INTRODUCTION [- How to Use This Manual ‘The 92 CIVIC Shop Manual (Maintenance, Repair and Construction) Is devided into two volumes (volume 1 and volume 2) Make sure to refer both volumes when carrying out repair or maintenance of 92 CIVIC or when you want to know its This manual (volume 2) is divided into 7 sections. The first page of | each section is marked with a black tab that lines up with its cor- responding thumb index tab on this page. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top comer of each page can also be used as a quick raference system. Each section includes: 1. A table of contents, or an exploded view index showing: © Parts disassembly sequence. © Bolt torques and thread sizes, @ Page references to descriptions in text. Disassembly/assembly procedures and tools. Inspection. Testingitroubleshooting Repair. Adjustments, ogaen (Special Information — — REMY tccicates a strong possibilty of severe personal injury | OF loss of Me if instructions are not followed. | CAUTION: Indicates a possibility of personal injury of equipment damage if instructions are not followed. NOTE: Gives helpful information CAUTION: Detailed descriptions of standard workshop pro cedures, safety pr 8 and service operations are not included. Please note that this manual contains warnings and cautions against some specific service methods which could cause PER SONAL INJURY, damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by HONDA might be done, of of the possible hazardous consequences of every con- ceivable way, nor could HONDA investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA, must satisfy himself thoroughly that neither personal safe- ty nor vehicle safety will be jeopardized. Al information contained in this manual is based on the latest pro- duct information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables First Edition 9/91 All Rights Reserved 990 pages HONDA MOTOR CO., LTD. Service Publication Office Sections below are in VOLUME 1 [As sections with * inclide SRS components, special precautions are required when servicing Transaxle *Steering vy Suspension Brakes bas (Including [ABS]) *Body *Heater and Air Conditioner *Electrical {Including [SRS))Driveshafts Special Tools . 4WD Power Trai Construction ......... Viscous Coupling Unit Front Driveshafts + 16-2 16-3 16-4 Removal .. 16-6 Disassembly 16-8 Disassembly/Inspection 16-9 Reassembly 16-10 Installation .. con -- 16-12 Intermediate Shaft Replacement . 16-14 Disassembly 16-15 Index/Inspection ..... o-- 16-16 Reassembly 16-17 Rear Driveshafts Removal ... 16-18 Disassembly 16-20 Disassembly /Inspex 16-21 Reassembly 16-22 Installation .. 16-24 Propeller Shafts Viscous Coupling Precaution Inspection - 16-26 Index/Inspection .- 16-28 Removal seess 16-30 No.1 Propeller Shaft Disassembly ... 16-31 Viscous Coupler (No. 2 Propeller Shaft), No.3 Propelier Shafts Disassembly .. 16-34 No.1 Propeller Shaft Reassembly .... 16-35 cous Coupler (No. 2 Propeller Shaft), No.3 Propeller Shaft Reassembly ...... 16-37 Installation .. 16-38 . 16-26Special Tools ty_| Page Reference Ref. No. Tool Number Deseruotion @ ¥07GAD—PG40100 | Oil Seal Driver 1 | 1617 ® LO7HAB—SD90101 | Companion Flange Holder 1 | 1631.36 @ | ~07JaF—sH20400 | Support Base Attachment 1 | 1618 @ | “o7ap—Pws0601 | Bearing Driver Attachment 1 | 16-17 ® ¥O7MAC—SL00200 | Ball Joint Remover, 28mm 1 | 166 @ | ©o7NAF-SR30100 | Half shaft Base 1 | 16-45 ® ~ 077460010300 | Attachment, 42 x 47 mm 1 | 1615 © = 077460010800 | Attachment, 52 x 55 mm. 1 | 1817 ® 07746-0010700 | Attachment, 24 x 26 mm 1} 16-15 ® 077430010000 _| Driver 1 | 16-15, 17 ® «078265030000 | Companion Flange Holder 1 | 1634, 37 @®__| -07865~s080100 _ | Support Base 1 | 16-15 ca) a) 16-24WD Power Train = (- Construction Power Flow: 2wo [____.transren Gears No.1 PROPELLER SHAFT awp ENGINE |—+] TRANSMISSION |—«[ FRONT DIFFERENTIAL |—+| FRONT ORIVESHAFTS | ————-[ FRONT