STEERING Power Steering - Element SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (IF STEERING MAINTENANCE IS REQUIRED) The ELEMENT SRS includes a driver's airbag in the steering wheel hub, a passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt -at belt buckle tensioners in the front seat belt buckles, and side airbags in the acks, Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( * ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items require special precautions and tools, and should be done only by an authorized Honda dealer. + To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work must be performed by an authorized Honda dealer Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags. Do not bump or impact the SRS unit, front impact sensors, side impact sensors when the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF: otherwise, the system may fail in a collision, or the airbags may deploy. SRS electrical conn are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, and around the floor. Do not use electrical test equipment on these circuits. SPECIAL TOOLS2004 Honda Element DX 2003-06 STEERING Power Steering - Element ‘Tool Number O7AAF-SDAATOO o7Gar-PH7OI0O Pilot Collar o7Mac-stoaz02 Ball Joint Remover, 281mm o7NAD.SRa0101 Driver Handle O7NAD.SRI0200 or O7NAD-SAIO20A—_ Cylinder End Seal Remover Attachment ‘7NAG-SR30800 or OTNAG-SR2090A Valve Seal ing Sizing Tool 70AD-Poa0700 | stachment, 42 mm 07¥AG-S2x0100 | Slaove Seal Ring Guide O7ZAA-S5A0100 Llocknt Wrench O7ZAe SSA0100 Pulley Holder O7ZAF-S5A0100 Driver, 27 mm 072AG-$5A0100 Sleove Seal Ring Sizing Tool, 36 mm 07ZAG-$540200 Valve Sel Ring Guide 107974-6890801 or 07974-689080A (Cylindar End Seal Slidor, 23 mm | O7VAK-P#AOTIA IS Joint Adaptor (Pump) O7ZAK-S7CA100 IS Joint Adapter Piste Pump) O7ZAK-S7CA200 PIS Joint Adopter Hose) 072AG-S7A0100 | Piston Seal Ring Guide, 42mm 072AG-S7A0200 Piston Seal Ring Sizing Tool, 42 mm 107406-0010001 or 07406-00100 IS Pressure Gauge 0746-0010100 ‘Altachment, 32 95 mm 0749-0070000 Driver 07916-SA5000 __[Locknur wrench, 40:mm Fig. 1: Identifying Special Tools Courtesy of AMERICAN HONDA MOTOR CO., IN COMPONENT LOCATION INDEX fA Ae2004 Honda Element DX 2003-06 STEERING Power Steering - Element DRIVER'S AIRBAG / POWER STEERING FLUID RESERVOR ‘STEERING WHEEL 9 STEERING COLUMN POWER STEERING PUMP \ POWER STEERING GEAREOX Fig. 2: Identifying Power Steering Component Location Courtesy of AMERICAN HONDA MOTOR CO., INC. SYMPTOM TROUBLESHOOTING INDEX Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause TROUBLESHOOTING SYMPTOMS REFERENCE Symptom Procedure(s) ‘Also check for: Hard steering Troubleshoot the system (see HARD © Modified STEERING ) suspension « Damaged] suspension « Tire sizes, tire| varieties, and air pressure| Assist Check the rack guide adjustment (see Front wheel| (excessively RACK GUIDE ADJUSTME!2004 Honda Element DX 2003-06 STEERING Power Steering - Element light steering at high speed) alignment (see| WHEEL ALIGNMENT ) Tire size, tire] varieties, and air pressure| Shock or vibration when the steering wheel is turned to full lock 1. Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). .. Check the drive belt for slippage (see DRIVE BELT INSPECTION ). 3. Check the power steering pump fluid pressure with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ) or T/N 07406-001000A (see PUMP: PRESSURE TEST WITH T/N 07406-001000A ). 4, Overhaul the steering gearbox (see STEERING GEARBOX OVERHAUL ). Steering wheel will not return smoothly 1. Check cylinder lines for deformation. 2. Check wheel alignment (see WHEEL ALIGNMENT ) 3. Overhaul the steering gearbox (see STEERING GEARBOX OVERHAUL ), check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). Uneven or rough steering 1. Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). 2. Check the drive belt (see DRIVE BELT INSPECTION ). 3. Check low or erratic engine idle speed (see IDLE SPEED INSPECTION ). 4. Check for air in the power steering system due to low fluid level or an air leak at the pump inlet hose 5. Check for low fluid level in the power steering reservoir due to2004 Honda Element DX 2003-06 STEERING Power Steering - Element possible leaks in the system. 6. Overhaul the steering gearbox (see STEERING GEARBOX OVERHAUL ). Steering wheel kicks back during wide turns 1. Check the drive belt (see DRIVE BELT INSPECTION ). 2. Check the power steering pump fluid pressure with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ) or T/N 07406-001000A (see PUMP PRESSURE TEST WITH T/N 07406-001000A ). Humming noise from the power steering system 1. Check when the noise occurs: If the noise is heard for about 2- 3 minutes after starting the engine in cold weather, this is normal. « If the noise is heard when the wheel is turned with the vehicle stopped, this is normal due to the fluid pulsation 2. Check for the high-pressure hose touching the subframe or body. 3. Check for air bubbles in the power steering fluid, and a leak on inlet side of the pump. 4. Damaged or kinked power steering line. 5. Plugged power steering reservoir filter (built into reservoir) 6. Check for automatic transmission converter noise. 7. Check the fluid for particle contamination, and check the reservoir for a restricted filter in the reservoir. Pump pressure| Power steering rack rattle or chattering 1. Check for loose steering components (tie-rod end ball joints). Tighten or replace as necessary.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 2. Check the steering column shaft for wobbling, If the steering column wobbles, replace the steering column assembly (see STEERING COLUMN REMOVAL AND INSTALLATION ), 3. Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). 4. Check the power steering pump pulley: « If the pulley is loose, tighten it (see step 47 ), « If the pump shaft is loose, replace the pump (see PUMP. REPLACEMENT ). Hissing « Check the fluid level. If low, fill the « Air in the P/S fluid| noise/foaming _ reservoir to the proper level and Restricted] fluid in reservoir check for leaks. reservoir screen| # Check the reservoir for leaks. # Check for crushed inlet hose or loose hose clamp allowing air into the suction side of the system # Check the power steering pump shaft oil seal for leaks. Noise from the ¢ Compare the pump noise at normal P/S pump pressure] Power steering operating temperature to another like |, Air in the P/S fluid| pump vehicle (pump noise up to 2-3 minutes after starting the engine in cold weather is normal). « Remove and inspect the pump for wear and damage (see PUMP OVERHAUL ). Squeaking from | Check the drive belt (see DRIVE BELT the power INSPECTION ). steering pump Fluid leaks from « Fluid leaks from the top of the valve the steering body unit: Overhaul the steering gearbox gearbox (see STEERING GEARBOX OVERHAUL ). Fluid leaks from boot A: Replace the2004 Honda Element DX 2003-06 STEERING Power Steering - Element valve oil seal on the pinion shaft. Replace the cylinder end seal on the gearbox side. Fluid leaks from boot B: Replace the left cylinder end seal. « Fluid leaks from pinion shaft near the lower steering joint bolt: Overhaul the valve body unit. Fluid leaks from the power steering line Fluid leaks from the cylinder line connections (flare nuts): Tighten the connection and retest. « Fluid leaks from a damaged cylinder line: Replace the cylinder line. « Fluid leaks from the pump outlet hose or return line fitting on the valve body unit (flare nuts): Tighten the fitting and retest. If it still leaks, replace the hose, the line, or valve body unit as necessary. Fluid leaks from the power steering pump « Fluid leaks from the front oil seal: Replace the front oil seal * Fluid leaks from the power steering pump housing: Replace the leaking O-rings or seals (see PUMP OVERHAUL ), and if nec: replace the power steering pump (see PUMP REPLACEMENT ). Fluid leaks from the power steering reservoir Fluid leaks from around the reservoir cap: Fluid level is too high, drain the reservoir to the proper level. Aerated fluid: Check for an air leak on the inlet side of pump. Fluid leaks from reservoir: Check for the reservoir for cracks and replace as necessary. Fluid leaks from the power steering pump outlet hose (high-pressure) # Check the fitting for loose bolts. If the bolts are tight, replace the fitting O-ring. # Fluid leaks at the swagged joint Replace the outlet hose.2004 Honda Element DX 2003-06 STEERING Power Steering - Element Fluid leaks from | Check the hose for damage, deterioration, the power or improper assembly. Replace or repair as steering pump necessary. inlet hose (low- SYMPTOM TROUBLESHOOTING HARD STEERING 1 Check the power assist (see STEERING WHEEL ROTATIONAL PLAY CHECK ). Is the starting load more than 29 N (3.0 kgf, 6.6 bf)? YES- Go to step 2 NO- Power assist is OK. Measure steady-state fluid pressure from the pump at idle with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ) or T/N 07406-001000A, (see PUMP PRESSURE TEST WITH T/N 07406-001000A ). Is the pressure 1,470 kPa (15.0 kefcm? , 213 psi) or less? YES- Go to step 3 NO- Go to step 7 Measure the pump relief pressure at idle with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ) or T/N 07406-001000A (see PUMP PRESSURE TEST WITH T/N 07406-001000A ). Is the pressure 7,460- 8,140 kPa (76-83 kefem? , 1,080- 1,180 psi) or less? YES- Go to step 4 NO- Faulty pump assembly With a spring scale, measure the power assist in both directions, to the left and to the right. Are the two measurements within 2.9 N (0.3 kgf, 0.66 lbf) of each other? YES- Go to step 5. NO- Go to step 8 Measure the fluid pressure with T/N 07406-0010001 (see step 12 on page 17-9) or with TIN 07406-001000A (see step 10 on page 17-10) with both pressure gauge valves open2004 Honda Element DX 2003-06 STEERING Power Steering - Element (if so equipped), while turning the steering wheel fully to the left and fully to the right Is the pressure 7,460- 8,140 kPa (76- 83 kef'em? , 1,080- 1,180 psi) or less? YES- Go to step 6 NO- Faulty gearbox. 