power steering HONDA CIVIC 1996 6.G Owner's Guide

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.

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.

Steering Gearbox
)
Removal
NOTE: Using solvent and a brush, wash any oil and dirt
off the valve body unit its lines. and the end if the gear-
box. Blow dry with comPressed air.
1. Drain the power steering fluid as described on page
2. Raise the front of vehicle, and support it on safety
stands in the proper locations (see section 11.
3, Remove the front wheels.
4. Remove the driver's airbag assembly, and steering
wheel (see page 17-35)
5. Bemove the steering joint cover.
6. Remove the steering joint lower bolt, and loosen
the steering joint upper bolt. Disconnect the steer-
ing joint by moving the ioint toward the column
tJ
17-47
TIE.ROD END
7. Remove the cotter pin from the castle nut {'96 -'97
models) or nut ('98 - '00 modslsl and remove the nut.
BALL JOINT REMOVER.28 mm07MAC - SLqI2|X)
'98 - '00 mod.b:NUT
8.
COTTER PINSRepl6ce.
lnstall the t0 mm hex nut on the ball joint.
Be sure that the 10 mm hex nut is flush with the ball
joint pin end, or the threaded section of the ball
joint pin might be damaged by the special tool.
NOTE: Remove the ball joint using the special tool.
Refer to section 18 for how to use ths ball joint
remover.
Seoarate the tie-rod ball joint and knuckle using the
specialtool.
CAUnON: Avoid damaging tho ball ioint boot.
Remove the left tie-rod end, then slide the rack all the
way to the right.
Separate the exhaust pipe A or TWC (see section 9).
Disconnect the shift linkage (see section 13 or section
14).
(cont'd)
9.
10.
11.
12.

)Reassembly
NOTE:
. clean the disassembled parts wrth a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly'
. Apply the recommended power steering fluid to the parts+ndicated in the assembly procedures'
o Do not a||ow dust, dirt, or other foreign materials to enter the power steering system.
a Use the appropriate special tools where necessary'
FLANGE BOLTS20 N.m (2.0 kgt'm, 14lbf ftl
CYLINDER LINE B
VALVE HOUSINGFLARE NUTS
28 N.m (2.7 ksf m,20 lbf ftl
VALVE OIL SEAL
Replace.
CYLINDER END SEAL
Replace.
f itllTllli".",'r'o,.n,ft
''*^'*-1$*€-/s6-,,mode,3:
EUSHINGReplace 'P'\-- BEARING
SLEEVE SEAL RINGS ..-------...... SS
.----
",a"a,,
*---
--,
Replace. lss-, Replace.
Xll,Y5"l'.
"o. --r...- gY------..r.u,
,-f-..-S: _ ,96 _,9? models:
--€l€--------=- ircriip'ii.rt'-l./BACKUPReplace.
I,
wAvE wAsHER d
-.-.-r_ i"pru"".
CYLINDER HOUSING // -\-
, AJ - O.RING
/ ,S-'..- ReDtace.
_ j GEAR HouslNG l.g --'\-
\- t F
tonsrnrr
.,_- s
- 'oo ,,iod"t., -s-'--------- vALvE SEAL R'NG
S_.<---,tj- 97 models onlY:
CYLINDER END SEAL
)@OOD m n"prac".
/'\N,."._nrNG I '98 - 'oo - RACK GUIDE
models:
:scREw I
O.RINGReplace..98 - '00 models:
CYLINDER END69 N.m {?.0 kgt'm,51 lbl'ft)
(cont'd)
17-55
CYLINDER LINE A
tJ

