Disc HONDA CIVIC 1997 6.G Workshop Manual

Steering Gearbox
l.r
Rack Guide Adjustment
NOTE: Perform the rack guide adjustment with the
wheels in the straight ahead position.
1. Loosen the rack guide screw locknut with the spe-
cial tool, then loosen the rack guide screw.
LOCKNUT WRENCH, 40 mm07916 - SA5000r
Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loosen
rt.
Retighten the rack guide screw to 4 N'm (0.4 kgf m,
2.9 lbf.ft), then back it off to specified angle.
Specilied Return Angle: 30' max.
Tighten the locknut while holding the rack guide
Check for tight or loose steering through the com-
plete turning travel.
Recheck steering effort (see page 17-4).
4.
RACK GUIDE SCREW
l,z
Removal
NOTE: Using solvent and a brush, to wash any oil and
dirt off the gearbox. Blow dry with compressed air.
1. Raise the front of vehicle, and support it on satety
stands in the proper locations (see section I ).
2. Remove the front wheels.
3. Remove the steering wheel (see page 17-35).
4. Remove the steering loint cover
Remove the steering joint lower bolt, and discon-
nect the steering joint by moving the joint toward
the column.
(cont'd)
17-5
STEERING JOINT COVER
LOWER BOLT
STEERING JOINT

Steering Gearbox
Removal(cont'd)
Remove the cotter pin from the castle nut ('96 - '97
models) or nut ('98 - '00 models) and remove the nut.
Installthe 10 mm hex nut on the ball joint.
Be sure that the 10 mm hex nut is flush with the balljoint pin end, or the threaded section of the ball joint
pin might be damaged by the balljoint remover.
NOTE: Remove the ball joint using the special tool,
Refer to section 18 for how to use tho ball joint
remover.
Separate the tie-rod ball joint and knuckle using the
specialtool.
CAUTION: Avoid damaging the 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 g).
Disconnect the shift linkage (see section 13 or sec-
tion 14).
Remove the stiffener plate.
7.
'10.
11.
12.
Replace.
17-6
13. Remove the mounting bracket,
Pull the steering gearbox all the way down to clear
th€ pinion shaft from the bulkhead, then remove thepinion shaft grommet,
Move the steering gearbox to right so the left rack
end clears the rear beam, then tilt the left side down
to remove it from the car.
t5.
STEENING GEARBOX
PINION SHAFT GROMMET

)
Disassembly
'1.
2.
Place the gearbox in a vise with a soft jaws, then
clamp the gearbox at the mount bracket or gear
housing.
CAUTION: Be carcful not to distort the gear hous-
in9 by clamping it too iight in the vise incorrectly.
Remove the tie-rod end and locknut.
Remove the boot bands and tie-rod clips. Pull the
bogts away from the ends of the gearbox.
/
TIE.ROD CLIP
4. Hold the steering rack with one wrench, and
unscrew the rack end with another wrench.
CAUTION: Be caleful not to damagc the rack sur'
facs with the wrench.
STEERING RACK ENO
l,
17-7
7.
Push the right end of the rack back into the cylinder
housing so the smooth surface that rides against
the seal won't be damaged.
Loosen the locknut, and remove the rack guide
screw.
Remove the disc washer, spring and rack guide
from the gear housing.
RACK GUIOE
SPRING
8.
9.
LOCKNUT RACK GUIDE SCREW
Remove the pinion dust seal and the 35 mm snap
nng.
Hold the pinion shatt with a vise securely
Remove the pinion by tapping evenly around the
flanged section of the gearbox with a plastic ham-
met.
CAUTION: Do not tap on tho steering rack.
NOTE| Do not reuse the removed pinion.
9._
ViF=\_
PINION DUST SEALReplace.
SNAP RING,35 mm
STEERING PINIONFeplace.
DISC WASHER