6. Adjust the rack guide (see RACK GUIDE ADJUSTMENT ), and retest. Is the steering OK? YES- Repair is completed. NO- Faulty gearbox 7. Check the feed and return lines between the pump and the gearbox for clogging and deformation. Are the lines clogged or deformed? YES- Repair or replace the lines. NO- Faulty valve body unit or pump. 8. Check the cylinder lines for deformation (see FLUID LEAKAGE INSPECTION ). Are the lines deformed? YES- Replace the lines. NO- Go to step 9. 9. Check for a bent rack shaft or misadjusted rack guide (too tight) Is the rack shaft bent or the rack guide adjusted too tight? YES- Replace the rack shaft or readjust the rack guide. NO- Faulty valve body unit. STEERING WHEEL ROTATIONAL PLAY CHECK 1. Tum the front wheels to the straight ahead position 2. Measure how far you can turn the steering wheel left and right without moving the front wheels. « If the play is within the limit, the gearbox and linkages are OK. « If the play exceeds the limit, adjust the rack guide (see RACK GUIDE ADJUSTMENT ). If the play is still excessive after rack guide adjustment, inspect the steering linkage and gearbox (see STEERING LINKAGE AND GEARBOX INSPECTION ),2004 Honda Element DX 2003-06 STEERING Power Steering - Element Rotational play: 0-10 mm (0-0.39 in.) G03678900 Fig. 3: Identifying Steering Wheel Rotational Play Limit Courtesy of AMERICAN HONDA MOTOR CO., INC. POWER ASSIST CHECK NOTE: This test should be done with original equipment tires and wheels at the correct tire pressure. 1. Check the power steering fluid level (see FLUID REPLACEMENT ). 2. Start the engine, let it idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 3. Attach a commercially available spring scale to the steering wheel. With the engine idling and the vehicle on a clean, dry floor, pull the scale as shown and read it as soon as the tires begin to turn. « If the scale reads no more than specifications, the gearbox and pump are OK. If the scale reads more than specifications, troubleshoot the steering system (see SYMPTOM TROUBLESHOOTING ). Initial turning load: 29 N (3.0 kgf, 6.6 Ibf) G03678901 Fig. 4: Checking Initial Turning Load Courtesy of AMERICAN HONDA MOTOR CO,, I2004 Honda Element DX 2003-06 STEERING Power Steering - Element STEERING LINKAGE AND GEARBOX INSPECTION Boots Inopect for éemage and deterioration. STEERING COLUMN Inspect for loose mounting ‘STEERING JOINT Shastra ent bot — ‘STEERING GEARBOX aS inspect forfoose mounting naroware (GEARBOX MOUNTING CUSHIONS BALL JOINT BOOT Iepect fr detetoraton Frepstion dao “He-Ro0 LockwuT. Cfeettoriesrelocknst.——_y¢\ng0 ENO BALL JomT Inspect tor suty movement and damage, g Steering Linkage And Gearbox Components Courtesy of AMERICAN HONDA MOTOR CO., INC. PUMP PRESSURE TEST WITH TIN 07406-0010001 Special Tools Required « P/S joint adapter (pump) 07VAK-P8AOI1A « P/S joint adapter plate (pump) 07ZAK-S7CA100 « P/S joint adapter (hose) 07ZAK-S7CA200 « P/S pressure gauge 07406-0010001 Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox, 1. Check the power steering fluid level (see FLUID REPLACEMENT ).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the alternator, frame, and other parts. Install the P/S joint adapter (pump) on the pump outlet (B). 07406-0010001 07ZAK-S7CA200 07ZAK-S7CA100 07VAK-P8A011A 03678903 Fig. 6: Disconnecting Pump Outlet Hose And Installing P/S Joint Adapter On Pump Outlet With Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., I 3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump2004 Honda Element DX 2003-06 STEERING Power Steering - Element 4 5. outlet hose to the P/S joint adapter (hose), Install the P/S pressure gauge to the P/S joint adapter (pump) Fully open the shut-off valve (A) G03678904 Fig. 7: Identifying Pressure Control And Shut-Off Valve Courtesy of AMERICAN HONDA MOTOR CO., [ Fully open the pressure control valve (B). Start the engine, and let it idle Tum the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (70°C). Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the pressure should be no more than 1,470 kPa (15.0 kgf/em” , 213 psi). If the pressure is too high, check the outlet hose or valve body unit (see Steering System2004 Honda Element DX 2003-06 STEERING Power Steering - Element Troubleshooting). Raise the engine speed to 3,000 RPM, and measure the fluid pressure. If the pump is in good condition, the pressure should be at least 1,470 kPa (15.0 kgffem? , 213 psi). If the pressure is too high, repair or replace the pump. Lower the engine speed, and let it idle. Close the shut-off valve, then close the pressure control valve gradually until the pressure gauge needle is stable. Read the pressure. NOTE: Do not keep the shut-off valve closed more than 5 seconds, or the pump could be damaged by over-heating. Immediately open the shut-off valve fully. If the pump is in good condition, the gauge should read at least this specification 7,460-8,140 kPa (76-83 kgf/cm? , 1,080-1,180 psi) A low reading means pump output is too low for full assist. Repair or replace the pump. PUMP PRESSURE TEST WITH T/N 07406-001000A Special Tools Required P/S joint adapter (pump) 07VAK-P8A011A P/S joint adapter plate (pump) 07ZAK-S7CA100 P/S joint adapter (hose) 07ZAK-S7CA200 P/S pressure gauge 07406-001000A Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox 1 2 Check the power steering fluid level (see FLUID REPLACE! IT). Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the alternator, frame, and other parts. Install the P/S joint adapter (pump) on the pump outlet (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07ZAK-S7CA200 07406-001000A 6x 1.0mm 11N-m (1.1 kgf. 8.0 Ibf-Ft) 07ZAK-S7CA100 07VAK-P8A011A 03678905 Fig. 8: Checking Power Steering Fluid Pressure And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump outlet hose to the P/S joint adapter (hose). 4. Install the P/S pressure gauge to the P/S joint adapter (pump). 5. Open the pressure control valve (A) fully.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678906 Fig. 9: Identifying Pressure Control Valve Courtesy of AMERICAN HONDA MOTOR CO., I 6. Start the engine, and let it idle. 7. Tur the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (70°C). 8. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the pressure should be no more than 1,470 kPa (15.0 kgf/em? , 213 psi). If the pressure is too high, check the outlet hose or valve body unit (see Steering System Troubleshooting). Raise the engine speed to 3,000 RPM, and measure the fluid pressure. If the pump is in good condition, the pressure should be at least 1,470 kPa (15.0 kgf/cm” , 213 psi). If the pressure is too high, repair or replace the pump. 0. Lower the engine speed, and let it idle. Close the shut-off valve gradually until the °2004 Honda Element DX 2003-06 STEERING Power Steering - Element pressure gauge needle is stable, Read the pressure. NOTE: Do not keep the shut-off valve closed more than 5 seconds, or the pump could be damaged by over-heating. 11, Immediately open the shut-off valve fully. If the pump is in good condition, the gauge should read at least this specification 7,460-8,140 kPa (76-83 kgf/em? , 1,080-1,180 psi) A low reading means pump output is too low for full assist. Repair or replace the pump. FLUID LEAKAGE INSPECTION PUMP ASSEMBLY / Check for leaks ate / Stal atthe inlet ad ote tings (EARBOX ond VALVE BODY UNIT hector eane ot the mating Surace Snd tre nut connections 7 “amoge eas 2.godowisig ic hnes on sing kee eous at hose sna ne Jom and aconatetions Fig. 10: Identifying Power Steering Fluid Leakage Components Courtesy of AMERICAN HONDA MOTOR CO., INC. FLUID REPLACEMENT Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Honda Power Steering Fluid. Using any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather2004 Honda Element DX 2003-06 STEERING Power Steering - Element System capacity: 0.83 L (0.87 US. qt) at disassembly Reservoir capacity: 0.27 L (0.28 US. qt) G03678908 Courtesy of AMERICAN HONDA MOTOR CO., INC. 1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603678909 Fig. 12: Identifying Reservoir Hoses And Upper Level Line Courtesy of AMERICAN HONDA MOTOR CO., INC, Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut-off the engine. Discard the fluid. Reinstall the return hose on the reservoir. Fill the reservoir to the upper level line (C). Start the engine, and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system. Recheck the fluid level, and add more if necessary. Do not fill the reservoir beyond the upper level line, Ththe tint ciconteminated (daritoridiscoloredurencathe praceduratactnce2004 Honda Element DX 2003-06 