air con HONDA CIVIC 2000 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

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

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.

)
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

)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'dl
64. Apply grease to the circumference of the rack endhousing.
RACK END GROOVE
=^.#-q!:s!!H
SILICONE GREASE
Apply a light coat of silicone grease to the bootgrooves on the rack ends.
lnstall the boots in the rack end with the tie-rodclips.
NOTE: Install the boots with the rack in the straightahead position (right and left tie-rods are equal inlength).
66.
RACK END
NOTE: Wipe the grease offthe thread section.
17-64
TIE.ROD CLIP
67. Adjust the air hose fitting position of the boots bvturning it as shown below.
LEFT BOOT(Viewed from theleft side)
RIGHT BOOT{Viewed from theright side)
AIR HOSE FITTING
Install new boot bands on the boot, and bend bothsets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
Lightly tap on the doubled-over portions to reducetheir height.
Slide the rack right and left to be certain that theboots are not deformed or twisted.

71.Connect the air tube between the right and left
boot.
lnstall the clips on the cylinder lines' then clamp the
air tube with the cliPs.
l./
CYLINDER LINE A
CLIP
l-,
lnstallation
CAUTION: Be carelul not to bend or damage the feed
line and cylinder lines when installing the gearbox'
1, Before installing the gearbox, slide the rack all the
way to right.
2. Install the mounting cushion on the steering gear-
DOX.
Install the pinion shaft grommet, then insert the pin-
ion shaft up through the bulkhead.
NOTE: Align the notch in the pinion shaft grommet
with the tab on the valve housing.
Install the mounting bracket over the mounttng
cushion, then installtwo gearbox mounting bolts'
MOUNTING BRACKET
cusHroN
39 N.m(4.0 kgj m, 29 lbtftlNOTE: Install the bracket
with the arrow Pornllngtoward the front.(cont'd)
17-65

Steering Gearbox
Installation (cont'dl
5. Install the stiffener plate with the two gearbox
mounting bolts and stiffener plate aftaching bolts.
CAUTION: Be sure the air tube is not caught orpinched by stiffener plate,
NOTE: Install the bolts loosely first, then tighten
them securely.
7.
8.
6.Install the return hose joint by tightening the l6 mm
flare nut.
Connect the relurn hose securely, and tighten the
adjustable hose clamp from the engine compart-ment.
Connect the feed line and tighten the 14 mm flare
nut.
NOTE: Make sure that there is no interference
between the fluid lines, the rear beam or any otherparts.
ADJUSTABLE HOSECLAMP(see page 17-39)
16 mm FLARE NUT28 N.m {2.9 ksl.m. 20 lbf.ft)
RETURN
1a mm FLARE NUT37 N.m (3.8 kg{.m, 27 lbt.ftl
ATTACHING AOLTS38 N.m 13.9 kgf.m, 28 lbf.ftl
MOUNTING BOLTS(} N.m (4.a kgt m, 32 lbf.ftl
17-66
9.Center the steering rack within its stroke.
Slip the lower end of the steering joint onto the pin-
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the upper and lower
steering joint bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.. Be sure that the lower steering joint bolt is securely
in the groove in the steering gearbox pinion.
. lf the steering wheel and rack are not centered,
reposition the serrations at lower end of the
steering joint.
10.
STEERING JOINTUPPER BOLT22 N.m (2.2 kgf.m,16 tbt.ftl
PINION SHAFT
Groove,
STEERING JOINTLOWER BOLT22 N.m (2.2 kgt.m, 16lbtttl
11.Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark onthe label points straight up. Reinstall the steeringwheel (see page 17 35).