Disc HONDA CIVIC 1997 6.G Workshop Manual

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
I
Removal/lnstallation
SRS components are located in this area. Review the
SRS component locations, precautions, and proceclures
in the SRS sectron (24) before pertorming repairs or ser-
vice.
NOTE: Before removing the steering column for SRS,
remove the driver's airbag assembly and cable reel lsee
section 24).
1. Remove the steering wheel (see page 17 35).
2. Remove the driver's dashboard lower cover and
driver's knee bolster (see section 20).
3. Remove the combination switch assembly from the
steering column sha{t by disconnecting the connec-
tors.
4. Disconnect the ignition switch connectors.
5. Remove the steering joint cover.
6. Bemove the steering joint bolls.
7. Disconnect the steering ioint by moving the joint
toward the column, and remove it from the column
shaft.
8. Remove the steering column by removing the
attaching nuts and bolt.
UPPER
RETAINING COLLABNOTE: Take care not to let the
retaining collar fall out ofposition during installation.
STEERING JOINT BOLTS22 N.m {2.2 kgf.m, 16lbtft}
9. Installation is the reverse of the removal procedure
NOTE:
. Make sure the steering joint is connected as follows:
a. Insert the upper end of the steering ioint onto the
steering shaft (line up the bolt hole with the flat on
the shait), and loosely install the upper joint bolt.
b. Slip the lower end of the steering joint onto the
pinion shaft (line up the bolt hole with the groove
around the shaft), and loosely install the lower
joint bolt.
Be sure that the lowei joint bolt is securely in the
groove in the pinion shaft.
c. Pull on the steering joint to make sure that the
steering joint js fully seated. Then tighten the ioint
bolts.
. 8e sure the wires are not caught or pinched by any
parts when installing the column
. Make sure the wire harness is routed and fastened
properly.
. Make sure the connectors are properly connected.
STEERING COLUMN
COMBINATION SWITCHASSEMBLY
FLANGE NUT13 N.m {1.3 kgl.m.9 lbf ft)
COLUMN COVER
FLANGE BOLTS22Nm12.2kgl'm,16 tbt.tr)
UPPER JOINT BOLTBolt musl line upon shaft.
Groove.
LOWER JOINT BOLT8oh must line up wrthgroove around on shaft.
CLIP
J
JOINT COVER
17-37

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

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

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.

Steering Gearbox
Removal {cont'dl
Loosen the 14 mm flare nut and disconnect the feed
line.
Loosen the adjustable hose clamp and disconnect
the return hose.
Loosen the 16 mm flare nut and remove the return
hose joint trom the valve body unit.
CAUTION: After disconnecting lhe hos6 and lin6.
plug or seal the hose and line with a pioca ol tapa
or equivalent to prevenl foreign matorials trom
entsring the valve body unit.
NOTE: Do not loosen the cvlinder line A and
between the valve body unit and cylinder.
ADJUSTABLE HOSECLAMP
Remove the stiffener Dlate.
NOTE: Some stiffener plate attaching bolts are also
used as gearbox mounting bolts. The gearbox will
tilt to side when these bolts are removed.
13.
14.
t9.
16.
17-48,
17. Remove the mounting brackets.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead. then remove the
pinion shaft grommet.
Move the steering gesrbox to right so the left rack
end clears the rear beam, then tilt the left side down
to remove it from the vehicle,
CAUTION: Be careful not io bend or damage the
fagd ling and cylindsr lin99 whgn rgmoving thg
ggarbox,
18.
STEERING GEANEOX

Wheel/Hub Inspection
\
Bearing End Play
1. Raise the vehicle off the ground, and suppon it wjth
safety stands in the proper locations (see section 1).
2. Remove the wheels, then reinstallthe wheel nuts
3. Attach the dial gauge as shown.
4. N4easure the bearing end play by moving the disc in
or outward.
Front/R€ar:
Standard: 0 - 0.05 mm l0 - 0.002 inl
Measure end play athub flange.
t./
Bear:
Measure end PlaY at center ofthe hub cap.
lf the bearing end play measurement is
the standard, replace the wheel bearing.lJmore than
1A-7
Wheel Runout
1. Raise the vehicle off the ground, and support it with
safety stands in the proper locations (see section I I
2. Check for bent or deformed wheels.
3. Attach the dial gauge as shown.
4. Measure the wheel runout by turning the wheel.
Front and Rear Wheel Axisl Runout:
Standard:
Steel Whoel: 0 - 1.0 mm (0 - 0.0,1 inl
Aluminum Wheel: 0 - 0.7 mm (o - 0.03 in)
Servica Limit:2.0 mm (0.08 inl
Front and Rear Wheel Radill Runout:
Standard:
Steol Wheel: 0 - 1.0 mm (0 - 0.04 in)
Aluminum Wheol: 0 - 0.7 mm (0 - 0.03 in)
Service Limit:1.5 mm {0.06 in}
lf the wheel runout is more than the service limit,
replace the wheel.