STEERING Power Steering - Element POWER STEERING HOSE, LINE, AND PRESSURE SWITCH REPLACEMENT 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 clamps for deterioration or deformation; replace the clamps with new ones if necessary « Add the recommended power steering fluid to the specified level on the reservoir, and check for leaks ADJUSTABLE HOSE CLAMP (A HOSE CLAMP 8 6 mo 6 {iF 25-55mm 20-40mm Greens iots“oomn) Fgh, 8.0 PUMP INLET HOSE FEED HOSE, A RETURN UNE FLARE NUT Fpeoyoserianenor 8h - es ekg 21 me ' > Bako, 27 wey rowensteEnng, / PrcssUne swe nevunwnose (i 2kgtm.6.7 mth) INDER LINE FLARE NUTS STN watz A 13: Identifying Clamp Distance From Hose End And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC.2004 Honda Element DX 2003-06 STEERING Power Steering - Element PUMP REPLACEMENT Place a suitable container under the vehicle. Drain the power steering fluid from the reservoir. Remove the drive belt (A) from the pump pulley (see DRIVE BELT REPLACEMENT ). eye 6x 1.0mm 11N-m (1.1 kgf-m, 8.0 Ibf-ft) E - 22N-m - (2.2 kgf-m, 16 Ibf-ft) 603678911 Fig. 14: Removing Power Steering Pump And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 4. Cover the auto-tensioner, alternator, and A/C compressor with several shop towels to protect them from spilled power steering fluid. Disconnect the pump inlet hose (B) and the pump outlet hose (C) from the pump (D), and plug them. Take care not to spill the2004 Honda Element DX 2003-06 STEERING Power Steering - Element fluid on the body or parts. Wipe off any spilled fluid at once. Do not turn the steering wheel with the pump removed, Remove the pump mounting bolts (E). Cover the opening of the pump with a piece of tape to prevent foreign material from entering the pump. Connect the pump inlet hose and the pump outlet hose with a new O-ring. Loosely install the pump in the pump bracket with the mounting bolts, then tighten the pump fittings securely. Install the drive belt (A). Note these items during belt installation: * Make sure that the belt is properly positioned on the pulleys (B). * Do not get power steering fluid or grease on the auto-tensioner, alternator, A/C compressor, and drive belt or pulley faces. Clean off any fluid or grease before installation.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678912 Fig. 15: Identifying Drive Belt And Pulley Courtesy of AMERICAN HONDA MOTOR CO., INC. 10. Tighten the pump mounting bolts to the specified torque 11. Fill the reservoir to the upper level line (see FLUID REPLACEMENT ). PUMP OVERHAUL EXPLODED VIEW in assembly if the parts indicated with asterisk (*) are worn or Replace the pump anaconda2004 Honda Element DX 2003-06 STEERING Power Steering - Element qe re comnsens f "ero B23Rn came WJARER EAL St [Bask colon anes Witte /-SIDE PLATE oe 214, ° @ ae pumpnouswa car Heonee Boke, 22me40 "code / * ROLL PIN a moron 1221 9mm O-RING a Fepicce Le Samm [23x 19mm ONG \ MAG, Ba wee é sangre 0 RY cn ao Pump paivesHarT / BALL BEARING 2 Y agra eee fers Sg Oe 16: Exploded View Of Power Steering Pump And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. Special Tools Required Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pulley holder 07ZAB-S5A0100 Disassembly NOTE: Refer to the EXPLODED VIEW as needed during the following procedure.2004 Honda Element DX 2003-06 STEERING Power Steering - Element we Svrwri)|s Drain the fluid from the pump (see FLUID REPLACEMENT ). Remove the power steering pump (see PUMP REPLACEMENT ) Hold the power steering pump (A) in a vise with soft jaws (B), hold the pulley (C) with the special tool (D), and remove the pulley nut (E) and pulley, Be careful not to damage the pump housing with the jaws of the vise. G03678914 Fig. 17: Disassembling Pump Courtesy of AMERICAN HONDA MOTOR CO., I Remove the inlet joint and O-ring. Remove the pressure control valve cap, O-ring, valve spring, and pressure control valve Remove the pump housing cap, O-ring, and pump preload spring. Remove the pump cover and pump cover seals. Pull out the roll pin. Remove the outer case, cam ring, rotor, vanes, and side plate. Remove the rubber seal and slipper seal from the outer case.2004 Honda Element DX 2003-06 STEERING Power Steering - Element il 12, Remove the O-rings from the bottom of the housing. Remove the 40 mm internal snap ring, then remove the pump driveshaft by tapping the shaft end with the plastic hammer. Remove the seal from the pump housing. Inspection Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve 03678915 Fig. 18: Identifying Pressure Control Valve Courtesy of AMERICAN HONDA MOTOR CO., INC. Inspect the bore of the pressure control valve on the pump housing for scratches and wear. Slip the pressure control valve (A) back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 17 ; if not, replace the pump as an assembly. The pressure control valve is not available separately2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678916 Fig. 19: Checking Pressure Control Valve Movements Courtesy of AMERICAN HONDA MOTOR CO., INC. 17. Attach a hose (A) to the end of the pressure control valve (B) as shown, Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and blow in the hose « Ifair bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm? , 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately « If the pressure control valve is OK, set it aside for reassembly later.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678917 Fig. 20: Attaching Hose To End Of Pressure Control Valve Courtesy of AMERICAN HONDA MOTOR CO., INC. 18. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B)2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678918 Fig. 21: Removing And Installing Ball Bearing Courtesy of AMERICAN HONDA MOTOR CO,, I 19, Inspect each part shown with an asterisk in the Exploded View; if any of them are worn or damaged, replace the pump as an assembly Reassembly 20. Install the new pump seal (A) (with its grooved side facing in) into the pump housing2004 Honda Element DX 2003-06 STEERING Power Steering - Element (B) by hand first, then drive it in using the special tools, and the seal is fully seated in the pump housing. Do not apply more than 1,370 N (140 kef, 308 Ibf) of pressure. 07749-0010000 07746-0010100 G03678919 Fig, 22: Installing New Pump Seal Into Pump Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 21. Position the pump driveshaft (A) in the pump housing, then press it in with the appropriate size socket wrench (B) as shown.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678920 23: Positioning Pump Driveshaft In Pump Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 22. Install the 40 mm internal snap ring (C) with its radius edge facing out 23. Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it on the bottom (B) of the pump housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678921 Fig. 24: Positioning O-Ring On Bottom Of Pump Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 24. Coat the new cover seals (A) and (B), and new 13.0 mm O-ring (‘06 model only) (C) with power steering fluid, then position them into the grooves on the cover (D) NOTE: For '06 model, be careful not to exchange the 13.0 mm O-ring and the inlet joint O-ring because they are same sizes.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678922 Fig. 25: Positioning Cover Seals And O-Ring Into Grooves On Cover Courtesy of AMERICAN HONDA MOTOR CO., INC. 25. Install the outer case (A) by aligning the slot (B) inside the outer case with the cover roll pin hole (C). Be sure that the slit (D) on the outer case is in the direction shown.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678923 Fig. 26: Installing Outer Case By Aligning Slot Inside Outer Case Courtesy of AMERICAN HONDA MOTOR CO., INC. Apply power steering fluid to the rubber seal (E) (black), and install it in the slot (F) of the outer case. Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you just installed. Install the cam ring (A) by aligning the slot (B) with the slot (C) in the outer case.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678924 Fig. 27: Installing Cam Ring By Aligning Slot With Slot In Outer Case Courtesy of AMERICAN HONDA MOTOR CO., INC. 29. Insert the roll pin (D) into the slots between the cam ring and outer case, then push the roll pin into the set hole (E). 30. Install the rotor (A) in the cam ring (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678925 Fig. 28: Installing Rotor In Cam Ring Courtesy of AMERICAN HONDA MOTOR CO,, I Set the 11 vanes (C) in the grooves in the rotor. Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring. 32. Place the side plate (A) on the cam ring, and align the roll pin set hole (B) with the roll pin (C).2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678926 Fig. 29: Aligning Roll Pin Set Hole With Roll Pin Courtesy of AMERICAN HONDA MOTOR CO., INC.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 33. Coat the new O-ring (D) with power steering fluid, then position it into the groove on the side plate. 34. Install the pump housing (A) over the cover assembly (B). G03678927 Fig. 30: Installing Pump Housing Over Cover Assembly Courtesy of AMERICAN HONDA MOTOR CO., INC. 35. Align the bolt holes in the cover (A) with the threaded holes in the pump housing Install the flange bolts loosely first, then torque the flange bolts in a criss-cross pattern in two or more steps.