WHEELS ~ T TRANSFER GEARS No.1 PROPELLER SHAFT —— Viscous COUPLING UNIT | No.2 PROPELLER SHAFT eae REAR DIFFERENTIAL —_—— REAR DRIVESHAFTS. FEAR WHEELS General When there is no difference in speed between the No.1 and viscous coupling unit (No.2 propeller shaft), power is trans: mitted to the front wheels through the front differential and the front driveshafts. The left driveshaft is connected to the differential by an intermediate shaft. The power is also turned 90 degrees by the transfer gears and transmitted to the No.1 propeller shaft. Whenever there is any speed difference between the No.1 propeller shaft and viscous coupling Unit (No.2 propeller shaft), power is transmitted to the rear wheels via the viscous coupling unit, the No.2 and No.3 propell shafts, the rear differential and the rear driveshafts. Front Driveshaft An intermediate shaft equalizes the length and angle of both driveshafts for easier steering on bumpy roads. The driveshaft end of this shaft runs on a bearing which is held by a holder on the engine case. A constant velocity universal joint at each end of the driveshafts ensures quieter operation and longer life, The front wheels run on an angular bearing for reduced friction, Propeller Shaft ‘The propeller shaft carries power from the transfer to the rear differential. Iti of a 2-piece construction and is supported by two rubber mounted bearings. The shaft has four universal joints: one tripod type and three yoke-and-spider type, These joints permit the shaft to lengthen and shorten, as the rear suspension moves. Rear Driveshafts Refer to page 16-6. 16-34WD Power Train - Viscous Coupling Yai A A A AAA ‘The viscous coupling unit is located on the front end of the No. 2 propeller shaft. It consists of @ housing that is con- ected to the No. 1 propeller shaft by 8 tripod joint, Inside of the housing are 79 plates, which have 0.2 mm (0.008 in) of clearance between one another, surrounded by silicone oil. The 40 housing plates are engaged with the splines in the housing and the 39 hub plates are splined to the shaft, The plates have holes in them to aid in heat dissipation. The viscous coupling unit also contains approximately 10% air to allow for the thermal expansion of the silicone oil No. 1 PROPELLER ‘SHAFT Housina NE a Ca HOUSING PLATE No. 2 PROPELLER, SHAFT ‘Whenever there is any difference in the speed of rotation between the No. 1 and No. 2 propeller shafts, such as when the front wheels lose traction, there is friction between the housing plates (drive side) and the hub plates (driven sidel. This friction is caused by the resistance of the plates sliding against the silicone oil. This resistance between the plates and the silicone oil is what begins to transmit torque from the housing plates to the hub plates and eventually to the rear Wheels. This transmission of torque is proportionate to the difference in the speed of rotation of the wheels. 16-4As the difference in propeller shaft speed continues, the temperature of the silicone oil keeps rising. Due to thermal ex- Pansion, the pressure inside the viscous coupling unit is also increasing as the temperature rises. When the pressure becomes high enough, the housing plates begin to contact the hub plates and the engine torque to {95 noted in the diagram at the right. To reduce plate wear, there are spacer rings to the rear wheels increases rapidly, limit plate to plate contact, As engine torque is delivered to the rear wheels, front and rear wheel traction stabilizes and the wheels begin to tum {at the same speed. At this happens, the temperature of the silicone oil and the preseure in the viscous coupling unit SILICON oI, TEMPERATURE. RAPID a. ‘TORQUE INCREASE ‘TorauE| INSIDE PRESSURE| Runnin Time decreases and power to the rear wheels decreases proportionately. 