locknut HONDA CIVIC 1999 6.G Service Manual

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

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

)
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

)
55. Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
materlal.
. Install the cylinder lines A and B by tighting the
flare nuts by hand first, then tighten the flare
nuts to the specified torque.
56.
57.
Grease the sliding surface of the rack guide, and
install it onto the gear housing
36 - '97 models:
Apply a thin coat of grease to the new O-ring, and
install it on the rack guide screw.
38 - '00 models:
Remove the old sealant off of the threaded section,
then apply new sealant all around the threads
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17-33)'
NOTE: After adjusting, check that the rack moves
smoothly by sliding the rack right and left'
'1 l:.r1
58.
-GlO.BINGReplace.
17 N.m {1.7 kgt'm, 12 lbl.ft)
28 N.m (2.7 kgf m,20 lbf ftl
CYLINDER LINE 8 CYLINDER LINE A
l/LOCKNUTS
60, lnstall the new lockwasher in the groove in the
steering rack.
61. Screw each rack ends into the rack'
62. Hold the steering rack with a wrench ('98 -'00 mod-
els: left end onlY), and tighten the rack ends'
CAUTION: Bo cateful nol to damage ihe rack sur-
face with the wranch.
NOTE: '96 -'97 model is shown.
STEERING RACK END
54 N'm t5 5 kgt m' 40 lbl'ft)
STEERING RACK
After tightening the rack ends, stake the four sec-
tions of lock washer with a drift and a mallet.
Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
Be sure the tool is aligned with the flst sections
of the steering rack end belore pressing.
Stake the lock washer in the center ot the flat
section of the steering rack end.
LOCK WASHER
NOTE: This drift has a flat,
to prevent puncturing
WOODEN BLOCK
{cont'd}
17-63

?
Front Toe Inspection/Adiustment
NOTE: Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Check the tire pressure.
Center steering wheel spokes.
Check the toe with the wheels pointed straight
a head.
Front toe: lN 1 1 2 mm llN l/16 r 1/16 inl
- lf adjustment is required, go on to step 4.
- lf no adjustment is required, remove alignment
equrpmenr.
Loosen the tie-rod locknuts, and turn both tie-rods
in the same direction until the front wheels are in
straight ahead position.
TIE.ROD LOCKNUT'14 x 1.5 mm
4.
tJ
6.
Turn both tie-rods equally until the toe readang on
the turning radius gauge is correct.
After adjusting, tighten the tie-rod locknuts.
NOTE: Reposition the tie-rod boot if it is twisted or
displaced.
4,1 N.m {4.5 kgf.m, 33 lb{.ft)
2.
Rear Toe Inspection/Adiustment
NOTE: Use commercially-available computerjzed Iour
wheel alignment equjpment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Release parking brake.
NOTE:
a Measure difference in toe measurements wlth
the wheels pointed straight ahead.
. if the parking brake is engaged, you may get an
incorrect readang,
Rear toe-in: 2 11 mm ttltollllS int
- lf adjustment is required, go to step 2.
- lf no adjustment is required, remove alignment
equipment.
Before adjustment, note the locations of adiusting
bolts on the right and left compensator arms
Loosen the adjusting bolts, and slide the compen
sator arm in or out. as shown, to adjust the toe
ADJUSTING BOLT10 x 1.25 mm
In CoMPENSAToR ARM
4. Tighten the adiusting bolts
. Example:
After the rear toe inspection, the wheel is 2 mm
(0.08 in) out of the specification.- Move the arm so the adjusfing bolt moves 2 mm
(0.08 in) inward trom the position recorded before the
adjustment.- The distance the adjusting bolt is moved should be
equal to the amount out-of-specification.
64 N.m 16.5 ksf m, 47 lbtft)
18-5

)
Brake Pedal
Pedal Height
1. Disconnect the brake switch connector, loosen the
brake switch locknut, and back off the brake switch
until it is no longer touching the brake pedal,
2. At the carpet cutout, measure the pedal height from
the right side center of the pedal pad.
PUSHRODLOCKNUT
Standard Pedal Height (with carpet removed):
M/T: 156.5 mm 16.16 inl
A/T, CVT: 161 mm (5 5/16 in)
3. Loosen the pushrod locknut, and screw the pushrod
in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten
the locknut firmly.
NOTE: Do not adiust the pedal height with the
Dushrod depressed.
It
PUSHROO LOCKNUT15 N.m(1.5 kgf.m. 11 lbI.ft)
POINT ICUTOUTI
4. Screw in the brake switch until its plunger is fully
depressed (threaded end touching the pad on the
pedal arm). Then back off the switch 1/4 turn to
make 0.3 mm (0.01 in) of clearance between the
threaded end and pad. Tighten the locknut firmly.
Connect the brake switch connector.
CAUTION: Make sure that the brake lights go off
when the pedal is released.
LOCKNUT
5. Check the brake pedal free play as described below.
Pedal Free Plsy
1. With the engine off, inspect the play on the pedal
pad by pushing the pedal by hand.
Free Play: 1 - 5 mm (1/16 - 3/16 inl
2. lf the pedal free play is out of specitication, adjust
the brake switch.
CAUTION: lf the pedal free play is insufficient, it
may result in brake drag.
BRAKE PEDAL PAO
)
19-5
*0.3 mm(0.01 in)