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 8x 1.25 mm 20N-m (2.0 kgf-m, 14 Ibf-ft} G03678928 ‘ig. 31: Installing Flange Bolts And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 36. Push in the cam ring (A) from the pump housing cap hole (B) with a flat-tip screwdriver to make sure the cam ring is fully seated against the outer case.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678929 Fig. 32: Pushing In Cam Ring From Pump Housing Cap Hole Courtesy of AMERICAN HONDA MOTOR CO., I 37. Install the pump preload spring (A) in the pump housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element Ot 29 N-m (3.0 kgf-m, 22 Ibf-ft) 03678930 Fig. 33: Installing Pump Preload Spring In Pump Housing And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 38. Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C). 39. Install the pump housing cap on the pump housing, and tighten it to the specified torque. 40. Install the pressure control valve spring (A) in the pump housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 41 42. 43. 44. ares ed | \ D 49N-m (5.0 kgf-m, 36 Ibf-ft) 03678931 Fig. 34: Installing Pressure Control Valve Spring In Pump Housing And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. Coat the pressure control valve (B) with power steering fluid, and install it in the pump housing Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the pressure control valve cap (D). Install the pressure control valve cap on the pump housing, and tighten it to the specified torque. Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678932 Fig. 35: Installing New O-Ring On Inlet Joint And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 45. Install the inlet joint on the pump housing. 46. Install the pulley (A), then loosely install the pulley nut (B). Hold the power steering pump in a vise with soft jaws (C). Be careful not to damage the pump housing with the jaws of the vise.2004 Honda Element DX 2003-06 STEERING Power Steering - Element B 64N-m (6.5 kgf-m, 47 Ibf-ft) 'G03678933 Fig. 36: Assembling Power Steering Pump And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 47. Hold the pulley with the special tool, and tighten the pulley nut to the specified torque. 48. Check that the pump turns smoothly by turning the pulley by band. If it turns hard, loosen the four flange bolts on the cover, then retighten them as in step 35 . Turn the pump again by hand STEERING WHEEL REMOVAL SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ) and the precautions and procedures (s PRECAUTIONS AND PROCEDURES ) before performing repairs or service. 1. Make sure you have the anti-theft codes for the audio, then write down the customer's audio presets 2. Align the front wheel: wheel (see DRIVER"! straight ahead, then remove the driver's airbag from the steering AIRBAG REPLACEMENT ).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 3. Disconnect the horn switch connector (A), radio remote switch connector (B), and the cruise control set/decel, Resume/accel, Cancel switch connector (C) G03678934 Fig. 37: Identifying Horn Switch, Radio Remote Switch And Cruise Control Switch Connector Courtesy of AMERICAN HONDA MOTOR CO., INC, 4. Loosen the steering wheel bolt (D). Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller. wa 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. If you thread the puller bolts (D) into the wheel hub more than five threads, the2004 Honda Element DX 2003-06 STEERING Power Steering - Element 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 603678935 Fig. 38: Installing Commercially Available Steering Wheel Puller On Steering Wheel Courtesy of AMERICAN HONDA MOTOR CO., INC. 6. Remove the steering wheel puller, then remove the steering wheel bolt and steering wheel from the steering column2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678936 Fig. 39: Removing Steering Wheel Bolt Courtesy of AMERICAN HONDA MOTOR CO., INC. STEERING WHEEL DISASSEMBLY/REASSEMBLY2004 Honda Element DX 2003-06 STEERING Power Steering - Element DAMPER STEERING WHEEL STEERING WHEEL HORN PLATE Rea COVER SUDE SCREW = “€ aS _--pignewore £y TOSEX model) 7 i © oe N i \ ae ~ gauise CONTROL SET/DECEL, a RES/ACCEL, CANCEL SWITCH — STEERING WHEEL TRIM Fig. 40: Exploded View Of Steering Wheel Courtesy of AMERICAN HONDA MOTOR CO., INC. STEERING WHEEL INSTALLATION 1, Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops, Then rotate it counterclockwise about two and a half turns, The arrow mark (B) on the cable reel label should point straight up.2004 Honda Element DX 2003-06 STEERING Power Steering - Element N G03678938 Fig. 41: Identifying Arrow Mark On Cable Reel Label Should Point Straight Up Courtesy of AMERICAN HONDA MOTOR CO., INC. Position the two tabs (A) of the turn signal cancelling sleeve (B) as shown. Install the steering wheel on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the canceling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678939 Fig. 42: Installing Cable Reel And Tabs To The Cancelling Sleeve Courtesy of AMERICAN HONDA MOTOR CO., INC. Install the steering wheel bolt (A), and tighten it to the specified torque. Connect the horn switch connector (B), radio remote switch connector (C), and Set/decel, Resume/accel, Cancel switch connector (D). Make sure the wire harness is routed and fastened properly2004 Honda Element DX 2003-06 STEERING Power Steering - Element 2 7 A 39N-m (4.0 kgf-m, 29 Ibf-ft) G03678940 Fig. 43: Installing Steering Wheel Components And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. Install the driver's airbag, and confirm that the system is operating properly (see DRIVER'S AIRBAG REPLACEMENT ). Do the power window control unit reset procedure (see RESETTING THE POWER WINDOW CONTROL UNIT ). Enter the anti-theft codes for the audio, then enter the customer's audio presets. Reset the clock. Check the horn and turn signal cancelling for proper operation STEERING COLUMN REMOVAL AND INSTALLATION SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ) and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before performing repairs or service. REMOVAL2004 Honda Element DX 2003-06 STEERING Power Steering - Element 1. Make sure you have the anti-theft codes for the audio, then write down the customer's audio presets Disconnect the battery. Remove the steering wheel (see STEERING WHEEL REMOVAL ). Remove the driver's dashboard lower cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ). 5. Remove the column covers (A). FON agen (team, rior Fig. 44: Exploded View Of Steering Column And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 6. Disconnect the wire harness connectors from the combination switch assembly (B). 7, Remove the combination switch assembly from the steering column shaft by removing the screw (C) on the top of the combination switch. 8. Disconnect the connectors from the ignition switch, and release the wire harness clips (D) from the steering column Disconnect the steering joint (E), and remove it from the column shaft. 10. Remove the steering column (F) by removing the attaching nuts and bolts. INSTALLATION 1. Install the steering column in the reverse order of removal, and note these items:2004 Honda Element DX 2003-06 STEERING Power Steering - Element « Take care not to let the sliding capsules fall out of position during column installation. Make sure the wires are not caught or pinched by any parts Insert the upper end of the steering joint onto the steering shaft (A) (line up the bolt hole (B) with the flat portion (C) on the shaft). FRONT TO Gosg7a9422004 Honda Element DX 2003-06 STEERING Power Steering - Element 6 Fig. 45: Inserting Upper End Of Steering Joint Onto Steering Shaft Courtesy of AMERICAN HONDA MOTOR CO., INC. Slip the lower end of the steering joint onto the pinion shaft (D) taking care to align gap it lower end of steering joint with the tab (E) of the center guide, Punch mark (F) on the pinion shaft (line up the bolt hole with the groove (G) around the shaft), and loosely install the lower joint bolt. Be sure that the lower joint bolt is securely in the groove of the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Then install the upper joint bolt and tighten it to the specified torque. Tighten the lower joint bolt to the specified torque. Finish the installation, and note these items: « Make sure the wire harness is routed and fastened properly. * Make sure the connectors are properly connected, Reinstall the steering wheel (see STEERING WHEEL INSTALLATION ), Reconnect the battery. = Do the power window control unit reset procedure (see RESETTING THE POWER WINDOW CONTROL UNIT ). = Enter the anti-theft codes for the audio, then the customer's audio presets. Reset the clock. « Verify horn and turn signal switch operation * Check wheel alignment, and adjust it if necessary (see WHEEL ALIGNMENT ). STEERING COLUMN TILT OPERATION CHECK N ww Set the steering wheel in the straight driving position, and loosen the tilt lever fully Attach the spring scale to the highest point of the steering wheel, and set the tilting position at the lowest Pull the spring scale straight up, and read the operation load during tilting. Attach the spring scale to the lowest point of the steering wheel. Pull the spring scale straight down, and read the operation load during tilting Tilting load (upward/downward): Standard: 68 N (7.0 kgf, 15 Ibf) or below2004 Honda Element DX 2003-06 STEERING Power Steering - Element UPWARD t DOWNWARD G03678943 Fig. 46: Checking Steering Column Tilt Operation Courtesy of AMERICAN HONDA MOTOR CO., INC.