lock HONDA CIVIC 2002 7.G Workshop Manual

EPS Components
Steering Gearbox Overhaul (cont'dl
Special Tools Required. Locknut wrench 07ZAA-S5A0100. Pincers, Oetiker 1098 or equivalent, commercially
available.
NOTE:. Refer to the Exploded View as needed during thisprocedure.
. Do not allow dust, dirt, or other foreign materials toenter into the steering gearbox.
Eemoval
1, Remove the steering gearbox (see page 17-b1).
Disassembly
2. Unbend the lock washer (A).
. - -,'i.
Hold the bracket (A) with one wrencn, anq unscrewboth tie-rod ends (B) with another wrench. Removethe lock washers.
17-56
4. Remove the stop plate (A). the 12 mm flange bolts(B), the O-rings (C), and the bracket (D) from thesleering gearbox.
Loosen the locknut (A), then remove the rack guide
screw (B), sprlng (C), disc washer (D), and rackguide (E) from the steering gearbox.
i::..:4,. , -- -. - :.--. '

6. Remove the two boot bands (A) from boot (B).
Compress the boot by hand, and apply vinyl tape
(C) so the boot ends stay collapsed and pulled back
Attach the yoke (A) of a universal puller to the
steering gearbox mounts with bolts. Securely
clamp the yoke in a vise as shown. Do not clamp
the steering gearbox housing in the vise.
1.
10.
8. Installthe special tool (A) on the lock screw (B)
securely. then loosen and remove the lock screw
from the steering gearbox housing.
07zAA-S5A0r00
Remove the special tool.
Pull on the rack housing (A) to remove it from the
steering gearbox housing, Remove the boot {B) and
slider guide (C) from the cylinder.
(cont'd)
17-57

EPS Components
Steering Gearbox Overhaul (cont'd)
'll. Check the slider guide for damage and cracks.Using vernier calipers to measure the thickness ofthe slider guide. lf the thickness is less than servicelimit, replace the slider guide,
f Z,-----:-r-.--------.t.t'E-r
I (fr--', -.----
/i Il il ( t t , ,)))
|i@r
25.3 mm{0.925 in.}
Remove and discard the stop ring {A)on the
cylinder by expanding it with snap ring pliers.
Remove and discard the lock screw {B}.
13. Install the new lock screw on the rack housing.
14. Installthe new stop ring in the groove (C)on thecylinder by expanding it with a snap ring pliers. Becareful not to scratch or damage the housing
surface with the stop ring edges.
25.3 mm{0.925 in.l
12
17-58
15. Apply multipurpose grease to the indicated part
{shaded part) of the outer surface of the rackhousing. Do not apply to the dents and grooves.
\
I

16. Set the new boot bands (A) on the band installation
grooves of the boot (B) by aligning the tabs (C) with
the holes (D) of the band. Do not close the ear of the
boot band in this step.
Compress the boot by hand, and apply vinyl tape
(E) to the bellows so the boot ends stay collapsed
and pulled back.
Pass the boot over the rack housing so the smaller
diameter end of the boot faces the steering
gearbox housing.
Attach the yoke (A) of a universal puller to the
gearbox housing mounts with bolts. then securely
clamp the yoke in a vise as shown. Do not clamp
the steering gearbox housing in a vise.
11.
18.
'19. Push the rack housing (A) into the steering gea rbox
housing (B) so the notch (C) is aligned with the pin
(D) on the bottom of the gearbox housing inside
20. Tighten the lock screw {A) by hand first, then install
the special tool (B) on the lock screw. Lightly
tighten the lock screw. Do not tighten the lock
screw to the specified torque Yet.
21. Remove the special tool.
(cont'd)
17-59

EPS Components
{Steering Gearbox Overhaul (cont'dl
22. Apply multipurpose grease to the sliding surfaceand circumference ofthe rackguide (A), and installit onto the gearbox housing. Wipe the grease offthe threaded section ofthe housrno.
...'.
,. ,l
.j
23. Installthe disc washer (B)with its convex sidefacing the rack guide. Installthe spring (C). Appty
sealant to the middle of the threads on the rackguide screw (D), then install and tighten it to 25
N m (2.5 kgf.m, 18 lbf.ft). Loosely instatlrhe tocknut(E).
24. Apply multipurpose grease to the sliding surface ofthe slider guide (A). Keep grease off of the rack-to-slider guide mating surfaces and the boot-to-sliderguide mating surfaces.
Slide the steering rack all the way to left, and place
the slider guide on the steering rack by aligning thebolt holes (B).
'1 - .- =-1, -
17-60
29.
25. Centerthe steering rack within its stroke, and alignthe slider guide (A)with the hotes (B) in the boot (C).
Fit the slider guide to the boot by pressing around
the edges of the holes securely
E25 N.m 12.5 kgt.m, 18 tbt.ft)
26. Before installing the bracket (D), clean the mating
surface ofthe 12 mm flange bolts (E) and thebracket. Coat the new O-rings {F) with multipurposegrease, and installthem on the '12 mm flange bolts.
27. Loosely install the bracket on the steering rack bytightening the 12 mm flange bolts to 25 N.m (2.5
kgf.m, 18lbf.ft).
28. Hold the gearbox housing using a yoke, then install
the specialtool on the lock screw (A). Retighten thelock screw to the specified torque values.
{16.5 kgt.m, 119 lbf.ft}
Remove the special tool.
A

