Lock HONDA CIVIC 2000 6.G Workshop Manual

Steering Gearbox
Installation (cont'dl
Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark on
the label points straight up. Reinstall the steering
wheel (see page 17-35).
Install the steering joint cov€r with the clamps and
clrps.
7.
STEERING JOINI COVER
17-14
9. Reconnsct the ti€-rod ends to the steering knuckles,
thon tightsn th€ castle nut ('96 -'97 models) or nut('98 -'00 models) to the specified torque, and install
new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint
tapered section and threads.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque
spocification, th€n tighton it only tar anough to
align the 3lot with tho pin hob. Do not align the
nut by loosening ('96 - '97 modcls onlyl.
TIE.ROD
COTTER PINSR6plac6.On rgassombly, b6nd
'96 - 37 model3:
cotter prn as shown.'98 - '00 modol3:
NUT4a N.m(4.5 kgf.m,33 lbr.ftl
CAST1T NUT,O - ilt N'm{4,0 - 4.8 kgf.m.29 - 35 tbtftl
10.Installthe exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
Install the front wheels.
After installation, perform the following checks.
. Adjust the front toe (see section 18).. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equally.
ll.

Troubleshooting
General Troubleshooting (cont'd)
Assist (excessively light steering) athigh speed.
Shock or vibration when wheel isturned to {ull lock.
Steering wheelwill not returnsmoothly.
lf the problem is not corrected byadiusting the rack guide, adjustthe front wheel alignment lseesection 181.
Check the rack guide for properadiustment (see page 17 33).
Check the rack guide for properadjustment (see page 17-33).
Rack guide is adjusted properly.
lfthe problem is not corrected byadjusting the rack guide, replacethe gearbox.Check the belt for slippage andaolust as necessary {see page11 32).
A and B cylinder lines are nor-mal, check wheel alignment (seesection 18).
Wheel alignment is abnormal,adjust as needed.
Wheel alignment is normal.Check the steering wheel opera-tion and power assist check {seepage lT-30).
It the measurements are out ofspecifications, adjust the ra ckguide.
lf the problem is not corrected byadjusting the rack guide, replacethe gearbox.
17-24

Inspection and Adjustment
Steering Operation
Place the front wheels in the straight ahead position,
and measure the distance the steering wheel can beturned without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm l0 - 0.39 inl
lf the play exceeds the service limit. perform rack guide
adjustment (see page 17-33).
lf the play is still excessive after rack guide adjustment.inspect the steering linkage and gearbox as describedon the nel(t pag€.
ROTATIONAL PLAY
17-30
Power Assist Gheck with
Vehicle Parked
1. Check the power steering fluid level (see page 17-33) and pump belt tension (see page 17-32).
2. Start the engine, allow it to idle. and turn the steer-ing wheel from lock-tolock several times to warm
up the fluid.
3. Attach a spring scale to the steering wheel. With theengine idling and the vehicle on a clean, dry floor,pull the scale as shown and read it as soon as thetires begin to turn.
The scale should read no more than 29 N (3.0 kgf.
6.6 lbf). lf it reads more, check the gearbox andpump,
D0

ISteering Linkage and Gearbox
TIE-ROD END BALL JOINT
Inspect for faulty movement
and damage.
STEERING COLUMN
Inspect for loose column
mounting bolts and nuts
BOOTInspectdamage and deteriorataon
STEERING GEARBOXlnspect for loose mounting bolts.
GEARBOX MOUNTING CUSHIONS
Inspect f or deterioration
STEERING JOINTSCheck for loose joint bolts.
l./
TIE-ROD LOCKNUTfor loose locknut
BALL JOINT BOOT
Inspect for damage and deteriorataon'
See page 17-68lor replacement.
SHAFT GROMMETInspect for damage and deteriorataon.
lrz
17-31