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 6. If the measurement is more than the specification, adjust the tilt lever preload (see step 1). STEERING COLUMNITILT LEVER INSPECTION/ADJUSTMENT * Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly # Check the sliding capsules (C) for distortion and breakage. If there is distortion or breakage, replace the steering column as an assembly. 47: Identifying Steering Column/Tilt Lever Components “ourtesy of AMERICAN HONDA MOTOR CO., INC. TILT LEVER PRELOAD INSPECTION 1. Move the tilt lever (A) from the loose position to the lock position 3 to 5 times; then measure the tilt lever preload 10 mm (0.39 in.) from the end of the tilt lever. Preload: 70-90 N (7-9 kgf, 15-20 Ibf)2004 Honda Element DX 2003-06 STEERING Power Steering - Element 10 mm (0.39 in.) = G03678945 Fig. 48: Measuring Tilt Lever Preload Courtesy of AMERICAN HONDA MOTOR CO., INC. 2. Ifthe measurement is out of the specification, adjust the preload using the following procedures. * Loosen the tilt lever, and set the steering column in the neutral position. « Remove the 6 mm lock bolt (B), and remove the stop (C). Be careful not to loosen the tilt lever when installing the stop or tightening the 6 mm lock bolt. * Adjust the preload by turning the tilt lock bolt (D) left or right « Pull up the tilt lever to the uppermost position, and install the stop. Check the preload again, If the measurement is still out of specification, repeat the above procedures to adjust STEERING LOCK REPLACEMENT2004 Honda Element DX 2003-06 STEERING Power Steering - Element N Remove the steering column (see STEERING COLUMN REMOVAL AND INSTALLATION ), Center-punch each of the two shear bolts, and drill their heads off with a 5 mm (3/16 in.) drill bit. Be careful not to damage the switch body when removing the shear bolts G03678946 Fig. 49: Drilling Shear Bolts Heads Courtesy of AMERICAN HONDA MOTOR CO., INC.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 3. Remove the shear bolts from the switch body 4. Install the switch body without the key inserted. Loosely tighten the new shear bolts. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns freely. 7. Tighten the shear bolts (A) until the hex heads (B) twist off. au 603678947 Fig. 50: Identifying Shear Bolts And Hex Heads Courtesy of AMERICAN HONDA MOTOR CO., INC. RACK GUIDE ADJUSTMENT Special Tools Required Locknut wrench, 40 mm 07916-SA50001 1. Set the wheels in the straight ahead position: 2. Loosen the rack guide screw locknut (A) with the special tool, then remove the rack guide screw (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07916-SA50001 03678948 Fig. 51: Loosening Rack Guide Screw Locknut Using Special Tool Courtesy of AMERICAN HONDA MOTOR CO., INC 3. Remove the old sealant from rack guide screw (A), and apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads (B), Loosely install the rack guide screw in the steering gearbox.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678949 Fig. 52: Identifying Rack Guide Screw And Threads Courtesy of AMERICAN HONDA MOTOR CO., INC. 4. Tighten the rack guide screw (A) to 25 N.m (2.5 kgf.m, 18 Ibf.ft), then loosen it2004 Honda Element DX 2003-06 STEERING Power Steering - Element 25 N-m | (2.5 kgf-m, 18 Ibf-ft) G03678950 Fig. 53: Identifying Rack Guide Screw Tightening Torque With Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. Retighten the rack guide screw to 6 N.m (0.6 kgf.m, 4 Ibf.ft), then back it off to the specified angle Specified return angle: 20° Max. Hold the rack guide screw stationary with a wrench, and tighten the locknut by hand until it's fully seated. Install the special tool on the locknut (B), and hold the rack guide screw stationary with awrench. Tighten the locknut an additional 30° with the special tool Check for unusual steering effort through the complete turning travel.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 9. Check the steering wheel rotational play and the power assist (see STEERING WHEEL ROTATIONAL PLAY CHECK ). STEERING GEARBOX REMOVAL Special Tools Required Ball joint thread protector, 12 mm 07AAF-SDAA100 # Ball joint remover, 28 mm 07MAC-SLOA202 Note these items during removal: Using solvent and a brush, wash any oil and dirt off the valve body unit, its lin the end of the gearbox. Blow dry with compressed air. Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur. 1. Raise the front of vehicle, and support it with safety stands in the proper locations (see SAFETY STANDS ). 2, Remove the front wheels. 3. Remove the steering wheel (see STEERING WHEEL REMOVAL ). 4, Remove the driver's dashboard lower cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ). 5. Remove the steering joint bolts, and disconnect the steering joint by moving the steering joint (A) toward the column.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678951 Fig. 54: Removing Steering Joint Bolts Courtesy of AMERICAN HONDA MOTOR CO., INC. Remove the center guide from the top of the pinion shaft (B) (if equipped), and discard it. 7. Remove the cotter pin (A) from the tie-rod ball joint nut (B), and loosen the nut2004 Honda Element DX 2003-06 STEERING Power Steering - Element O7AAF-SDAA100 O7MAC-SLOA202 G03678952 Fig. 55: Removing Cotter Pin From Tie-Rod Ball Joi Courtesy of AMERICAN HONDA MOTOR CO.,, I 8, Separate the tie-rod ball joint and damper steering arm using the ball joint thread protector and ball joint remover (see BALL JOINT REMOVAL ). Repeat on the other side of the vehicle. 9. Remove the P/S heat baffle plate (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678953 Fig. 56: Removing P/S Heat Baffle Plate Courtesy of AMERICAN HONDA MOTOR CO., INC. 10, Remove the engine wire harness clamp and clip (A) from the two mounting brackets.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678954 Fig. 57: Removing Engine Wire Harness Clamp And Clip From Two Mounting Brackets Courtesy of AMERICAN HONDA MOTOR CO., I 11. Loosen the adjustable hose clamp (A) and disconnect the return hose (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 14x 1.5 mm 03678955 Fig. 58: Identifying Adjustable Hose Clamp And Return Hose Courtesy of AMERICAN HONDA MOTOR CO., INC. 12. Loosen the 14 mm flare nut (C), and disconnect the feed line (D) 13. Open the hose holders (A) on the return hose, and remove the return hose clamp bolt ().2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678956 Fig. 59: Removing Return Hose Clamp Bolt Courtesy of AMERICAN HONDA MOTOR CO., INC. 14. Disconnect the power steering pressure switch connector (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603678957 Fig. 60; Disconnecting Power Steering Pressure Switch Connector Courtesy of AMERICAN HONDA MOTOR CO., INC. 15. Remove the feed line (B) on the P/S line mounting bracket (C), and move it aside. 16. Remove the body stiffener (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element ene 10 x 1.25 mm G03678958 Fig. 61: Removing Body Stiffener Courtesy of AMERICAN HONDA MOTOR CO., INC. 17, Remove the two 10 mm flange bolts (A) and washers (B) from the left side of gearbox:2004 Honda Element DX 2003-06 STEERING Power Steering - Element A [peer B o, Oi Fy G03678959 Fig. 62: Removing Two 10 Mm Flange Bolts And Washers From Left Side Of Gearbox Courtesy of AMERICAN HONDA MOTOR CO., INC. 18, Remove the 10 mm flange bolt (A) and nut (B) from the right side of gearbox, and remove the mounting bracket (C)2004 Honda Element DX 2003-06 STEERING Power Steering - Element @ S Us 10 x 1.25 mm 10 x 1.25 mm 603678960 Fig, 63: Removing Mounting Bracket Courtesy of AMERICAN HONDA MOTOR CO., INC. 19, Lower the steering gearbox, and rotate it so the pinion shaft points upward, and remove the mounting cushion (D). 20. Remove the pinion shaft grommet (A) from the top of the valve body unit2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678961 Fig. 64: Identifying Pinion Shaft Grommet Courtesy of AMERICAN HONDA MOTOR CO., INC. 21. Carefully move the steering gearbox and tie-rods as an assembly toward the driver's side until the pinion shaft (A) clears the wheelwell opening (B) on the frame.