16-5Front Driveshafts Check the boots on the driveshaft for cracks, damage, leaking grease or loose boot bands. If any damage is found, replace the boot. ‘Spline Looseness ‘Tum the driveshaft by hand and make sure the spline and, joint are not excessively loose. It damage is found, replace the inboard joint. Twisted or Cracked Make sure the driveshatt is not twisted or cracked Replace if necessary. 1. Raise the cor and place safety stands in the proper locations (see Section 1) 2. Remove the front wheels. 3. Drain the transmission oil (see Section 15). 4. Raise the locking tab on the spindle nut and remove it WHEEL NUT SPINDLE NUT 221.5 mm Replace. Removal INSPECTION 5. Remove the damper fork nut and damper pinch bol. Driveshaft Boot 6. Remove the damper fork. DAMPER PINCH BOLT (SELF-LOCKING BOLT) 10% 1.25 ram DAMPER FORK NUT (GELF-LOCKING NUT) 32x 1.25 mm Replace. 7. Remove the cotter pin from the lower arm ball joint castle nut and remove the nut. 8. Install the 12 mm hex nut on the ball joint. Be sure that the 12 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 ball joint remover. NOTE: Use the Ball Joint Remover, 28 mm, as shown on page 18-11, to separate the ball joint and lower arm. 9. Position the special tool between the knuckle and lower arm as shown, then separate the lower arm. CAUTION: Be careful not tot damage the ball joint boot. BALL JOINT REMOVER, 28 mm ~ O7MAC—SL00200 12 mm HEX NUT ‘COTTER PIN Replace. caStie NUT 16-6(oxo) 10. Pry the driveshaft assembly with a screwdriver as shown to force the set ring at the driveshaft end past the groove. ‘SCREWDRIVER 2 , 3.8 mm 4 Timm 11. Pull the inboard joint and remove the driveshaft and CV joint from the differential case as an assembly. — With Intermediate Shaft: Remove the right driveshaft from the bearing support by tapping the inboard joint of the driveshaft with a plastic hammer. CAUTION: © Do not pull on the dri ‘come apart © Use care when prying out the assembly and pull it straight to avoid damaging the differential oil seal. shaft, as the CV joint may 12. Pull the knuckle outward and remove the driveshaft outboard joint from the front wheel hub using @ plastic hammer. 16-7Front Driveshafts - Disassembly 1. To remove the boot band, pry up the locking tabs with a screwdriver and raise the end of the band, NOTE: Carefully clamp the driveshaft in a vise with soft jaws, CAUTION: Take care not to damage the boots. 2007 BAND Replace. Remove the inboard joint and rollers. |. Remove the circlip, then remove the spider using a commercially available bearing remover. NOTE: Before disassembly, mark the spider and driveshaft so they can be reinstalled in their original positions. BEARING carcue REMOVER O_O STOPPER RING 16-8isassembly/Inspection NOTE: © Mark the rollers and roller grooves during dis- assembly to ensure proper positioning during reassembly. © Before disassembly, mark the spider and driveshaft 80 they can be reinstalled in their original positions. © The inboard joint must be removed to replace the boots. © If the boot band is the welded type, cut off as shown. CAUTION: Tal care not to damage the boots. INBOARD JOINT Check splines for wear or damage. ‘Check inside bore for wear. tnapeet for eracke. N ‘SET RING———"' SRB Replace. Saat Pack cavity with grease. Replace. Pack cavity with grease, DYNAMIC DAMPER Boot eae Replace. ‘ourBoaro JOT B00T Ingpeet for cracking, splitting and wear BOOT BAND Replace, SEEN Thoroughly pack the inboard joint and both joint boots with joint grease included. in the. new Siveshatt set ‘Quantity: Inboard Joint Outboard Joint 120-130 90-100 9 (3.23.5 oz) B1GA2, D16A8, D16A9 engines: Install the holder oF roller f Siection Of fey O)\\ x wtoen A >@ (i STOPPER RING INBOARD JOINT BOOT Inspect for cracking, splitting and weer Boot BAND Replace. OUTBOARD JOINT Inspect for faulty movement and Inspect ball bearings while rotating Dornot try to disassemble. OUTBOARD RING ‘Check for damage, DRIVESHAFT 16-9Front Driveshafts y Reassembly 1. Wrap the splines with viny! tape to prevent damage to the boots and dynamic damper. 