Inspection and Adjustment
Pump Belt
NOTE: When using a new belt, first adjust the deflection
or tension to the values for the new belt, then readjust
the deflection or tension to the values for the used beltafter running engine for five minutes.
Inspection
Attach the special tool to the belt and measure the ten-sion of the belt.
Tension:'99 -'00 mod€ls: B1642 Engin. Type onlyUsed Bsh: 390 - 540 N lao - 55 kgt.88 - 120 tbf)New Belt:740 - 880 N {75 - 90 kgf, 170 - 200 tbt}'96 - '00 models: Other Engine Types
Used Beh: 340 - 490 N (35 - 50 kgf, 77 - ilO tbflNew Belt:640 - 780 N 165 - 80 ksf, 1& - 176 tbf)NOTE:
. lf there are cracks or any damage evident on the belt,reDlace it with a new one.. Follow the manufacturer's instructions for the tensiongauge.
BELT TENSION GAUGE07JGG _ 001010A
Inspect the pump belt for cracks or any damage.Replace the belt with a new one if necessary.
Measuremont without Beh Tension Gauga:
Apply a force of 98 N (10 kgt,22 lbfl and measure thedeflection between the power steering pump and thecrankshaft pulleys.
Dsflectior:'99 -'00 model3: 816A2 Engine Typ€ ontyUsed Beh: 7.5 - 11.0 mm t0.30 - 0.43 inlNew Beh:5.0 - 7.0 mm (0.20 - 0.28 in)'96 - '00 models: Othor Engine Typos
Used Behi 10.5 - 14.0 mm (0.ial - 0.59 inlNow Beh:7.5 - 10.0 mm (0.30 - 0.39 inl
POWER STEERING PULUY
CRANKSHAFT PULLEY
17-32
Adiustment
1. Loosen the power steering pump mounting bolts.
2. Adjust the belt tension.
'99 - '00 mod€ls: 816A2 Engin€ Typo only
. Turn the adjusting bolt by hand to get the proper belttension, then retighten the mounting bolts,
ADJUSNNG BOLT
PUMP MOUNNNG BOLTS24 N.m (2.4 kgf'm, 17 tbtftlPOWER STEERINGPUMP
'96 -'00 modek: Othcr Engins Typos
. Pry power steering pump away from the engine witha wrench to get the proper belt tension, then retight-en the mounting bolts.
PUMP MOUNTING BOLT24 N.m (2,4 kgf.m, 17 lbl.ftl
PUMP MOUNTING BOLT24 N.m {2.a kgt m, 17 tbtftl
Start the engine and turn the steering wheel fromlock-to-lock several times, then stop the engine andrecheck the deflection of the belt,

IRack Guide Adjustment
NOTE: Perform rack guide adjustment with the wheels
in the straight ahead Position.
1. Loosen the rack guide screw locknut with the
cialtool.
'96 - '97 models:
Loosen the rack guide screw
'98 - '00 models:
Remove the rack guide screw and remove the old
sealant off of the threaded section.
Apply new sealant all around the threads. Loosely
installthe rack guide screw
Tighten the rack guide screw to 25 N'm (2.5 kgf'm.
18 lbf.ft), then loosen it.
Retighten the rack guide screw to 3 9 N'm (0.4 kgim,
2.9 lbf.ft), then back it off to specified angle.
Specified Return Angle: 20" max.
Tighten the locknut while holding the rack guide
screw.
Check for tight or loose steering through the com-
plete turning travel.
Perform following insPections:
. Steering operation (see page 17-30).
. Power assist with vehicle parked.
4.
LOCKNUT WRENCH, 40 mm
lr
17-33
Fluid Replacement
Check the reservoir at regular intervals, and add fluid as
necessary.
CAUTION: Always us€ Genuine Honda Power Stearing
Fluid-V or S. Using any other type of power sto€ring
tluid or automatic transmission lluid can cause
increased wear and poor steering in cold weathor.
SYSTEM CAPACITY:
0.85 liter 10.90 US' qt,0.75 lmp'qt)
at disassembly
RESERVOIR CAPACITY:
0.4 liter (0.42 US. qt, 0.35 lmP.qt)
LEVEL LINE
LOWER LEVEL LINE
1. Raise the reservoir, then disconnect the return nose.
2. Connect a hose of suitable diameter to the discon-
nected return hose, and put the hose end in a suit-
able container.
CAUTION: Take care not to spill tho fluid on the
body and parts. Wipe off any spill€d fluid at oncs'
3. Start the engine, let it run at idle, and turn the steer-
ing wheel from lock-to-lock several times When
fluid stops running out of the hose, shut off the
engine, Discard the fluid.
4. Reinstall the return hose on the reservoir'
5. Fill the reservoir to the upper level line.
6. Start the engine and run it at fast idle, then turn the
steering trom lock-to-lock several times to bleed air
trom the system.
7. Recheck the fluid level and add some it necessary.
CAUTION: Do not fill the reservoir beYond the
upper l€vel line.
HOSE

lnspection and Adjustment
Pump Pressure Check
Check the fluid pressure as follows to determine
whether the trouble is in the pump or gearbox.
NOTE: First check the power steering fluid level andpump belt tension.
CAUTION: Disconnect the high pr$sure hos€ with care
so as not lo spill the power sieering tluid on tha frame
and other parts.
1. Disconnect the outlet line from the Dumo outlet fit-
ting, then installthe P/S joint adaptor (pump) on the
Dumo outlet.
2. Connect the P/S joint adaptor (hose) to the power
steering pressure gauge, then connect the outlet
hose to the adaptor.
3. Install the power steering pressure gauge to the P/Sjoint adaptor (pump) as shown.
ourlEr HosE FnrNo ,t"ll lrilu"ott
P/S JOINT ADAPTOB IHOSEI07RAK - S0i10l2rol07RAK- 50{{)120
P/S PRESSURE GAUGE07406 - 001000Aor07406 - 0010001
4. Open the shut-off valve fully.
5. Open the pressure control valve fully.
17-34
(Pa.t of tooll11 N.m11.1 kgt m, 8 lbf.ftl
PRESSURECONTROL VALVE
SHUT.OFFVALVE
PUMP OUTLETFITTING
6 x 1.0 mm BOLTlPart of tool)11 N.m11.1 kgf m, 8 lbtftl
7.
Start the engine and let it idle.
Turn the steering wheel from lock-to-lock several
times to warm the fluid to operating temperature.
Measure steady-state fluid pressure while idling. If
the pump is in good condition, the gauge should
read less than 1500 kPa (15 kgf/cmr, 213 psi).
lf it reads high, check the outlet line or valve body
unit (see General Troubleshooting 17-22).
Close the pressure control valve, then close the
shut-off valve gradually until the pressure gauge
needle is stable. Read the oressure.
lmmediately open the pressure control valve fully.
GAUTION: Do not keep lhe prossure control valve
clos€d more then 5 soconds or the pump could be
damagod by over-heating.
lf the pump is in good condition, the gauge should
read at least 6,400 - 7,400 kPa (65 - 75 kgflcm,, 920 -
1,070 psi). A low reading means pump output is too
low for full assist. Repair or replace the pump,
9.
P/S PBESSURE GAUGE07{16 -@1@OA
oi
SI{UT.OFF VALVE