30, Retighten the 12 mm flange bolts (A) to the
soecified toroue value.
After tightening the 12 mm flange bolts, install a
new stop plate (B) over one of the bolt heads. Be
sure the tabs (C) of the stop plate are aligned with
the flat surfaces of the bolt head.
Clean off any grease or contamination from the
boot installation grooves on the housing.
Expand the boot (A) by removing the vinyltape,
and fit the boot ends (B) in the installation grooves
on the cylinder housing.
5t.
32,
74 N.m (7.5 kgf.m,5ir lbf.ft)
34. Close the ear portion (A) ofthe bands (B)with
commerciallv available pincers, Oetiker 1098 or
equivalent (C).
35. Installthe new lock washer (A) with its radiused
side facing (B) the tie-rod (C), and screw the tie-rod
on the bracket (D). Repeat this step for the other
side of the tie-rod. Hold the bracket with one
wrench, and tighten the tie-rods to the specified
torque with another wrench.
,,";=-...,.,
(cont'd)
*=,,',
17-61

EPS Components
Steering Gearbox Overhaul (cont'dl
36. Bend the lock washer against the flat spots on thebracketwith a Iarge pair of pliers.
37. Adjust the rack guide screw {see page 17-13).
17-62

EPS Components
4
17.
18.
Steering Gearbox Installation (cont'dl
Install the motor on the steering gearbox (see page
17-49).
lnstall the steering joint (A). and reconnect the
steering shaft (B) and pinion shaft (C). Make sure
the steering joint is connected as follows:
. Insertthe upperend of thesteering jointontothe
steering shaft (line up the bolt hole (D) with the
flat portion (E) on the shaft).. Slip the lower end of the steering joint onto thepinion shaft (line up the bolt hole with the groove
(F) around the shaft), and loosely installthe lowerjoint bolt. Be sure that the lower joint bolt is
securely in the groove in the pinion shaft.. Pull on the steering joint to make sure that the
steering joint is fully seated. Then install the
upper joint bolt, and tighten it to the specified
torque. Tighten the lower joint bolt to the
specified torque.
8 x '1.25 mm28 N.m{2.9 kgf.m,21 tbt.ft)
19.
20.
Installthe driver's dashboard lower cover (see
page 20-59) and under cover (see page 20-60).
lf the steering wheel was turned, center the cable
reel by first rotating it clockwise until it stops. Then
rotate it counterclockwise (about two and half
turns) untilthe arrow mark on the label points
straight up. Reinstall the steering wheel (see page
17 -8).
Install the front wheels.)1
17-66
22. After installation, perform the following checks.
. Perform the front toe inspection.. Check the steering wheel spokeangle. lfsteering
spoke angles to the right and left are not equal(steering wheel and rack are not centered),
correct the engagement of the joinvpinion shaft
serrations, then adjust the front toe by turning
the tie-rods, if necessarv.
\

EPS Control Unit Removal/
Installation
1. Remove the passenger's under panel.
2. Turn up the floor carpel, remove lhe EPS control
untr.
Disconnect the EPS control unit connectors.
lnstallthe EPS control unit in the reverse order of
removal.
After installation, start the engine, and let it idle.
Turn the steering wheelfrom lock-to-lock several
times. Check that the EPS indicator does not come
on.
3.
E
Tie-rod Ball Joint Boot Replacement
Special Tool Required
Attachment, 42 mm 07OAD-P0A0100
l. Remove the boot from the tie-rod end, and wipe the
old grease off the ball pin.
2. Pack the lower area of the ball pin(A)wilhfresh
mulr purpose grease.
3. Pack the interior of the new boot (B) and lip (C) with
fresh multipurpose grease.
Note these items when installing new grease;
. Keep grease offthe boot installation section (D)
and the tapered section (E) of the ball pin.
. Do not allow dust, dirt, or other foreign materials
to enter the boot.
4. Installthe new boot (A) using the specialtool. The
boot must not have a gap at the boot installation
sections (B). After installing the boot. check the ball
pin tapered section for grease contamination, and
wipe it if necessary.
07(lAD-P0A0100
*-4
r/ \-,d______i.l+_D
-6rA
17-67

Front Toe Inspection/Adjustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
equipment manufacturer's instructions,
1. Center the steering wheel spokes.
2. Checkthetoe. lf it is not with in the specif ication, go
to step 3.
Front toe-in: 0 t 3 mm {0 t 0.12 in.)
3. Loosen the locknut (A) while holding the tie-rod end(B ).
A14x 1.5 mm,14 N.m(a.5 kgt m,33 lbt.ftl
5.
Turn the tie-rod (C) untilthe toe is correct.
After adjusting, tighten the locknut while holding
the tie-rod end. Make sure the toe setting does not
change.
1,;
Rear Toe Inspection/Adiustment
Use commercially-available computerized four wheel
alignment equipment to measure wheel alignment(caster, camber, toe, and turning angle). Follow the
equipment manufacturer's instructions.
1, Release the parking brake.
2. Checkthe toe. lf it is not within the specification. go
to step 3.
Rear toe-in {inspection):
1 1 3 mm (0.04 a 0.12 in.)
3. Loosen the self-locking nut (A)while holding the
adjusting bolt (B).
Do not loosen lhe special bolts (C) on the
lower arm to adjust the alignment.
4. Replace the self-locking nut with a new one, and
lightly tighten.
NOTE: Always use a new self-locking nut whenever
it has been loosened.
Turn the adjusting bolt until the toe is correct.
Rear toe.in (adiustment):
2 ' , mm {0.08 "' ,. in.}
Tighten the self-locking nut to the specified torque
while holding the adjusting bolt.
(cont'd )
18-7