2. Install the outboard boot, dynamic damper and in- board boot to the driveshaft, then remove the vinyl tape. OUTBOARD BOOT a “a i ~ ~ mong soor ee ) SY 1D16A7, D16z6, D1627, D16A8, D16A9, B16A2 engines Lofe: Except D168, D16A9 engines 3. Install the stopper ring onto the driveshaft groove. 4. Install the spider on the driveshaft by aligning the ‘marks on the spider and end of the driveshaft. 5. Fitthe rollers to the spider with their high shoulders facing outward. ‘CAUTION: © Reinstall the rollers to their original positions on the spider. . driveshaft assembly so the inboard joint points up, to prevent it from falling off. ROLLER High shoulder faces toward outside STOPPER RING 6. Fit the citclip onto the driveshaft groove. ‘cIRCLP 7. Pack the outboard joint with the joint grease includ- ed in the new driveshaft set. Grease Quantity: 90-100 g (3.2—3.5 02) 16-108. Pack the inboard joint with the joint grease included in the new driveshaft set. Grease Quantity: 120 — 130 g (4.2 —4.6 oz) 9. Fit the inboard joint onto the driveshaft. CAUTION: To prevent it from falling off, hold the driveshaft assembly so the inboard joint points up. D16A8, D16A8, 81602 engin Align the holder direction of the ro toward the slot of inboard joint a shown below. Boone direction INBOARD JOINT HOLoER 10. Adjust the length of the driveshafts to the figure below, then adjust the boots to helfway between full compression and full extension. NOTE: The ends of boots seat in the groove of the driveshaft and joint. 2wo: Loft © Except 1.6 ¢ DOHC: 773.1—778.1 mm (30.44—30.63 in) col {ile ob II © D16A8, D16A9 engines: '500.6—505.6 mm (19.71—19.91 in} © B16A2 engine: 475.1 —480.1 mm (18.70— 18.90 in} == Right © Except B1GA2 engine: '500.6—505.6 mm (19.71—19.91 in) © B16A2 engine: 478.1 —480.1 mm (18.70—18.90 in) 4WD: 496.1—501.1 (19.53—19.73 in) 11. Install new boot bands on the boot and bend both sets of locking tabs. 12. Lightly tap on the doubled-over portions to reduce ‘their height. LocKiIne TABS: 13. With dynamic damper Position the dynamic damper as shown below. © Lightly tap on the doubled over portion to reduce its height. © Install a new dynamic damper band and bend down both sets of locking tabs. Left © B16A2 engine: 29:2 mm (1.10.08 in) © Except D16A8, D16A9, 816A2 engines: 7522 mm (3.00.08 in) Right © B16A2 engine: 29:2 mm (1.1::0.08 in) © D16Z6, D16Z7, D16A8, D16A9 engines: 552 mm (2.20.08 in) © 4WD: 49.522 mm (1.9520.08 in) DYNAMIC DAMPER rt 16-11Front Driveshafts Installation 1. Install the outboard joint in the knuckle, then loose- ly install the spindle nut. 2. Apply 11.9 (0.03-0.06 02) of specified grease to the whole spline surface of the intermediate shaft. NOTE: After applying grease, remove the grease from the spline grooves at interval of 2—3 splines and set ring groove for air bleeding in the inboard joint. 3. Install the new set ring onto the driveshaft or inter: mediate shatt groove. CAUTION: Always use a new set ring whenever the Grivoshatt is being installed. 4. Install the inboard end of the driveshaft into the differential or intermediate shaft. INBOARD JOINT. RIGHT DRIVESHAFT Make sure the right driveshaft locks in the differential side gear groove, and the CV joint sub- ‘ade bottom In the diferential INTERMEDIATE SHAFT SET RING GROOVE NOTE: After applying grease, remove the ‘grease from the spline grooves at interval of 2-3 splines and set ring grooves. NEW SET RING INBOARD JOINT [ SET RING GROOVE LEFT DRIVESHAFT Insert the left driveshaft CV joint sub-axle into the intermediate shaft until the intermediate shat set fing locks in the groove in the loft driveshaft 16-125, Install the damper fork over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab is aligned with the slot in the damper fork. Loosely install the damper pinch bolt and the new damper fork nut. NOTE: The bolts and nut should be tightened with the