Front Suspension
Knuckle/Hub Replacement
CAUTION:
. Replaco tho salf-locking nuts after romoval.
. The vehiclo should be on tho ground bsfore any bohs or nuls connected to rubber mounb or bushings are tightened.. Torqu€ th€ castle nut to the lowor torque specification, ihen tighton it only far enough to align th€ slot whh the pin
hole. Do not align the nut by loosening.
NOTE:
. Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damagethe aluminum wheels.
. On the aluminum wheels, remove the center cap from the inside of the wheel after removing the wheel,. Before installing the brake disc, clean the mating surfaces of the front hub and brake disc,. Before installing the wheel, clean the mating surfaces of the brake disc and wheel.o Wipe off the grease before tightening the nut at the ball joint.
CALIPER MOUNTING BOLT12 x 1.25 mm108 N.m {11.0 kgl.m, 80lbf.ft)
LOWER BALL JOINTInspect for faultymovement and wear.
CASTLE NUT10 r 1.25 mm39 - ia7 N.m (4.0 - 4.8 kgf.m, 29 - 35 lbf,ftl
COTTER PINReplace.
WHEEL BEARINGReplace.Replacement, page 18-14
CIRCLIP
SCREW5x0.8mm5 N.m {0.5 ksl.m, 4 lbf.ftlReplacement, page 18-16
SET RING
BALL JOINT BOOT
FRONT HUBCheck for damage andcracks.Replacement,page 18-10Check for deteriorationand damage.
CASTLE NUT12 x 1.25 mm49 - 59 N.m l5.O - 6.0 kg{.m. 36 - /(} lbf,ftl
SPINDI.T ]{UT22 r 1.5 mmlEl N.m {18.5 kgf.rn, 13{ lbl.ttlReplace.NOTE:. Before instelling the spindle nut. apply6n9ine oilto th6 seating surface ofthe nut.. Atter tightening, uso a drift to stake thespindle nut should6r against the driveshaft.
BRAKE DISCCheck for wear andrust.Replacement, page 18-11lnspection, section 19.
WHEEL NUT12 x 1.5 mm'108 N.m1r1.0 kgf.m, 8lt lbf.ft)
6 mm BRAKE DISC RETAINING SCREW9.8 N.m 11.0 kgf.m, 7 lbtft)
18-10

)
1.Loosen the wheel nuts slightlY.
Raise the front of the vehicle, and support it with safe-
ty stands in the proper locations (see section 1).
Remove the wheel nuts and wheel.3.
l)
WHEEL NUT'108 N.m
18'l N.m 118.5 kgf m, 134lblfti
Replace.NOTEI Before installing the spandle nut, apply
engine oil to the seating surface of the nut After
tightening, use a drift to stake the spindle nut
shoulder againsl the driveshaft
Raise the locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKE HOSE MOUNTING BOLT
I x 1.25 mm12 N.m (1,2 kgtm,8,7 lbf'ftl
6. Remove the caliper mounting bolts and hang the
caliper assembiy to one side
CAUTTON: To prevent accidental damage to the
caliper assembly or brake hoso' use a short piece of
wire to hang the caliPer tlom lhe undelcarriage.
{11 kgf m, 80 lbl.ft)
CALIPER MOUNTING BOLTS12 x 1.25 mm108 N.m {'11.0 kgtm, 80 lbt.ft)
7. Remove the 6 mm brake disc retaining screws.
8.
I x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bolts into the disc to push it
away from the hub,
NOTE: Turn each bolt two turns at a tame to prevent
cocking the disc excessivelY.
Remove the brake disc from the knuckle.
Check the front hub for damage and cracks.
Remove the wheel sensor from the knuckle (for
vehicles with ABS).
NOTE: Do not disconnect the wheel sensor connec-
tor.
N.m
6 mm BRAKE OISCRETAINING SCREWS9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{'1.0 kgf m,
7 tbf.ft)
10.
11.
MOUNTING
WHEEL
BOLTS9.8 N.m11.0 kgf,m, 7 lbf'ft)(cont'd)

I
NOTE: Wash the knuckle and hub thoroughly in
high flash point solvent before reassembly.
31. Press a new wheel bearing into the knuckle using
the specialtools and a press as shown
NOTE: Place the wheel bearing onto the knuckle
with the pack seal (metal color) toward the inside
Be careful not to damage the sleeve of the pack
seal.
Press
HANOI.E07749 - 001
DRIVERATTACHMENT58x72mm07947 - 6340201
DOUBLE LIP SEAL
{BLACK COLOR)
KNUCKLE
SUPPORT BASE07965 - SD90100
Installthe circlip securely in the knuckle groove'
Installthe splash guard, and tighten the screws.
scREws5 N.m (0.5 kgd m, 4lbt'ft)
32.
33.
l-,
18-15
34. lnstall the hub on the knuckle using the specialtools
shown and a hydraulic press as shown.
CAUTION: Take care not to distort tho splash gusrd'
HUB/ASSEMBLYGUIDE ATTACHMENT07GAF- SEflt2d)
KNUCKLE
FRONT HUB
SUPPORT BASE
07966 - StXx)100SPLASH GUARD
tnstall the knuckle in the reverse order of removal'
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
torque valugs.
. Torque the castls nuts to the low€r torque specl-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. lnstall new cotter pins into the castle nuts after
torquing.
. Avoid twistin0 the sensor wires when installing
the wheel ssnsor.
. Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the wheel, clean the mating sur-
face ofthe brake disc and the inside of the wheel
. Check the front wheel alignment, and adjust it if
necessary (see page 18-4).