pump HONDA CIVIC 1999 6.G Workshop Manual

Power Steering Pump
RemovaUlnstallation
NOTE: Eefore disconnecting the hoses from the pump,
Dlace a suitable container under the vehicle.
1. Remove the belt by loosening the pump mounting
bolts and adjusting bolt ('99 -'00 models: 81642
Engine Type only).
OUTLET LINE11 N.m {1.1 kgf'm,8
L
PUMP MOUNTING BOLT24 N.m (2.4 kgl.m, 17 lbf ft)
2. Cover the Ay'C compressor with several shop towels
to protect it from spilled power steering fluid.
3. Disconnect the inlet hose and the outlet line from
the pump, and plug them.
NOTE: Take care not to spill the fluid on the body
or parts, Wipe off any spilled fluid at once.
4. Remove the pump mounting bolts and adjusting
bolt ('99 -'00 models: 816A2 Engine Type only),
then remove the pump.
NOTE:
. Do not turn the steering wheel with the pump
removeo.
. Wrap the opening of the pump with a piece of
tape to prevent foreign material from entering
the pump.
17-40
1.
8.
Connect the inlet hose and the outlet line. Tiqhten
the pump fittings securely.
Loosely install the pump in the pump bracket with
mounting bolts and adjusting bolt ('99 -'00 models:
81642 Engine Type only).
Installthe pump belt.
CAUTION:
. Make sure that the power steering belt is prop-
orly positioned on the pulleys.
. Do not get power stoering tluid or grease in the
power steering bsh or pulley faces. Clean off any
fluid or grease before installrtion.
Adjust the pump belt (see page 17-32).
Fill the reservoir to the upper level line (see page

Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.
NOTE:
. Ctean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Alwavs replace the O-rings and rubber seals with new ones before assembly.
. Apply recommended power steering fluid to the parts indicated in the assembly procedures'
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.
. Replace the pump as an assembly ifthe parts indicated with asterisk (*) are worn or damaged'
FLANGE BOLTS20 N.m {2.0 kgf.m,14 rbf ft)
5 mm ROLLER
4.5 mm ROLLER
*OUTER SIOE PLATE
*SUB-VALVE
.PUMP NOTOR
}SIDE PLATE
l,/SNAP RING13 x 1.9 mm O-RINGReplace.
15.2 x 2.4 mm O-RINGReplace.
INLET JOINT
51 x 2.4 mm O-RINGReplace.
FLANGE BOLTS11 N m 11.1 kgf.m,8 rbf.ftl
PUMP SEALReplace.
PUMP SEAL SPAC€R
.PUMP DRIVE SHAFT
BALL BEARINGlnspection and RePlacement,see page 17-43
10 mm CIRCLIP
*FLOW CONTROI- VALVEInspection and Overhaul,se[ pase tt.tz g
4 --{;'rX!;'seatuc/ $
mm O-RINGPULLEY NUT6il N.m {6.5 kgf.m,47 tbf.frlFI-OW CONTROL VALV€ CAP49 N.m {5.0 kgt m,36 rb{.ft)
(cont'd)
17-41
J

Power Steering Pump
Disassembly (cont'dl
2.
't.Drain the fluid from the pump.
Hold the steering pump in a vise with soft jaws,
hold the pulley with the special tool, and remove
the pulley nut and pulley.
CAUTION: Be careful not to damage the pump
housing with the iaws of the vise and extension bar.
UNIVERSAL HOLDER
Loosen the flow control valve cap with a hex wrench
and remove it.
4. Remove the O-ring, flow control valve and spring.
5. Remove the inlet joint and O-ring.
6. Remove the pump cover and pump cover seal.
7. Remove the outer side plate, pump cam ring, pump
rotor, pump vanes, side plate and O-rings.
8. Remove the snap ring, then remove the sub-valve
from the pump housing.
9. Remove the circlip, then remove the pump drive
shaft by tapping the shaft end with the plastic ham-
mer.
10. Remove the pump seal spacer and pump seal.
17-42
Inspection
Flow Control Valve:
1. Check the tlow control valve for wear. burrs, and
other damage to the edges of the grooves in the
vatve,
FLOWCONTROL VALVE
Check fordamage to edges.
Inspect the bore the flow control valve for scratches
or wear.
Slip the valve back in the pump, and check that it
moves in and out smoothly.
lf OK, go on step 4; if not, replace the pump as an
assembly. The flow control valve is not available
separately.
Attach a hose to the end of the valve as shown.
FLOW CONTROL VALVE TIOSE
4.