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678962 Fig, 65: Identifying Pinion Shaft And Wheelwell Opening Courtesy of AMERICAN HONDA MOTOR CO., INC. 22. Remove the steering gearbox (A) through the wheelwell opening on the driver's side Be careful not to damage the hoses, lines, and wire harnesses2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603678963 Fig. 66: Removing Steering Gearbox Courtesy of AMERICAN HONDA MOTOR CO,, I 23. Remove the P/S line mounting bracket (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678964 Fig. 67: Removing P/S Line Mounting Bracket Courtesy of AMERICAN HONDA MOTOR CO., INC. STEERING GEARBOX OVERHAUL EXPLODED VIEW2004 Honda Element DX 2003-06 STEERING Power Steering - Element SRE Dareane > Ae “ye 9 Bese as 4 fore ame guromoosn | gage wen wae a ee bn ERE x nga Ferme nary en cxaoxvousn VRE —_ ~\ Sime vc opine. BACKUP RING. oor ou Odie mpg LocxnuT _S 2007 BAND ANGE RoLT ra ack une sonew Bi soos | BMRBNAG ‘ewer’ \ \ | sackur rine x | / sea STEERING RACK clr ack eno tue Seka, 25 31 Ne 8.3 hn, 6 mor TIE-RODEND Fig. 68: Exploded View Of Steering Gearbox And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. Special Tools Required « Cylinder end seal remover attachment 07NAD-SR30200 or 07NAD-SR3020A « Driver, 27 mm 07ZAF-S5A0100 « Valve seal ring sizing tool 07NAG-SR30900 or 07NAG-SR3090A jeeve seal ring guide 07Y AG-S2X0100 « Sleeve seal ring sizing tool, 36 mm 07ZAG-S5A0100 « Attachment, 32 x 35 mm 07746-00101002004 Honda Element DX 2003-06 STEERING Power Steering - Element « Driver 07749-0010000 Piston seal ring guide, 42 mm 07ZAG-S7A0100 « Piston seal ring sizing tool, 42 mm 07ZAG-$7A0200 Pilot collar O7GAF-PH70100 « Locknut wrench 07ZAA-S5A0100 * Driver handle 07NAD-SR30101 « Cylinder end seal slider, 23 mm 07974-6890801 or 07974-689080A # Valve seal ring guide 07ZAG-S5A0200 « Pincers, Oetiker 1098 or equivalent, commercially available NOTE: Refer to the EXPLODED VIEW as needed during this procedure. Removal 1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL ). Disassembly 2. Remove cylinder lines (A) and return line joint (B) from the gearbox 03678966 Fig. 69: Identifying Cylinder Lines And Return Line Joint2004 Honda Element DX 2003-06 STEERING Power Steering - Element Courtesy of AMERICAN HONDA MOTOR CO., I 3. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth. 4, Unbend the lock washers (A) 03678967 Fig. 70: Unbending Lock Washers Courtesy of AMERICAN HONDA MOTOR CO., INC. 5. Hold the bracket (A) with one wrench, and unscrew both tie-rods (B) with another wrench. Remove the lock washers.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678968 Fig. 71: Removing Lock Washers Courtesy of AMERICAN HONDA MOTOR CO., INC. 6. Remove the stop washer (A), the 12 mm flange bolts (B), O-rings (C), and bracket (D) from the steering gearbox.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603678969 Fig. 72: Removing Stop Washer, 12 Mm Flange Bolts, O-Rings And Bracket From Steering Gearbox Courtesy of AMERICAN HONDA MOTOR CO., INC. 7, Remove the boot guard (A) by removing the 8 mm flange bolt (C) on the rack end2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678970 Fig. 73: Removing Boot Guard Courtesy of AMERICAN HONDA MOTOR CO., INC. Remove the boot band (D) and clip (E), Pull the boot B away from the end of the steering gearbox. Remove the rack end plug (F). Loosen the locknut (A), then remove the rack guide screw (B), spring (C), and rack guide (D) from the steering gearbox.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678971 Fig. 74: Removing Rack Guide Screw, Spring And Rack Guide From Steering Gearbox Courtesy of AMERICAN HONDA MOTOR CO., INC. 10. Remove the internal snap ring (A) and backup ring (B) from the cylinder housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678972 Fig. 75: Removing Internal Snap Ring And Backup Ring From Cylinder Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 11. Remove the valve body unit (A) from the steering gearbox. Remove the O-ring (B) and discard it.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678973 Fig. 76: Removing Valve Body Unit From Steering Gearbox2004 Honda Element DX 2003-06 STEERING Power Steering - Element Courtesy of AMERICAN HONDA MOTOR CO., INC. 12. Remove the two boot bands (B) from boot A. Compress boot A by hand, and apply vinyl tape (C) so the boots stay collapsed and pulled back. G03678974 Fig. 77: Removing Two Boot Bands From Boot Courtesy of AMERICAN HONDA MOTOR CO., I2004 Honda Element DX 2003-06 STEERING Power Steering - Element 13, Hold the gearbox housing using a C-clamp (commercially available) (A) and the wooden blocks (B) as shown. Do not clamp the cylinder part of the housing or gearbox housing in the vise. 03678975 Fig. 78: Holding Gearbox Housing Using C-Clamp And Wooden Blocks Courtesy of AMERICAN HONDA MOTOR CO., INC. 14, Install the special tool (A) on the lock screw (B), then loosen and remove the lock screw from inside of the gearbox housing (C)2004 Honda Element DX 2003-06 STEERING Power Steering - Element A 07ZAA-S5A0100 G03678976 Fig. 79: Removing Lock Screw Using Special Tool Courtesy of AMERICAN HONDA MOTOR CO., I 15. Remove the special tool 16. Pull on the cylinder to remove it from the gearbox housing. Remove boot A and the slider guide (B) from the cylinder.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678977 80: Removing Boot And Slider Guide From Cylinder sy of AMERICAN HONDA MOTOR CO., INC. 17. Check the slider guide for damage and cracks. Use vernier calipers to measure the thickness of the slider guide. If the thickness is less than the service limit (A), replace the slider guide2004 Honda Element DX 2003-06 STEERING Power Steering - Element A A 25.3 mm 25.3 mm {0.925 in.) (0.925 in.) 03678978 Fig. 81: Identifying Thickness Of Slider Guide Courtesy of AMERICAN HONDA MOTOR CO., INC. 18. Remove and discard the stop ring (A) on the cylinder by expanding it with snap ring pliers. Remove and discard the lock screw (B) 603678979 Fig. 82: Removing Stop Ring And Lock Screw urtesv of AMERICAN HONDA MOTOR C2004 Honda Element DX 2003-06 STEERING Power Steering - Element 19, Set the cylinder housing (A) in a press so the cylinder side points downward, then press the cylinder end seal (B) and steering rack (C) out of the cylinder. Hold the rack to keep it from falling when pressed clear 4 03678980 Fig. 83: Pressing Cylinder End Seal And Steering Rack Out Of Cylinder Courtesy of AMERICAN HONDA MOTOR CO., INC.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 20. Remove the cylinder end seal from the steering rack. 21. Insert the special tools into the cylinder. Make sure the attachment (A) of the special tools is securely positioned on the bushing edges (B) 07NAD-SR30101 A 07NAD-SR30200 or 07NAD-SR3020A G036789812004 Honda Element DX 2003-06 STEERING Power Steering - Element Fig. 84: Inserting Special Tools Into Cylinder Courtesy of AMERICAN HONDA MOTOR CO., INC. 22. Place the cylinder in a press, then remove the cylinder end seal (C), backup ring (D), and bushing from the cylinder by pressing on the special tool end Note the items when pressing the cylinder end seal « Keep tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal * Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the cylinder end seal, and the seal would remain in the cylinder. 23. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston, Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring, 03678982 Fig. 85: Prying Piston Seal Ring And O-Ring Off Rack Piston Courtesy of AMERICAN HONDA MOTOR CO,, I 24, Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678983 Fig. 86: Removing Valve Housing Courtesy of AMERICAN HONDA MOTOR CO., I 25. Separate the valve housing from the pinion shaft/valve using a press. 26. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it.2004 Honda Element DX 2003-06 STEERING Power Steering - Element NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped. G03678984 Fig. 87: Checking Inner Wall Of Valve Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 27. 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. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678985 Fig. 88: Identifying Sleeve Edges Of Grooves Courtesy of AMERICAN HONDA MOTOR CO., INC. 28. Remove the external snap ring (A) and sleeve (B) from the pinion shaft.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678986 Fig. 89: Removing External Snap Ring And Sleeve From Pinion Shaft Courtesy of AMERICAN HONDA MOTOR CO., INC. 29. Using a cutter or an equivalent tool, cut and remove the 4 seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and the outer surface when removing the seal rings.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678987 Fig. 90; Removing 4 Seal Rings From Sleeve Courtesy of AMERICAN HONDA MOTOR CO., INC. Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the groove (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03678988 Fig, 91: Removing Valve Seal And O-Ring Courtesy of AMERICAN HONDA MOTOR CO., I 31, Remove the valve oil seal (A) and wave washer (B) from the pinion shaft. Note these items during disassembly: ‘ Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play or wear, replace the pinion shaft and sleeve as an assembly « The pinion shaft and sleeve are a precise fit, do not intermix old and new pinion shafts and sleeves.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 32. 03678989 Fig. 92: Removing Valve Oil Seal And Wave Washer From Pinion Shaft Courtesy of AMERICAN HONDA MOTOR CO., INC Press the valve oil seal (A) and roller bearing (B) out of the valve housing using a hydraulic press and special tool2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07GAF-PH70100 03678990 Fig. 93: Pressing Valve Oil Seal And Roller Bearing Using Hydraulic Press And Special Tool Courtesy of AMERICAN HONDA MOTOR CO., I Reassembly 33. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with the power steering fluid.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678991 Fig. 94: Installing Valve Oil Seal And Wave Washer Courtesy of AMERICAN HONDA MOTOR CO., INC. 34, Install the wave washer (B). Coat the inside surface of the new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). Remove the vinyl tape. 35. Install the special tool over the pinion, and coat the surface of the tool with power steering fluid. Slip the new O-ring (A) and new valve seal ring (B) over the special tool, and expand them.