Section 23 HONDA CIVIC 2000 6.G Workshop Manual

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

It
12.
13.
lnstall the new lock washer in the groove in the
steering rack.
Installthe steering rack end into the rack
LOCK WASHER RACK END 54 N m ts.s kgf'm, 40 lbtft)
Replace.
TAB
(l*v
14.
15.
RACK END
Hold the steering rack with a wrench and tighten
the rack end with another.
CAUTION: Be careful not to damage the tack sur-
fac€ with the wrench.
After tightening the rack ends, stake the four sec-
tions of the lock washer with a roll pin 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 flat sections
of the steering rack end before pressing
. Stake the lock washer in the center of the flat
section of the steering rack end.
ROLL PIN DnlFTl(Commorci.lly .Yril.blolSnap-On No. PPRS or oquival.nt
NOTE: This drift has a flat
tip, to prevent puncturing
of metal washer.
srEEatruG nlCr/rl,WOODEN BLOCK
TIE.ROO CLIP
16. Apply grease around the outside ot the rack end
housing.
Apply a light coat of silicone grease to the boot
grooves on the rack ends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rods are
equal in length).
=-..r=-q!q!!.n
SILICONE GREASE
17.
(cont'd)
17-11
NOTE| WiPe grease off
the thread sectlon

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.

Component Locations
I
lndex
Power Steering:
NOTE:
. li an intact airbag assembly has been removed trom a scrapped vehicle or has been found defective or damaged dur-
ing transit. storage or service, it should be deployed (see section 24).
. Before removing the gearbox, remove the driver's airbag assembly and steering wheel.
. After installing the gearbox, checkthewheel alignmentand adjust if necessary.
SRS components are located in this area. Review the SRS component locations. precautions, and procedures in the SRS
section {24} before performing repairs or service.
STEERING WHEELRemoval/lnstallation, page 17-35
Disassembly/Feassembly, page 17-36
DRIVER'S AIRBAG ASSEMBLYRemoval/lnstallation, see section 24
STEERING GEAREOXRack Guide Adiustment, page 17'33
/
Removal, page 17 47Disassembly, page 17-49Reassembly, page 17-55Installation, page 17-65VALVE EODY UNITOverhaul, page 17 52
COLUMNFemoval/lnstallation, page 17-37Inspection, page 17-38CASLE REELRemoval/lnstallation, see section 24
IGNITION SWITCHSee section 23
POWEF STEERING PUMPPump Belt Inspection, page 11-32Pump Belt Adiustmenl, page 11'32Pump Pressure Check, page 17 34Removal/lnstallation, page 17'40Disassembly/Reassembly, page 17-41
TIE.ROD END BALL JOINTBallJoint Boot Replacement, page 17-68
1,,
17-15

System Description
Steering Gearbox
The rack-and-pinion type steering gearbox has a valve body unit incorporated with the pinion to control the steering fluidpressure. Steering fluid from the pump is regulated by a rotary valve in the valve body unit and is sent through the cylin,der line to the power cylinder, where hydraulic pressure is applied. The steering fluid in the other side of the power cylin,der returns through the cylinder line and valve body unit to the reservoii.
VALVE EODY UNIT
CYLINDER LINE
To RESERVOm +-From PUMP -;
POWER CYLINDER
Valve Body Unit
Inside the valve body unit is the valve, which is coaxial with the pinion shaft, and controls the steering fluid pressure. Thevalve housing is connected with the fluid line from the pump, the return line to the reservoir, and the two cylinder linesfrom the respective power cylinder. The pinion shaft is double - structured with the input shaft connected to the piniongear, both of which are interconnected with the torsion bar.
The pin inserted in the valve and the pinion shaft groove engage; this allows the pinion shaft to rotate together with thevalve. Because of this construction, the difference in angle in the circumferential direction between the input shaft and thevalve becomes larger according to the torsional strength of the pinion or steering resistance. However, maximum torsionbetween the shafts is regulated by the engaged splines of the shafts at the pin engagement section to hold the torsion barwithin the set value,
This allows the steering system to function as an ordinary rack-and-pinion type steering if the steering fluid is not pressur-
ized because of a faulty pump,
VALVE
Difforence in angle botwoon theinput shaft and pinion shsft
PINION SHAFT
lo
INPUT SHAFT
-l
a
17-20
INPUT SHAFT

Pressure Control
Low assist at higher speeds:
WhensteeringresistanceIsIow,suchaswhendrivingathighspeeds,orwhendrivingstraightahead,theinputshaftis
near or in the neutral position, so there is little or no fiow ro any of the power cylinder orifices. Most oI the feed pressure
fromthepumpisbypassedtothereservoir.Becauseofthis,thepressurestaysthesameinbothsidesofthepowercy||n-
der, resulting in low or no asslst
VALVE From PUMP
SECTION A-A
RETURN PASSAGElTo RESERVOIRI
POWER CYLINDER
STEERING GEARBOX
High assist at lower speeds:
When steering resistance is high. such as when driving at low speeds' or when turning the wheel wirh the vehicle
stopped,thedifference|nang|ecreatedbetweentheinputshaftandtheVa|veopensthef|uidpassageononeside,and
c|osesthefluidpassageontheotherside,ateachpairoforifices'Thef|uidpressureincreasesinthesideo|thepower
cy|inder|edbythe|argerf|uidpassage'Thisincreasedpressurepushesontherackpiston,a|lowingthesteeringwhee|to
be turned with light effort. on the other side of the power cylinder, the return passage opens allowing the steering tluid to
returnthroUghtheinputshafttothereservoir'Thef|uidpassagestothepowercy|inderautomatica||ychangeins|ze,
increasing as the steering resrstance increases. In other words, the passages become larger and power assist increases
when the steering effort would normally be high, (for example' when parking or making low speed turns)' and the pas-
sagesbecomesma||erandpowerassistdecreaseswhenthesteeringeffortwou|dnorma||ybe|ow,(forexamp|e,when
driving at high speeds or straight ahead).
FLUIO PASSAGE TO
POWER CYLINDER
/t=\\a!-4,))
=YjJ
RESERVOIR
SECTION A-A
l'
{High fluid Pressure}

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

/
Uneven or rough steering
Steering wheel kicks back
during wide t!rns.
ll,
)
Adjust the rac* guide (see page 17-3).
lf the problem is not corrected bY
adjusting the rack guide, replace
the gearbox.
Adiust the belt tension. Feplace the
belt, il necessary (see Page 17 32).
lfthe engine stalls when the wheel
is turned while car is stopped or
moving at low speed, adjust the
idle spe€d (see section 11)
ldle speed low or erratic.
Check power sleering fluid level lf
the level is excessively low, check
lor leaks in the system. Add lluid
to the specified level.
Air in reservoir, or check Powersteering Iluid level.
lf ltuid level is OK, check O-rings
and seals on both ends of thepump inlet hose, and the P/Spump housing mating surfaces
and the pumP shaft oil seal for
suction leaks. RePlace Parts as
nocessary.
Adjust the belt tension (see Page17 32)or replace belt.Pump belt sliPPing on PLrlleY(pump stops momentarilY)
Check if pump press{rre is normal
and the gauge needle travel is 500
kPa (5 kgl/cm?, 7l Psi) or less.
Chock the flow control valve if the
needle travel exceeds 500 kPa (5
kgflcm', 71 Psi). l{ the flow control
valve is normal, replace the PumPas an assemoly.
Install the power steering pressure
gauge, Close the Pressure contrcl
valve fully and m6ssure the PumPpressure {s€e page 17-34}.
17 -25,

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