I
5, Submerge the valve in a container of power steer-
ing fluid or solvent. and blow in the hose. lf air bub-
bles leak through the valve at less than 98 kPa
(1.0 kgf/cm', 14.2 psi), repair it as follows.
, AIR PRESSURE
?
i-- POWER STEERTNGFLUID or SOLVENT
Hold the bottom end of the valve with a open end
wrench.
Unscrew the seat in the top end of the valve. and
remove any shims, the relief check ball. relief valve
and relief valve spring.
7.
l./
RELIEF CHECK BALL
1.,
SEAT9 N.m
{0.9 kgf'm, 6.5 lbt'ftl
RELIEF VALVESPRING
Clamp this end ina open end wrench,
8. Clean all the parts in solvent, dry them off, then
reassemble and retest the valve. lf the flow control
valve tests OK, reinstall it in the pump. lf the flow
control valve still leaks air, replace the pump as an
assembly. The flow control valve is not available
separatelY.
NOTE: 11 necessary, relief pressure is adjusted at
the factorv by adding shims under the check ball
seat. lf you found shims in your valve, be sure you
reinstall as many as You took out.
RELIEF VALVE
{W-*"'
FLOW CONTROL VALVE
17-43
Ball Bearing:
1. Inspect the ball bearing by rotating the outer race
slowly. lf any play or roughness is felt, replace the
ball bearing.
Remove and discard the ball bearing using a press
as snown.
Installthe new ball bearing using a press as shown.
Ball Boaring Rsplaccmont:
lnstallwith thered shielded sidefacing down.
NOTE: Support the inner race
with the tool securely.
BALL BEARING
Prcrt

Power Steering Pump
Reassembly
1.Align the pin of the sub-valve with the oil passage
in pump housing. and push down the sub-valve.
Installthe snap ring properly.
OIL PASSAGEAlign the pin of
the oil passage.
PUMP HOUSINGSNAP RING
Install the new pump seal in the pump housing by
hand, then installthe pump seal spacer.
NOTE: Insert the pump seal with its grooved side
facing in.
Position the pump drive shaft in the pump housing,
then drive it in using a special tool as shown.
Install the 40 mm circlip with its radiused side fac-
ing out,
ATTACHMENT, 30 mm
BALL BEARING
40 mm CIRCLIP
d
gf'uMP oRrvE sHAFr
/ffi\
f.\'vj
H PUMP SEAL SPACER
n,/
/:K
/ZA\.-- PUMP SEAL
V Reptace.
17 -44
ROLl.ERS
Coat the pump cover seal and the cover bushing
with the power steering fluid, then install the pump
cover seal into the groove in the pump cover.
lnstall the outer side olate over the two rollers.
ROL1IR
OUTER SIDE PLATE
4.5 mm ROLLER
5 mm ROLLER
PUMP COVERBUSHING
Set the pump cam ring over the two rollers with the" o " mark on the cam ring upward.
7.
ROI,IIR SET HO'"ES
PUMP CAM RING

I
8.
9.
Assemble pump rotor to the pump cover with the" " " marks on the rotor facing down.
Set the 10 vanes in the grooves in the rotor.
NOTE: Be sure that the round ends ot the vanes are
in contact with the sliding surface of the cam ring.
Coat the O-ring with power steering fluid, and
install it into the grooves in the side plate.
Install the side plate on the cam ring by aligning the
roller set holes in the side plate with the rollers.
mm O-RING
ROLIIR SET HOTT
SET HOI.^E
0E
gn
10.
11.
r
E15.2 x 2,1Replace.
PUMP ROTOR
SIDE PLATE
ROI.I.ERSl,
't2.Coat the O-ring with power steering fluid. and posi
tion it into the pump housing.
Install the pump cover assembly in the pump hous-
tng.
FI.ANGE EOLTS20 N.m (2.0 kgf.m,14 tbf.ft)
PUMP COVERASSEMBLY
51 x 2.4 mmReplace.
Coat the flow control valve with power steerlng
fluid.
15. lnstall the flow control valve and spring on the
pump housing.
Coat the O-ring with power steering fluid, and
install it on the Jlow control valve cap.
Install the flow control valve cap on the pump hous-
't 4.
16.
17.
ing, and tighten it.
{cont'd)
17-45
FLOW CONTROLVALVE CAP49 N.m (5.0 kgj m,
36 tbf.ft)