vehicle's weight on the damper. DAMPER PINCH BOLT ALIGNING TAB (SELF-LOCKING BOLT) 44 Nem (4.4 kg-m, 32 Ib) DAMPER FORK NUT (SELF-LOCKING NUT) 85 Nem (6.5 kg-m. 47 Ib-fe) Install the knuckle on the lower arm, then tighten the castle nut and install new cotter pin. CAUTION: © Bo careful not to damage the ball joint boot. © Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the rut by loosening. ‘COTTER-PIN, (On reassembly, bend the cotter pin ‘as shown 12% 1.25 mm 50-60 Nem (5.66.0 kgm, 36—43 Ibe) 6. Tighten the new spindle nut. NOTE: Before installing the wheel, clean the mat- ing surface of the brake disc and inside of the wheel. 7. Install the wheel with the wheel nuts. WHELL NUT 121.5 mm 110m 250 Nim (25 kg-m, 181 fb-te) After tightening, use a drift to ‘take spindle nut shoulder against the driveshaft. 8. Tighten the damper pinch bolt and the new damper fork nut (see step 4). 9. Refill the transmission (see Section 15). 10. Check the front wheel alignment and adjust if neces- sary (see 18-4). 16-13Intermediate Shaft - Replacement 1. Drain the transmission oil. (see Section 15) 2. Remove the left driveshaft assembly (page 16-6). 3. Remove the three bolts. 4. Remove the intermediate shatt assembly from the differential CAUTION: To prevent damage to the differential oll seal, hold the intermediate shaft horizontal until it Is clear of the differential. 5. Installation Is the reverse order of removal. BOLT. 10x 1.25 mm 40 Nem (4.0 kg-m, 29 Ib) 16-145, [ Disassembly Remove the set ring. Remove the intermediate shaft outer seal from the bearing support. Remove the external circlip. EXTERNAL cIRCLIP ouren Seat Replace. SET RING Replace. 4, Press the intermediate shaft out of the shaft bear- ing using the special tools and hydraulic press as shwon, river (07749—-0010000 lo ATTACHMENT, 24 x 26 mm (077460010700, SUPPORT BASE ATTACHMENT. INTERNAL (07,JAF—SH20400 cIRCLIP, © 5 | | lo Remove the internal circlip. 6. Pross the intermediate shaft bearing out of the bear- ing support using the special tools and hydraulic press as shown. B16A2 engine: Hydraulic prose arracimern, ot Sais ne Tr rat SSl0390 DRIVER ae SUPPORT BASE ATTACHMENT ‘O7JAF—SH20400 || ld oy ‘support BASE (079658090100 Except B16A2 engin Hydraulic press ATTACHMENT, 42.47 mm (077460010300 HALF sHarT BASE ‘O7NAF—SR30100 16-15Intermediate Shaft — Index/Inspection CAUTION: Do not damage the lip on outer seals during installation. INTERMEDIATE SHAFT Check for damage BEARING SUPPORT RING Check for damage or distortion EXTERNAL, INTERMEDIATE SHAFT RING Check for damage or distortion. INTERNAL cIRCLIP INTERMEDIATE SHAFT BEARING Replace. BEARING SUPPORT Chock for damage. ‘OUTER SEAL Replace. 16-16[- Reassembly 1. Press the intermediate shaft bearing into the bear- ing support using the special tools and hydraulic press as shown. Driver 077490010000 ATTACHMENT, 52x 55 mm (07746--0010400 2. Seat the internal circlip in the groove of the bearing support. CAUTION: Install the ci facing out. ip with the tapered end 3. Press the intermediate shatt into the shaft bearing using a hydraulic press as shown, Hydraulic pros 4 ] INTERMEDIATE | — SHAFT O INTERNAL CIRCLIP, 4. Seat the external circlip in the groove of the inter- mediate shaft. CAUTION: Install the circlip with the tapered end facing out. Press the outer seal into the bearing support using the special tools and hydraulic press as shown. NOTE: Press the seal flush with the bearing support. Hydraulic prose Horn 07749-00100 an Pack the interior and lip of tho outer seal. ‘Olt SEAL DRIVER 07Ga0~PGa0100 oUTeR seat g | BEARING DRIVER ATTACHMENT. | (O7LAD—-Pws50601 exrenvar \O | 6. Install the new set ring in the intermediate shaft groove. 