gearbox HONDA CIVIC 2002 7.G Owner's Guide

Steering Gearbox Installation
2.
'1.Before installing the steering gearbox, slide the
rack all the way to the passenger's side (right
direction).
Pass the right side of the steering gearbox together
with the tie-rods through the wheelwell opening on
the passenger's side. Continue moving the steering
gearbox toward the passenger's side untilthe
driver's side tie-rod end and gearbox clears the
master cylinder and under-hood fuse Ielay box.
Lower the steering gearbox. and move it toward
the driver's side untilthe steering gearbox is ln
Dosition.
Be careful not to damage the hoses, lines
and wire harnesses.
3. Installthe pinion shaft grommet (A).
4. Insert the pinion shaft up through the bulkhead,
then slip the right side of the steering gearbox
housing (A) over the mounting stud (C) on the
gearbox mounting bracket.
\- --' '.'', i
10 x '1.25 mm61 N.m{6 2 kgl m, 45 lb{ ftl
Install the steering stiffener B, and lightly tighten
the steering gearbox mounting nuts.
Install the steering stiffener A with the gearbox
mounting bolts. Then tighten allthe steering
gearbox mounting hardware to the specified torque.
10 x 1.25 mm6l N.m(6.2 kgt.m, 45 lbt.ft)
: --.-{..
(cont'd )
:-1....
17-63

EPS Components
Steering Gearbox Installation (cont'd)
7. Installthe body stiffener (A), and torque the
mounting bolts to the specified torque.
8 x 1.25 mm29 N.m {3.0 kgf.m,22lbf.ftl
LInstall the heater valve (A) on the bulkhead, and
connect the heater valve cable end (B) to the heater
valve arm (C). Readjust the heater valve cable {seepage 21-46).
9.8 N.m(1.0 kgf m,7.2 tbf.ftl
L-t ,:.i.t'
17-64
9. Reinstall the heater hose (A) on the hose bracket.
Install the engine wire harness clamps (B) to the
three harness brackets.
Under the steering gearbox, install the ground
cable terminal (A) on the steering gearbox housing.
10.
'I t.
9.8 N.m{1.0 kgf.m, 7.2lbf.ft)

12. lnstallthe EPS wire harness bracket (A) on the
gearbox housing, and connect the 6P connector (B)
propefly.
9.8 N.m{1.0 kgt m,7.2 lbt.ftl
13. Installthe heat shield (A).
,.!,..''6f
14.
15.
Center the steering rack within its stroke.
Wipe off any grease contamination from lhe ball
joint tapered section and threads. Then reconnect
the tie-rod ends 1A)to the damper steering arms.
lnstall the ball joint nut (B) and tighten them.
Install the new cotter pins (C), and bend them as
shown.
(cont'd)
B10 x 1.25 mmi€ N.m{4.4 kgf.m.32 tbt.ftl
to.
, -', ''l
:1)
17-65

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.
\

Service Manual lndex
(cont'dl
Power Window Switch, Passenger'slnput Test .............-......
Replacement...,-.-.-...,..
Radialor Cap
Rocker Arm AssemblyRemovalD;sassembly/Reassembly
Specifications6-26 (See section 2)22-13022 13222-133..................... 6-27
ComponentLocation Index ..............22 124Circuit Dia9ram .................. ............... 22 125
Ouaner Window Glass8ep1acement ......................................... 20-29
lnstallation6-38
Rocker ArmsTestInspecton6-28
Roof MoldingsReplacement
Seat BeltsComponent Location Index ................... 23-3
Seat 8ehs, FrontReplacementrnspec!on
sRsComponent Location Index ................. 23-13Description ....................................... 23-31Circuit D;agram ... .... ...........2334lnspection/Replacemenl ................... 23 1 126-7
SRS lndicator CircuilTroubleshooting
Startel
Stabilizer BarReplacementFront SuspensionRear Suspension
Stabilizer LinksRemoval/lnstallationFront SuspensionRear Suspension
23 105oSRS UnitReplacement..-.................................... 23-122s
R
1A-1718-30
18 1818-31RadiatorTest......23-9
23-1Replacement ...........
Radiator and Condenser FansCommon CircuitTroubleshooling......... ..... .........21 29
10-310-10Seat Behs, RearReplacement
Seat Cover, FrontReplacement
Seat Cushion Cover, R6ar10-3Replacement
ReplacementTest
Test
20-75
20-84
Overhaul
Starter SolenoidTest..-.-...4-7
Radiator Fan AssemblyTestSeat, Driver'sRemovaf/lnstaf lation ............................ 20 1 1Disassembly/Reassemb1y ................... 20-73
Sedt, Faont Passenger'sDisassembly/Reassemb1y ................... 20-74
Seat, RearRemoval/lnstallation ............................ 20-80
Seat-back Cover, Reer
Starting SystemComponent Location Index...............-..... 4-3CircuitDia9ram ........................................ 4 4
\'{........................ r0-4
Radiator Fan CircuitTroubleshooting
Radiator Fan SwhchReplacementTest
Radiator Fan Switch CircuitTroubleshooting
Rear Air OutletReplacement
Circuil DiagramTest
Rear Window D€rogger WiresRepair
RearWindow GlassReplacement
Troubleshooting10-14
10-1710-17
10 16
17 -3
11-4
17-9
SteeringComponent Location Index................-..Inspectaon ...................
Steering ColumnRemoval/lnstallationReplacementInspection11 11
17-5117 5517 63
20 68
Seat-back Latch, ReaI2Q-104Replacement
Seat-back Striker. RearReplacement
Steering GearboxRemovalOverhaulRear Window DefoggerComponentLocalion Index ..............22 104lnstallation
Steering Hanger BeamReplacement
Steering LinkageInspefiron
Steering LockReplacement
Steering Rack GuideAdiustment
22-10522 106
22-106
SeatsComponent Location Index....-............ 20-70
Shift ForksInspectton13,21
20-25
2l-3621 36
21 25
Disassembly/Reassembly ................... 13-22
Shitt Lever TrimRemoval/lnstallation ............................ 20 61
.....11-12
SecirculationReplacementControl Motor17-13Test.....
Recirculation Control Motor CircuitTroubleshooting
Side Airbag, Drivel'sReplacement
Side lmpact SensorsReplacement
Spark Plugs
23-115
23 123
Side Marker LightRep1acement......................................... 22-A3
17417-6Disassembly/Reassembly ..................... 17 71nsta11ation .............................................. 17-8
SublramesReplacement
Removal
RefrigerantReplacement ..-.-.-...................... 21 53, 54, 55Test ........................................................ 21-56
Retrigerant OilReplacement...............................-........... 21-6. .._..4_19
20 112