Steering Gearbox
Reassembly (cont'd)
Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl taoe with
the power steering fluid.
2. Install the backup ring ('96 -'97 models) or wavewasher ('98 -'00 models) with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil sealwith power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being
careful not to damage the sealing lip.
Vinyl t.po{Stepped ponion}
Tap6red position.
BACKUPGroove side.
sure the spring isseatod in the oil seal.
'98 - '00 mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Apply vinyl tape to the splines and stepped portion
of the shaft, and coat the surface of the vinyl tapewith the power steering fluid.
Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaft
and the groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft,
'96 - '97 models:
lip
7.
VALVE SEAL RIiIGReplace.Do not over-expand.
17-56
8. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
9. Apply power steering fluid to the inside of the spe-cial tool. Set the larger diameter end of the specialtool over the valve seal ring.
10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.11, Remove the soecial tool.
12. Turn the special tool over, and set the smaller diam-eter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinion
shaft.
PISTON SEAL BINGSIZING TOOL07NAG - SR:togoAol07NAG - SR3|X)00
(g(m
Use the larger diameterend of the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe specialtool.

I
14.
Apply power steering fluid to the surface of the spe-
cial tool. Set the new seal rings over the special tool
from the smaller diameter end of the tool, and
expand the seal rings. Do two rings at a time from
each end of the sleeve.
NOTE;
. Do not over-expand the seal ring. Installthe resin
seal rings with care so as not to damage them'
After installation, be sure to contract the seal
rings using the specialtool (sizing tool).
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleeve seal rings as they are not compatible
Set the special tool in the grooves in the sleeve, and
set each ring in each groove securely.
NOTE: After installation, compress the seal rings
with your fingers temPorarilY
BALL JOINT BOOI CLIP GUIDE
07S7,1- SA50800
SLEEVE
15. Apply power steering fluid to the seal rings on the
sleeve, and to the entire inside surface of the spe-
cial tool.
16. lnsert the sleeve into the specialtool slowly'
17. Move the sleeve each direction several times to
make the seal rings snugly fit in the sleeve'
NOTE: Be surerings are not turned uP.
SITEVE SEAL RINGSIZING TOOL0797a - SA5020A or07974 - SA50200
that the seal
fr
J
17-57
18. Apply power steering fluid to the surface o{ the pin-
ion shaft. Assemble the sleeve over the pinion shaft
by aligning the locating pin on the inside of the
sleeve with the cutout in the shaft. Then install the
new circlip securely in the pinion shaft groove'
NOTE:
Be careful not to damage the valve seal ring
when inserting the sleeve.
Installthe circlip with its radiused side toward the
sleeve.
Apply power steering fluid to the seal ring lip of the
valve oil seal. then install the seal in the valve hous-
ing using a hydraulic press and special tools as
shown.
CAUTION: Install the valve oil seal with its grooved
side facing the tool.
'19.
ATTACHMENT.32x35mm0774.6 - q)101(x)Pre3s
IDRIVER07749 - 0010000
VALVE OIL SEALReplace.Make sure thespring is in the
oil seal. (cont'd)

Steering Gearbox
Reassembly (cont'd)
SLEEVE SEAL RINGSReplace.8e sure that theseal nngs are notturned up, theninsta ll.
21. Apply vinyl tape to the pinion shaft. then coat thevinyltape with power steering fluid.
Sealing lip face.VALVE OIL SEAL
VALVE HOUSING
Press the new bearing ('96 - '97 models) or newbushing ('98 -'00 models) into the valve housingusing a hydraulic press and special tool as shown,
NOTE: Place the roller bearing ('96 -'97 models) onthe valve housing with the stamped letter facing uptowards the valve side.
DRIVER077itg-001tXlOO
22. Insert the pinion shaft into the valve housino.
CAUTION: Be careful noi to damage th€ valve sealrings.
23. Remove the vinyltape from the pinion shaft.
20.
Pr033
+3:Ix35mm07746 - 0010,t(x)
'96 - '97 models:ROLLER BEARINGLetter stamped taceupward.
ATTACHMENT,
'98 - '00 modob:
?/_vusHrNG
['---v-lt
\4)
PINION
E
17-5A
24. Press the pinion shaft/sleeve using a hydraulicpress as shown.
NOTE: Check that the pinion shafvsleeve turnssmoothly by turning the pinion shaft.