Master Cylinder/Brake Booster
Pushrod Glearance Adjustment
NOTEr
. The master cylinder pushrod-to-piston clearancemust be checked and adjustments made, if neces_sary, before installing the master cylinder.. ABS type is shown, conventional brake type is similar.
1. Set the special tool on the master cylinde. body; push
in the center shaft until the top of it contacts the endofthe secondary piston by turning the adjusting nut.
Without disturbing the center shaft's Dosition, installthe specialtool upside down on the booster.Install the master cylinder nuts, and tighten to thespecified torque.
Connect the booster in-line with a vacuum gauge O _
101 kPa (0 - 760 mmHg, 30 in.Hg) to the booster,sengine vacuum supply, and maintain an enginespeed that will deliver 66 kpa (500 mmHg, 20 in.Hg)vacuum.
With a feeler gauge. measure the clearance Detweenthe gauge body and the adjusting nut as shown.
Clearance: 0 - 0.4 mm {0 - 0.02 in)
VACUUM GAUGE(Comm€rcially availeblel0 - 101 kPa{0 - 760 mm Hg, 30 in.Hg)
AOJUSTING NUT
FEELER GAUGE
19-22
10.
NOTE: lf the clearance between the gauge bodyand adjusting nut is 0.4 mm (0.02 in), the pushrod-to-piston clearance is 0 mm. However, if the clear_ance between the gauge body and adjusting nut is0 mm, the pushrod-to-piston clearance is 0.4 mm(0.02 in) or more. Therefore, it must be adjusted andrechecked.
6. lf clearance is incorrect, loosen the star locknut, andturn the adjuster in or out to adjust.
NOTE;
. Adjust the clearance while the specified vacuumis applied to the booster.. Hold the clevis while adjusting.
Tighten the star locknut securely.
Remove the special tool.
0 - 0.4 mm (0 - 0.02 in)
7.
ADJUSTERPUSHRODADJUSTMENT GAUGE07JAG - SD('1(x)
9. Adjust the pushrod length as shown if the boosterrs removed.
STAR LOCKNUT22 N.m{2.2 kg,f.m, 16lbtft)
11610.5 mm{{.571 0.02 in)
PUSHRODLOCKNUT15 N.m 11.5 kgf.m, 11 tbtftl
Install the master cylinder {see page l9-21).

Rear Brake Galiper
Disassembly (cont'd)
7. Remove the piston by rotating the piston counter-clockwise with the tool, and remove the piston
boot.
CAUTION: Avoid damaging the piston.
PISTON BOOTReplace.
Remove the piston seal.
CAUTION: Take care not to damage the cylinderbore.
CALIPER BODYCheck for scoring on
9. Install the special tool between the caliper bodv andspnng cover.
CAUTION: Be caretul not to damags the inside ofthe caliper cylinder during caliper disassembty.
BRAKE SPRINGCOMPRESSOR07HAE - SG00100
11.
LOCKNUTS
Position the locknuts as shown. then turn the shaftuntil the plate just contacts the caliper body.
NOTE: Do not compress the spring under thespring cover.
Turn the shaft clockwise 1/4 -'ll2 tu.n to comoressadjusting spring B in the caliper body.
CAUTION: To preyant damage to the inner compo-nonts. do not turn the shaft mor€ than 1/2 turn.
SHAFT
LOCKNUTS
PISTON SEALReplace.
ADJUSTII{GSPRING 8
19-28

\
13.
Lower the locknuts fully, and tighten them securely.
NOTE: Keep the locknuts in this position until you
reinstallthe circlip.
Remove the circlip with snap ring pliers.
SNAP RINGPLIERS07914 - SA50001
't 4.Hold the plate with your fingers, and turn the shaft
counterclockwise. Remove the special tool from the
calioer.
LOCKNUTS
l./
15. Remove the adjusting bolt.
Remove the spring cover, adjusting spring B, spacer,
bearing A, and cup from the adjusting bolt.
Remove the sleeve piston, and remove the pin from
the cam in the caliper body.
'17 .
SLEEVE PISTONCheck lor wear anddamage,
i
I
I
6-50-awl \
IO-RIITGRepl6ce.
(cont'd)
19-29

10. lnstall the special tool onto the spring cover, and
turn the shaft until the locknut contacts the plate.
Check that the flared end of the spring cover is below
the circlip groove.
Install the circlip into the groove. then remove the
special tool.
NOTE: Check that the circlip is seated in the groove
properly.
11.
12.
CIRCLIP
t.t
SPRING COVER
13. Coat a new piston seal with recommended silicone
grease in the caliper seal set, and install it in the cali-
per.
PISTON BOOTReplace. RUBBER GREASE
Apply recommended rubber grease in the caliper
seal set to the sealing lips and inside of a new pis-
ton boot, and install it in the caliper.
Coat the outside of the piston with brake fluid, and
install it onto the adjusting bolt while rotating it
clockwise with the tool.
CAUTION: Avoid damaging the piston and piston
boot.
PISTON SEALReplace.
-6l
14.
PISTON
(cont'd)
19-33