ect HONDA CIVIC 2003 7.G Workshop Manual

EPS Indicator Circuit Troubleshooting
1.Turn the ignition switch ON (ll), start the engine,
and watch the EPS indicator.
Does the EPS indicator come on?
YES lf the EPS indicator comes on and goes off, it's
OK. lf the EPS indicator stays on or blinks. go to
step 12.
NO Go to step 2.
Turn the ignition switch OFF, then ON (ll) again,
and watch the brake system indicator,
Does the brake system indicator come on?
YES-Go to step 3.
NO Repair open in the indicator power source
circuit.l. Blown No. 10 (7.5A)fuse.
. Open in the wire between the No. 10 (7.5A) fuse
and gauge assembly.. Open circuit inside the under-dash fuse/relay box,. Faulty gauge assembly.
Turn the ignition switch OFF,
Connect a jumper wire between the gauge
assembly 22P connector terminal No. 13 and body
ground, then turn the ignition switch ON (ll).
GAUGE ASSEMBLY 22P CONNECTOR (Blue connector)
Wire side of female terminals
Does the EPS indicator come on?
YES-Go to step 5.
NO Inspect the EPS indicator bulb, if the bulb is
OK, replace the bulb circuit board in the gauge
assembly.l
3.
4.
5. Turn the ignition switch OFF.
6. Disconnect EPS control u n it connector C (20P).
7. Turn the ignition switch ON (ll).
8. Connect EPS control unit connector C (20P)
terminal No. 6 to body ground with a jumper wire.
Wire s d€ oflemale16rmina s
Does the EPS indicatot come on?
YES Go to step 9.
NO Repair open in the wire between the gauge
assembly and the EPS control unit.l
Turn the ignition switch OFF.
Disconnect EPS control unit connector A (2P),
Check for continuity between EPS control unit
connector A terminal No. 2 and body ground.
EPS CONTROL UNITCONNECTOA A I2PI
wire s de oftemale terminals
ls there continuity?
YES Check for loose or poor connections at the
EPS control unit. lf the connections are good,
substitute a known-good EPS control unit. lf the
symptom/indication goes away, replace the
original EPS control unit and recheck.I
NO Repair open in the wire or a bad ground at
G151,t(cont'd)
9.
10.
'l 1.
EPS CONTBOL UNIT CONNECTOB C {2OP)
17-47

EPS Components
I
12.
EPS Indicator Circuit Troubleshooting (cont'dl
Turn the ignition switch OFF.
Disconnect EPS control unit connector C (20P).
Turn the ignition switch ON (ll).
Does the EPS indicator come on?
YES-Repair short to ground in the YEUBLU wire
between the gauge assembly and the EPS control
unit, or replace the bulb circuit board in the gauge
assembly.l
NO-Go to step 15.
Measure the voltage between EPS control unit
connector C (20P)terminal No. 10 and body ground.
EPS CONTROL UNIT CONNECTOR C I2OP)
Wire side of female terminals
ls there battery voltage?
YES-Go to step 16.
NO-Repair open in the wire between EPS control
unit connector C (20P) and the No, 10 (7.5A) fuse. t
13.
14.
17-48
16. Measure the voltage between EPS control unit
connector A (2P)terminal No. '1 and body ground.
EPS CONTROL UNITCONNECTON A (2P}
+B (WHT/BLUI H
Itr
v-L
17.
18,
19.
20.
Wire side of female terminals
ls there battery voltage?
YES-Go to step 17.
NO-Check for a blown No. 18 (604) fuse in the
under-hood fuse/relay box or open/short in the
WHT/BLU wire between the under-hood fuse/relay
box and the EPS control unit.l
Turn the ignition switch OFF.
Reconnect EPS control unit connector A (2P).
Turn the ignition switch ON (ll).
Measure the voltage between EPS control unit
connector C (20P)terminal No. 8 and body ground.
EPS CONTROL UNIT CONNECTOR C (2OP)
Wire side of female terminals
ls therc about 10 V?
YES Check for loose or poor connections at the
EPS control unit. lf the connections are good,
substitute a known-good EPS control unit. lf the
symptom/indication goes away, replace the
original EPS control unit and recheck.l
NO Repair short to ground in the BRN wire
between the data link connector and the EPS
control unit.I

Motor Removal/lnstallation
Bemoval
1. Make sure you have the anti-theft code for the radio,
then write down the frequencies for the preset
buttons.
2. Disconnect the negative cable from the battery, and
wait 3 minutes before beginning work.
3. Remove the air cleaner assembly (A).
4. Remove the connector bracket (A) onthegearbox
housing, and disconnect the motor 2P connector(B).
9.8 N.m {1.0 kgf.m,
5. Remove the motor {A) from the gearbox housing.
6. Remove the O-ring (B) and discard it.
(cont'd)
17-49