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07ZAG-S5A0200 G03678992 Fig, 95: Installing Special Tool Over Pinion Courtesy of AMERICAN HONDA MOTOR CO., INC. Fit the O-ring in the groove of the pinion shaft. Then slide the valve seal ring over the shaft and in the groove on the pinion shaft 37. Remove the special tool, and apply power steering fluid to the surface of the valve seal ring (A) 362004 Honda Element DX 2003-06 STEERING Power Steering - Element 40. 07NAG-SR30900 or 07NAG-SR3090A 03678993 Fig. 96: Applying Power Steering Fluid To Surface Of Valve Seal Ring Courtesy of AMERICAN HONDA MOTOR CO., INC. ‘Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring, and move the special tool up and down several times to make the valve seal ring fit in the pinion shaft groove. Remove the special tool, turn it over, and slide the smaller diameter end over the valve seal ring. Move it up and down several times to make sure the valve seal ring fits snugly in the pinion shaft groove. Apply power steering fluid to the surface of the special tool. Slip two new seal rings (A) over the special tool from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B). Note these items when installing the seal rings: + Do not over-expand the seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal rings using the special tool (sizing tool).2004 Honda Element DX 2003-06 STEERING Power Steering - Element « There are two types of sleeve seal rings; black and brown. Do not mix the different types of rings as they are not compatible J 07YAG-S2X0100 G03678994 Fig. 97: Installing Seal Rings Courtesy of AMERICAN HONDA MOTOR CO., INC. 41, Align the special tool with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily. 42. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool2004 Honda Element DX 2003-06 STEERING Power Steering - Element 43. 44. 07ZAG-S5A0100 G03678995 Fig. 98: Inserting Sleeve Into Special Tool Courtesy of AMERICAN HONDA MOTOR CO., INC. Move the sleeve back and forth several times to make the seal rings fit snugly in the sleeve. Make sure the seal rings are not twisted Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new external snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve,2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603678996 Fig. 99: Installing Pinion Shaft Components Courtesy of AMERICAN HONDA MOTOR CO., I 45. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press and special tools. Install the seal with its grooved side facing the tool.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07749-0010000 -\ 07746-0010100 603678997 Fig. 100: Installing New Valve Oil Seal Courtesy of AMERICAN HONDA MOTOR CO., I 46. Press the roller bearing (C) into the valve housing with a hydraulic press and special tools. 47. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03678998 Fig. 101: Inserting Pinion Shaft Into Valve Housing Courtesy of AMERICAN HONDA MOTOR CO., INC, 48. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C) and valve oil seal sealing lip (D). 49. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 50. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaf/sleeve turns smoothly by hand after installing it. G036789992004 Honda Element DX 2003-06 STEERING Power Steering - Element 3 54, Fig. 102: Pressing Pinion Shaft/Sleeve Into Valve Housing Using Hydraulic Press Courtesy of AMERICAN HONDA MOTOR CO., INC. Coat the special tool with power steering fluid, then slide it onto the rack, big end first. Position the new O-ring (A) and new piston seal ring (B) on the special tool, then slide them down toward the big end of the tool. Note these items during reassembly « Do not over expand the resin seal ring. Install the resin seal ring with care so as not to damage it. After installation, be sure to contract the seal ring using the special tool (sizing tool), * Replace piston's O-ring and seal ring as a set. 03679000 Fig. 103: Positioning New O-Ring And New Piston Seal Ring On Special Tool Courtesy of AMERICAN HONDA MOTOR CO., INC. Pull the 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 (A) and the inside of the special tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07ZAG-S7A0200 603679001 Fig. 104: Sliding Tool Onto Rack And Over Piston Seal Ring Courtesy of AMERICAN HONDA MOTOR CO., INC. and forth several times to make the piston ring fits Move the special tool bé snugly in the piston. Set the new bushing (A) on the special tool, and insert the special tools into the cylinder housing (B).2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07NAD-SR30101 07ZAF-S5A0100 G03679002 Fig. 105: Inserting Special Tools Into Cylinder Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 57. Set the cylinder in a press, and install the bushing into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the new bushing2004 Honda Element DX 2003-06 STEERING Power Steering - Element 58. Coat the sliding surface of the special tool (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the special tool with its grooved side (C) facing opposite the special tool A 07974-6890801 or 07974-689080A 603679003 Its Grooved Side Fig. 106: Placing Cylinder End Seal On Special Tool Courtesy of AMERICAN HONDA MOTOR CO., INC. 59. Apply a thin coat of power steering grease to the inside of the special tool 60. Install the cylinder end seal (A) onto the steering rack (B) with its grooved side (C) toward the piston (D). Make sure the gap in the special tool is opposite of rack teeth,2004 Honda Element DX 2003-06 STEERING Power Steering - Element P.S. GREASE (P/N 08C35-B0534L) 07974-6890801 or 07974-689080A 603679004 Fig. 107: Installing Cylinder End Seal Onto Steering Rack With Its Grooved Side Courtesy of AMERICAN HONDA MOTOR CO., INC. 61. Separate the cylinder end seal from the special tool, then remove the special tool.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07974-689080A 03679005 Fig. 108: Removin: Courtesy of AMERICAN HONDA MOTOR CO.,, [ 62. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C).2004 Honda Element DX 2003-06 STEERING Power Steering - Element / 603679006 Fig. 109: Installing New Backup Ring On Steering Rack Courtesy of AMERICAN HONDA MOTOR CO., INC. 63. Mark (A) a position on the steering rack surface with a felt-tip marker, 7.7 mm (0.3 in.) from the rack end, 7.7 mm (0.3 in.) — I ( | } | A 603679007 ition From Rack End Fig. 110: Identifying Steering Rack Surface Marking Po Courtesy of AMFRICAN HONDA MOTOR CO_ INC2004 Honda Element DX 2003-06 STEERING Power Steering - Element 64. Apply power steering grease to the steering rack teeth, then insert the steering rack (A) into the cylinder (B). Be careful not to damage the inner surface of the cylinder wall and bushing with the rack edges sy) P.S. GREASE (P/N 08C35-B0534L) G03679008 Fig. 111: Inserting Steering Rack Into Cylinder Courtesy of AMERICAN HONDA MOTOR CO., INC. 65. Set the cylinder (A) in a press, then press the cylinder end seal (B) into the bottom of the cylinder until the mark (C) on the rack meets the edges (D) of the cylinder.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679009 . 112: Pressing Cylinder End Seal Into Bottom Of Cylinder Courtesy of AMERICAN HONDA MOTOR CO., INC, 66. Coat the inside and outside surfaces of the new cylinder end seal (A) with power steering fluid2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679010 Fig. 113: Installing Cylinder End Seal Onto Steering Rack Courtesy of AMERICAN HONDA MOTOR CO., INC. 67. Install the cylinder end seal onto the steering rack (B) with its grooved side (C) toward the piston, Push in the cylinder end seal with your finger. 68. Place the backup ring (D) on the cylinder end seal with its flat side facing upward. Then drive the backup ring in with the appropriate size socket wrench until the its surface is below the internal snap ring groove (F). Install the snap ring (F) in the groove, 69. Install the new lock screw (A) on the cylinder.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603679011 Fig. 114: Installing New Lock Screw On Cylinder Courtesy of AMERICAN HONDA MOTOR CO., INC. 70. Install the new stop ring (B) in the groove (C) on the cylinder by expanding it with snap ring pliers. Be careful not to scratch or damage the cylinder surface with the stop ring edges. 71. Coat the housing surface with multipurpose grease as shown.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603679012 Fig. 115: Coating Housing Surface With Multipurpose Grease Courtesy of AMERICAN HONDA MOTOR CO., INC. 72. Set the new boot bands (B) on the band installation grooves of boot A by aligning the tabs (C) with the holes (D) of the band. Do not close the ear portion of the boot band yet.