Reassembly
NOTE:
. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip the rubber parts in solvent.
. Alwavs replace the non reuseable parts with new ones before assembly
. Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
-6,1
PINION OUST SEALReplace.RACK ENO BUSHING
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-6i
GEARBOX MOUNTING CUSHIONS
V."^pR,NG,3smm
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")*o''o"'"'*
DISC WASHER
RACK GUIDE
(cont'd)
17-9
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Steering Gearbox
Reassembly (cont'dl
LApply a thin coat of grease to the inside surface of
the rack end bushing.
Grease quantity: 1 - 3 S 10.04-0.1 ozl
CAUTION: Do not till the slots with greas€; th€y
must remain open to serve as air passages,
Install the rack end bushing by aligning the round
projection on the bushing with the hole in the cylin-
der housing
4.
Grease the steering rack teeth.
Install the steering rack into the cylinder housing
carefully to avoid damaging the rack end bushing.
CYLINDER HOUSING
17-10
11. Adjust the rack guide screw (see page 17-5).
Drive in the steering pinion in the gear housing with
the soecial tools.
ORIVER.22 mm l.D.o7716-qr20100SNAP RING, 35 mm
PINION DUSTSEALReplace.
Vinyltape
STEERINGPINION
7.
Install the 35 mm snap ring securely in the gear
housing groove.
Apply vinyl tape to the pinion shaft, then coat the
vinyltape with grease.
Install the pinion dust seal on the gear housing until
it seats properly, then remove the tape.
Grease the sliding surface of the rack guide, and
install it on to the gear housing.
Install the spring, disc washer and rack guide screw
on the gear housing.
NOTE: Install the disc washer with its convex side
facing in.
LOCKNUT
SPRING RACK GUTDE
RACK GUIOE SCREW
10.
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)
Steering Pump
Construction
The pump is a vane-type incorporating a flow control valve (with an integrated relief valve) and is driven by a POLY-V-belt
from the crank pulley. The pump features 10 vanes. Each vane performs two intake/discharge operations for every rota-
tion of the rotor. This means that the hydraulic fluid pressure pulse becomes extremely small during discharge.
/
ROTORVANE CAM RING
Operation
The belt-driven pulley rotates the rotor through the drive shaft. As the rotor rotates, the hydraulic pressure is applied to
the vane chamber of rhe rotor and the vanes will rotate while being pushed onto the inner circumference of the cam ring.
The inner circumference of the cam ring has an extended portion with respect to the center of the shaft, so the vanes
move downward in the axial direction as the rotor rotates. As a result of this roller movement. the internal volume of the
vane chamber will change, resulting in fluid intake and discharge
START OF FLUID INTAKE:FLUID INTAKE:FLUID MOVEMENT:FLUID DISCHARGE:
The vanes are pushed ontothe inner circumference ol the
cam ring,
lhe volume ofthe vane cham- The sucked-in fluid moves
ber increases so that fluid is toward the discharge port.
sucked in.
As the vanes return to the
their original Position on theinner side, the volume of the
vane chamber decreases so
the fluid is discharged from
the discharge port.
(cont'd)
a-t 4-I I- | t
FLOW CONTROL VALVE
J

System Description
Steering Pump (cont'dl
The flow control valve and sub-valve in the pump per-
forms the following steps @ through @ to control the
flow of fluid, that is to increase the discharge volume
when engine speed is low, and to decrease it when the
engine speed increases. The assistance thrust of the
steering gearbox changes in compliance with the
change in the discharge volume.
When the engine starts, fluid discharged from the
discharge port starts to flow through oil passage A,
the fixed orifice and the variable orifice to the steer-
ing gearbox. When the engine speed is extremely
low, the return port is closed by the flow control
Fluid pressure discharged from the discharge port
is applied to the top of the sub-valve, and the fluid
pressure that passed through oil passage A is applied
to the bottom of the sub-valve. When this happens,
the pressure difference between the ends of oil pas-
sage A, which is caused by the resistance oil passage
A when the fluid flows through the passage. is
applied to the sub-valve, However, the pressure dif-
ference applied to the sub-valve. that is the force
that pushes the sub-valve down, is too small to
overcome the spring force, and the variable orifice is
fully open when the engine speed is extremely low.
Because the fluid volume flowing through the fixed
orifice and variable orifice increases, a pressure dif-
terence is created between the ends of these ori-
fices, and it increases in proportion to the engine
speed. As the fluid pressure that passed the fixed
orifice and variable orifice is directed to the bottom
of the flow control valve. a pressure difference is
created between the top and bottom of the valve,
which pushes down the flow control valve and
opens the return port. As a result, pan of the fluid
discharged from the discharge port feturns to the
pump suction port, keeping the discharge volume
constant.
In this condition, the sub-valve does not move. and
the variable orifice stays fully open.
lo
trrtrrlo3
J
o
PUMP R.P.M.
To STEERING GEARBOXSUB.VALVE
To STEEnING GEARBOX
FLOW CURVE
!rs+/f/ffih\
o,,-i^"l^tKzYt)91y ul3Yl
FLOW CONTNOL VALVE
su8-vALvE
ORIFICE
ToP
17-18
FLOW CONTROL VALVE

t
To STEERING GEARBOX
To STEERING GEAREOx
@ The fluid volume that flows thorough oil passage A
and the pressure djfference applied to the sub-valve
increase in proportion to the engine speed. The
sub-valve lowers overcoming the spring force, and
it stans to close the variable orifice to regulate the
discharge volume, When this happens, the fluid vol-
ume flowing to the steering gearbox decreases as
the engine speed increases. At the same time, the
flow control valve continues to control the fluid vol-
ume to the return Port,
@ As the engine speed increases funher, the pressure
difference at the sub-valve increases further as well.
The sub-valve then closes the variable orifice com-
pletely, regulating the discharge volume further.
When this happens, the fluid volume discharged
from the pump to the steering gearbox is regulated
and maintained at a given level until the engine
speed reaches the high speed range The flow con-
trol valve functions continues to control the fluid
volume to the return Port.
Pressure Relief
Pressure at the discharge side of the fixed orifice is
directed to the bottom of the flow control valve. When
the pressure builds up, the relief valve in the flow con-
trol valve opens to release the pressure at the bottom of
the valve. This allows the flow control valve to be
pushed back by the pressure difference, and the fluid
volume to the pump return port increases.
As explained above. the system keeps the pump dis-
charge pressure (relief pressure) from exceeding the
given level by controlling the volume of the fluid to the
pump relurn pon,
1.,DAMPING ORIFICE{Docreases excessiv€vibration in the valv6.)
17-19
)
RELIEF VALVE {Opan)
SUB.VALVE
FLOW CONTROL VALVE
/F ft>..\
'-€/K\A/A
o'.'to"5lo'#2"n af11\D7
FLOW CONTROL VALVE

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