Power Steering Pump
Reassembly (cont'dl
Coat the O-ring with power steering fluid, and
install it into the grooves in the inlet joint.
Install the inlet joint on the pump housing.
'11 N.m (1.1 kgt.m,8 |bnft)
Install the pulley as shown below, then loosely
install the pulley nut. Hold the steering pump in a
vise with soft jaws.
CAUTION: Be car€ful not io damage the pump hous-
ing with the jaws ot the vise.
15.2 x 2.4Replace.-
EI
17-46
21. Hold the pulley with the specialtool, and tighten the
pulley nut.
UNIVERSAL HOLDERPULLEY NUT64 N.m {6.5 kgf.m,
Check that the pump turns smoothly by turning thepulley by hand.

I
Bleeding
CAUTION:
. Always use Genuine Honda DOT 3 Brake Fluid. Using 8
non-Honda brak€ fluid can cause corrosion and
docrea3e the life of the system.
. Make surs ||o dirt or other foteign matter is allowed
to contaminate the brake fluid,
. Do not spill brake lluid on the vehicle, it may damago
the paint; if brake lluid doos contac{ the paint, wash
it ofl imm€diately with water.
NOTE: The reservoir on the master cylinder must be at
the MAX (upper) level mark at the start of the bleeding
procedure and checked after bleeding each brake
caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at
the MAX lupper) level line.
MAX {UPPER) LEVEL
CYLINDER
Have someone slowly pump the brake pedsl several
times, then apply steady Pressure.
Loosen the brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securely.
Repeat the procedure for each wheel in the sequence
shown below until air bubbles no longer appear in
the fluid.
Refill the master cylinder reservoir to the MAX (up-
per) level line.
ELEEDING SEOUENCE:
O Front Right(D Bo.r Right
O Front LeftO Rear Left1,,
19-7
FRONTT
REAR lDrum Brakel:
REAR (Disc Brake):
AIEED SCREW9 N.m (0.9 ksf m, 6.5 lbf'ft)

L-
t
Anti-lock Brake System (ABSI
Special Tools ............. 19-44
Component Locations ......................... 19-45
Anti-lock Brake System (ABS)
Features/Construction ..................., 19-46
Operation ............... 19-47
Circuit Diagram ......... 19-50
ABS Control Unit Terminal
Arrangement ......... 19-52
Troubleshooting Precautions ............. 19-54
Diagnostic Trouble Code (DTCI
Diagnostic Trouble Gode (DTCI
Indication ........... 19-56
DTC Erasure ........... 19-57
Symptom-to System Chart ............. 19-58
Troubleshooting
ABS Indicator Light Does Not
Come On ............ 19-60
ABS Indicator Light Does Not
Go Off ............................................ 19-62
Wheel Sensor ........ 19-64
Solenoid ................. 19-60
ABS Pump Motor ............................. 19-68
Main Relay ............. 19-71
lgnition Voltage .... 19-73
Central Processing Unit {CPU} ........ 19-74
Modulator Unit
Removal/lnstallation ....................... 19-75
ABS Control Unit
Replacement ......... 19-76
Pulsers/Wheel Sensors
Inspection .............. 19-76
Wheel Sensor Replacement ............ 19-77
t/

Component Locations
ta
SERVICE CHECK CONNECTOR {2PIBIGHT.REAR WHEELSENSOR CONNECTORMOOULATOR UNITABS CONTROL UNIT
RIGHT-REAR WHEEL SENSOR
LEFT.R€AR WHEELSENSOR CONNECTOR
J
UNDER.DASH FUSE/RELAY 8OX
LEFT.FRONT WHEEL SENSOR
ABS +B (20 A) FUSE
UNDER.HOOD FUSE/RELAY BOX
lcl lilo Al FUSE
ABS INDICATOR LIGHT
UNOEF.DASI{ FUSE/RELAY BOX
HORN/STOP I15 A) FUSE
UNDER.HOOO ABS FUSE/RELAY BOX
PUMP MOTOR {'O A} FUSE
PUMP MOTOR BELAY
E
o
METEB I7.5 AI FUSE
0
0
0
00000 n
00000 u
BR DEF RLY 17,5 A) FUSE
t
MTR CHECK (7.5 AI FUSE
19-45