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679013 Fig. 116: Installing New Boot Bands Courtesy of AMERICAN HONDA MOTOR CO., INC. 73. Compress boot A by hand, and apply vinyl tape (E) to the bellows so the boots stay collapsed and pulled back. Slide boot A over the cylinder so the smaller diameter end of the boot faces the gearbox housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 74. Apply power steering grease to the sliding surface of the slider guide (A). Keep grease off of the rack-to-slider guide matching surfaces and the boot-to-slider guide matching surfaces. Slide the steering rack all the way to left, and place the slider guide on the steering rack by aligning the bolt holes (B) P.S. GREASE {P/N 08C35-B0534L) G03679014 Fig. 117: Placing Slider Guide On Steering Rack By Aligning Bolt Holes Courtesy of AMERICAN HONDA MOTOR CO., INC, 75. Hold the gearbox housing using a C-clamp (commercially available) (A) and the wooden block (B) as shown. Do not clamp the cylinder or gearbox housing in the vice.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679015 Fig. 118: Holding Gearbox Housing Using C-Clamp And Wooden Block Courtesy of AMERICAN HONDA MOTOR CO., INC, 76. Push the cylinder (A) into the gearbox housing (B) so the notch (C) is aligned with the pin (D) inside of the gearbox housing.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679016 Fig. 119: Pushing Cylinder Into Gearbox Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. 77. Tighten the lock screw (A) by hand first, then install the special tool (B) on the lock screw. Lightly tighten the lock screw. Do not tighten the lock screw to the specified torque yet2004 Honda Element DX 2003-06 STEERING Power Steering - Element B 07ZAA-S5A0100 t G03679017 Fig. 120: Installing Special Tool On Lock Screw Courtesy of AMERICAN HONDA MOTOR CO., INC. 78. Remove the special tool. 79. Coat the new O-ring (A) with power steering grease, and carefully fit it on the valve housing,2004 Honda Element DX 2003-06 STEERING Power Steering - Element P.S. GREASE (P/N 08C35-| BO534L) | ao j 603679018 Fig. 121: Installing Valve Body Unit And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 80. Apply power steering grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections). Tighten the flange bolts (D) to the specified torque. 8 Apply power steering grease to the sliding surface and circumference of the rack guide (A), and install it into the gearbox housing. Wipe the grease off the threaded section of the housing2004 Honda Element DX 2003-06 STEERING Power Steering - Element 82. 83. P.S. GREASE (P/N 08C35-B0534L) 03679019 Fig. 122: Applying Power Steering Grease And Installing Rack Guide, Spring And Rack Guide Screw To Gear Box Housing Courtesy of AMERICAN HONDA MOTOR CO., INC. Install the spring (B), and rack guide screw (C), then install and tighten it to 25 Nm (2.5 kgf.m, 18 Ibf-ft). Loosely install the locknut (D). Center the steering rack within its stroke, and align the slider guide (B) with the holes (C) in the boot A. Fit the slider guide to boot A by pressing around the edges of the holes securely.2004 Honda Element DX 2003-06 STEERING Power Steering - Element E P.S, GREASE (P/N 08C35-B0534L) G03679020 Fig. 123: Installing Bracket Courtesy of AMERICAN HONDA MOTOR CO., INC. 84. Before installing the bracket (D), clean the mating surface of the 12 mm flange bolts (E) and bracket. Coat the new O-rings (F) with power steering grease, and install them on the 12 mm flange bolts. 85. Loosely install the bracket on the steering rack by tightening the 12 mm flange bolts to 25 N.m (2.5 kgf.m, 18 Ibf.ft) 86. Hold the gearbox housing u: screw (A). Retighten the lock tool ing a C-clamp, then install the special tool on the lock rew to the specified torque values. Remove the special2004 Honda Element DX 2003-06 STEERING Power Steering - Element 07ZAA-S5A0100 162 N-m (16.5 kgf-m, 119 Ibf-ft) G03679021 Fig. 124: Installing Special Tool On Lock Screw And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 87. Retighten the 12 mm flange bolts (A) to the specified torque values.2004 Honda Element DX 2003-06 STEERING Power Steering - Element A 91 N-m (9.3 kgf-m, 67 Ibf-ft) 03679022 Fig. 125: Identifying Flange Bolts Tightening Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 88. After tightening the 12 mm flange bolts, install a new stop washer (B) over one of the bolt heads (C). Be sure the tabs (D) of the stop washer are aligned with the flat surfaces (E) of the bolt head. 89. Clean off any grease or contamination from the boot installation grooves around the housing 90. Expand boot A by removing the vinyl tape, and fit the boot ends (B) in the installation grooves on the cylinder housing2004 Honda Element DX 2003-06 STEERING Power Steering - Element 603679023 Fig. 126: Identifying Boot And Boot Ends Courtesy of AMERICAN HONDA MOTOR CO., I 91. Close the ear portion (A) of the bands (B) with a commercially available pincers. Oetiker 1098 or equivalent (C).2004 Honda Element DX 2003-06 STEERING Power Steering - Element (0.04—0,08 in.) G03679024 Fig. 127: Closing Ear Portion Of Bands Using Commercially Available Pincers Or Oetiker 1098 Courtesy of AMERICAN HONDA MOTOR CO., INC. 92. Install the rack end plug (A). Clean off any grease or contamination from the boot installation grooves (C) around the housing and the rack end plug.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 20N-m A {2.0 kgf-m, 14 Ibf-ft) 34 N-m (3.5 kgf-m, 25 Ibf-ft) 03679025 Fig. 128: Installing Rack End Plug And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC. 93. Slide the steering rack, and adjust the distance between the cylinder housing end and the end of the rack end plug to 70.5 mm (2.8 in.). Install the boot B, and set the boot end in the installation grooves in the cylinder housing and the rack end plug properly. Install the clip (D) and boot guard (E). Install the new boot band (F) in the band grooves of boot B by aligning the tabs (G) with the holes (H) in the band, 94. Close the ear portion (A) of the band (B) with a commercially available pincers, Oetiker 1098 or equivalent (C). Slide the rack right and left to be certain that the boots are not deformed or twisted,2004 Honda Element DX 2003-06 STEERING Power Steering - Element 95, (0.08—0,12 in.) G03679026 Fig. 129: Closing Ear Portion Of Band Using Commercially Available Pincers Or Oetiker 1098 Courtesy of AMERICAN HONDA MOTOR CO., INC. Install a new lock washer (A) on the tie-rod (B) with the radius side of the washer toward the tie-rod, and screw the tie-rod into the bracket (C). Repeat this step for the other tie-rod. Hold the bracket with one wrench, and tighten both tie-rods to the ecified torque with another wrench2004 Honda Element DX 2003-06 STEERING Power Steering - Element = 54N.m {5.5 kgf-m, 40 Ibf-ft) G03679027 Fig, 130: Installing New Lock Washer On Tie-Rod And Torque Spec Courtesy of AMERICAN HONDA MOTOR CO., INC. 96. Bend the lock washers (A) against the flat spots on the bracket with a large pair of pliers2004 Honda Element DX 2003-06 STEERING Power Steering - Element 03679028 Fig. 131: Bending Lock Washers Courtesy of AMERICAN HONDA MOTOR CO., INC. 97. Install the cylinder lines (A) and return line joint (B) Note these items during reassembly Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material. « Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.2004 Honda Element DX 2003-06 STEERING Power Steering - Element B 28 N-m {2.9 kgf-m, 21 Ibf-ft) 17Nm (1.7 kgf-m, 12 Ibf-ft) 03679029 Fig. 132: Installing Cylinder Lines And Tightening Flare Nuts To The Specified Torque Courtesy of AMERICAN HONDA MOTOR CO., INC. 98. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT ). After adjusting, check that the rack moves smoothly by sliding it right and left 99. Install the steering gearbox (see STEERING GEARBOX INSTALLATION ) STEERING GEARBOX INSTALLATION 1, Install the P/S line mounting bracket (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element A 6x 1.0mm g \ 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) G03679030 Fig. 133: Installing P/S Line Mounting Bracket And Torque Specifications Courtesy of AMERICAN HONDA MOTOR CO., INC, 2, Pass the cylinder of the steering gearbox (A) together with the tie-rods (B) through the wheelwell opening on the driver's side2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679031 Fig. 134: Passing Cylinder Of Steering Gearbox Together With Tie-Rods Courtesy of AMERICAN HONDA MOTOR CO., INC. 3. Carefully move the steering gearbox toward the passenger's side until the pinion shaft (A) clears the wheelwell opening (B) on the frame. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. NOTE: Make sure the power steering return hose is routed between the gearbox and right tie-rod.2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679032 Fig. 135: Identifying Pinion Shaft And Wheelwell Opening Courtesy of AMERICAN HONDA MOTOR CO., INC. 4. Install the pinion shaft grommet (A).2004 Honda Element DX 2003-06 STEERING Power Steering - Element G03679033 Fig. 136: Installing Pinion Shaft Grommet Courtesy of AMERICAN HONDA MOTOR CO., INC. Insert the pinion shaft up through the bulkhead, and place the steering gearbox on the mounting brackets. Be sure that the pinion shaft grommet is in place securely. Loosely install the two 10 mm flange bolts < A >) and washers (B) on the left side of the gearbox.2004 Honda Element DX 2003-06 STEERING Power Steering - Element 7 > 03679034 Fig. 137: Installing Two 10 Mm Flange Bolts And Washers On Left Side Of Gearbox Courtesy of AMERICAN HONDA MOTOR CO., I Install the mounting cushion (A) on the right side of the gearbox. Position the cutout (B) on the mounting cushion as shown.