Steering Wheel
l,/
Removal
SRS components are located in this area Review the
SRS component locations, precautions, and procedures
in the SRS section (24) before performing repairs or ser-
vice.
NOTE: Before removing the steering wheel. align the
front wheels straight ahead.
1. Remove the driver's airbag assembly from the
steering wheel (see section 24)
2. Disconnect the horn connector and cruise control
switches connector.
CRUISESWITCHES CONNECTOR
3. Remove the steering wheel nut
STEERING WHEEL NUT
Replace.
Remove the steering wheel by rocking it slightly from
side-to-side as you pull steadily with both hands.
ag N.m {5.0 kgt rn, 36lbfft)
1.,
17-35
lnstallation
CAUTION: Do not tap on the steering wheel or steering
column shaft when installing the stsering wheel.
NOTE: Before installing the steering wheel, align the
front wheels straight ahead.
1. Before installing the steering wheel, center the
cable reel, Do this by first rotating the cable reel
clockwise until it stops. Then rotate it counterclock-
wise approximately two turns The arrow mark on
the cable reel label should points straight up.
Install the steering wheel with the steering wheel
nut.
NOTE: Be sure the steering wheel shaft engages
the cable reel and canceling sleeve.
Attach the cruise control switches connector io the
steering wheel cliP,
Connect the horn connector.
Install the driver's airbag assembly, and confirm
proper system operation (see section 24).
Check the horn and cruise control switches for
proper operatrons.
CAELE REEL

Steering Column
Inspection
NOTE: The tilt steering column type is shown; the con-
ventional steering column is similar except for the tilt
mechantsm.
Check the steering column ball bearing and the steer-ing joint bearings for play and proper movement. lf
there is noise or if there is excessive play, replace the
steering column as an assembly.
Check the retaining collar for damage. lf it is dam-
aged, replace the retaining collar.
Check the absorbing plates, absorbing plate
and sliding capsules for distonion or breakage.
Replace the steering column as an assembly
are distorted or broken.
COLUMN BALL
ABSORBING PLATE GUIDES
guides
if they
SLIDING
BEARINGS
TILT LOCK BOLTTighten the lock bolt withthe tilt lever raised.
This part is attachodto the column bracketwith the plastic injections.
1.Move the tilt lever from the loose position to lockposition 3 to 5 times; then measure the tilt leverpreload l0 mm {0.4 in) from the end ofthe tilt lever.
Preload: 70 - 90 N (7 - 9 kgf. 15 - 20 lbf)
lf the measurement is out of the specification,
adjust the pfeload using the following procedures.
a. Loosen the tilt lever, and set the steering column
in the neutral position.
b. Remove the 6 mm lock bolt and remove the stop.
c. Adjust the preload by turning the tilt lock bolt left
or flgnr.
d. Pull up the tilt lever to the uppermost position and
install the stop. Check the preload again. lf the
measurement is still out of specification, repeat
the above procedures "a" through "c" to adjust.
CAUTION: Be caretul not to loosen tho tilt lever
when installing the stop or tightening the 6 mm
lock bolt.
17 3a
10 mm (0.4 inl
9.8 N.m (1.0 kgl.m,7 lbf.ft)

)
Disassembly
t)
Steering Rack DisassemblY
NOTE:
r Before disassemble the gearbox, wash it off with sol
vent and a brush.
. Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox (see page 17-47]..
2. Remove the tie-rod end and locknut.
3. Remove air tube and cliPs.
Remove the boot bands and tie-rod clips Pull the
boots away from the ends of the gearbox.
BOOT
(|-,TIE.ROD CLIP
Hold the steering rack with a wrench ('98 -'00 mod-
els: left end only), and unscrew the rack end with
another wrench.
CAUTION: Be caroful not to damage the rack 3ur-
faco whh the wrench.
NOTE: '96 -'97 models is shown.
STEERING RACK END
STEERING RACK
Loosen the locknut, then remove the rack guide
screw and O-ring ('96 -'97 models only)
Remove the spring and the rack guide from the gear
housing.
7.
{cont'd}
17 -49
LOCK WASHER