EPS Components
(Motor RemovaUlnstallation (cont'dl
lnsiallation
7. Clean the mating surface of the motor (A) and
gearbox.
Apply a thin coat of silicone grease (P/N 08733-
8070E)to the new O-ring (B), and carefully fit it on
the motor.
Apply grease {Nippon Grease WR-S or equivalent
steering gear grease) into the motor shaft (C).
qE
8 x '1.25 mm20 N.m12.0 kgt.m,7 .2lbl ftl
L==-c].E@
9.
17-50
r0.Install the motor on the gearbox by engaging the
motor shaft and worm shaft (D). Note the motor
installation position {direction of motor wires).
Before tightening the bolts, turn the motor two or
three times right and left about 45 degrees. lvlake
sure the motor is evenly seated on the steering
gearbox and that the O-ring is not pinched betlveen
the mating surfaces.
Installthe removed Darts in the reverse order of
removal. and note these items:
lvlake sure the motor 2P connector is properly
connected.
lvlake sure the motor and EPS wires are not
caught or pinched by any parts.
Reconnect the negative cable to the battery.
Do the engine control module (ECM) idle learn
procedure (see page 11-139).
Enter the anti-theft code for the radio station
Dresets. Reset the clock,
Do the oower window control unit reset
procedure (see page 22-1241.
After installation, start the engine, and let it idle.
Turn the steering wheel from lock-to-lock several
times. Check that the EPS indicator does not come
on.
11.
12.
13.

Steering Gearbox Removal
Special Tool Required
Ball ioint remover,2S mm 0TlvlAC-S100200
1. Raise the front of vehicle, and make sure it is
securely supponed.
2. Remove the front wheels.
Remove the driver's airbag (seepage23-113).
Remove the steering wheel (see page 17-6).
Remove the motor on the steering gearbox (see
page l T-49).
Remove the driver's dashboard lower cover (see
page 20-59) and under cover {see page20-60).
Remove the steering joint bolts (A), and disconnect
the steering joint by moving the steering joint (B)
toward the column.
4.
5.
6.
7.
'il
_t\
l- '/
,a.: --L -
8. Remove the cotter pin (A)from the tie-rod balljoint
nut {B), and loosen the nut.
r0 mm HEX NUT07MAC-S100200
Separate the tie-rod balljoint and damper steering
arm using the special tool (see page 18-10). Repeat
on the other side of the vehicle.
Grasp the right side tie-rod, and pull the rack all the
way to the passenger's side,
Remove the heat shield (A) mounting bolts from
the body stiffener, and let the heat shield lay
against the exhaust.
11.
9.
10.
(cont'd)
17-51

EPS Components
Steering Gearbox Removal (cont'd)
Disconnect the EPS wire harness 6P connector (A),
and remove the EPS wire harness (B) and mountino
bracket (C).
12.
Remove the ground cable terminal (A) from the
steering gearbox housing.
..(
.,/ a
b-H\
ry T,-.lt'^ \
'" \--
13.
_-1..1.-'
-a--zii F--_1
17-52
14. Remove the engine wire harness clamps {A)fromthe three mounting brackets.
Remove the heater hose {B) from the bracket.
Open the heater valve cable clamp (A), and
disconnect the heater valve cable (B). Remove theheater valve (C) from the bulkhead, and move jt
aside.
t5.
16.
I

I x '1.25 mm20 N.m (2.0 kgf.m,7.2lbt ftl
O.RINGReplace.
PINION SHAFT GROMMET
-'t ''
v
\>--. i-*\{i#r^i
. s(./t' J
SLTDER GUIDE
-l
\
{^il stot *,tttc
\J" Renrace
LocK scREw '162 N.m lto.s rgf m,119lbf ft)
BOOTBAND Beqtace.
- Replace.
@
II
ASHER
rtE54
TIE.ROD END
CONNECTOR
Steering Gearbox Overhaul
Exploded View
RACK GUIDE
6^:,;
BOOT BAND '"''/
Beplace.
. -@ -sPRrNG. DISC WASHEB @'---g
L)-RACKGUIDE SCREW
6v---\' \.oc**u.
SRACKET
LOCK WReplace.
-RODN m {5.5 kgf.m,40lbf ft)
kgf.m,
(cont'd)
17-55
33 tbt.ft)44 N m {4.5

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

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)