16-17Rear Driveshafts ‘SPINDLE NUT 22% 1.5 mm Replace. r Removal IsPEcTiON 5. Disconneet the brake hose from the brake pipe us- ing 2 10 mmm far nok wrench Driveshaft Boot Check the boots on the driveshaft for eracks, damage, CAUTION: Avoid pling bake fluid on pointed sur leaking grease or loose boot bands. faces au severe damage cen result. Wipe up spied ifany demage fe found, replace tho boot fsd at once and rnge wall with clon water. Spline Looseness ‘Him the driveshaft by hand and make sue the spline and SRAKE PPE ioint are not excessively loose y if damage ts found, replace the Inboer joint. “Twisted or Cracked Make sure the crivethatt is not twisted or cracked : Replace it necessary. Y 1. ais the car and place safety stands inthe proper foeatans foe sgcton th A \ 2. Remove the rear whe \ er | 3. Remove the brake drum, | i 4. Remove the hub cap, than raise the locking tab on ] | the spindle nut, then remove the nut d wwe car NOTE: Take cae not to damage the hub Sap and hub at on desea. Ropsace the tub cap ie camoged enake Hose ce oace. 6. Remove the speed sensor wire bracket NOTE: Do not disconnect the speed sensor wire. 6 mm BOLTS 16-187. Raise the rear suspension with @ floor jack until the Weight of the lower arm is relieved. 8. Remove the trailing arm bushing bolts. 9. Disconnect the upper arm and lower arm from the trailing arm, UPPER ARM BUSHING BOLT {SELF-LOCKING BOLT} 10x 1.25 mm LOWER ARM BUSHING BOLT (SELF-LOCKING BOLT) 10x 1.25 mm TRAILING ARM BUSHING BOLTS (SELF-LOCKING BOLTS) 121.25 mm 10. Pull the trailing arm outward and remove the rear driveshaft outboard joint from the trailing arm using a plastic hammer. OUTBOARD JOINT TRAILING ARM 11. Pry the driveshaft assembly with a screwdriver as shown to force the set ring at the driveshaft end past the groove. 12. Pull the inboard joint and remove the driveshaft and CV joint out of the differential case as an assembly. CAUTION: © Do not pull on the driveshaft, or the CV joint ‘may come apart, © Use care when prying out the assembly and pull it straight to avoid damaging the differential oil a. 16-19Rear Driveshafts [ Disassembly 1. To remove the boot band, pry up the locking tabs with 2 screwdriver and raise the end of the band, NOTE: Carefully clamp the driveshaft in a vise with soft jaws, CAUTION: Take care not to damage the boots. 2. Remove the boot band cover. 8007 BAND Replace. BOOT BAND COVER Remove the inboard joint and rollers. Remove the stopper ring, then remove the spider using a commercially available bearing remover. NOTE: Before disassembly, mark the spider and driveshaft so they can be reinstalled in their original positions. BEARING STOPPER RING REMOVER © SPIDER STOPPER RING 16-20EO} [- Disassembly/Inspection Nore: —SGEEH Thoroughly pack the inboard joint and @ Mark the rollers and roller grooves. during dls: both joint Boots with joint grease included in the new assembly to ensure proper positioning, during driveshaft set reassembly © Before disassembly, mark the spider and driveshaft -— SUPPORT SEAL, < Replace fue nur (GP 22's mm y Sa etaeane cane 6 12-POINT BOLT x 1,2 rom. 33 Nem (3.3 kg-m, 24 Ib-tt) FRONT CENTER BEARING ‘SUPPORT SEAL PROPELLER SHAFT HUB Roplace. REAR BEARING SUPPORT Check for damage, (Pus nur 22x 1.5 mm 60 Nem (6.0 kg-m, 43 tt) paola. o@ CENTER BEARING sae (a SEAL ae 2 Ne a 12-POINT BOLT 8x 1.25 mm 33 Nem (3.3 kg-m, 24 lb-ft) BEARING SUPPORT viscous courter ‘SEAL (No. 2 propeller shatt) Roplace. 40 x 1.25 mm FLANGE BOLT 40 Nem (4.0 kgm, 29 lb-ft) Yoke NUT No. 3 PROPELLER SHAFT ‘Check for damage. No. 3 PROPELLER SHAFT PROTECTOR 12-90mNT BOLT Bx 1.25 mm 33 Nim (3.3 kg-m, 24 Ib) 16-28FO} Real Time INTRAC 4WD: 007 BOLT 6x 1.0 mm 1ONim (1.0 kgm, 7 tote) BOOT RING 33.N'm (3.3 kgm, 241-40 vo. 4 PROPELLER SHAFT Chock for damage, ad0T BAND YOKE NUT Replace. PROPELLER SHAFT HUB FRONT BEARING SUPPORT Aaa ‘Check for damage, REAR CENTER BEARING ‘SUPPORT SEAL Replace. ‘uB NUT 22x 1.5 mm 60 Wim (6.0 kg-m, 43 tot) JOINT HOUSING Replace. Vey Yor Nut {2-Powr aout OE CENTER BEARING 8x 1.25 mm ‘SUPPORT SEAL 33 Nem (3.3 kgm, 24 Ib-tt) Replace. 10 x 1.26 mm FLANGE BOLT Voxe unit 40 Nem (4.0 kg-m, 29 lb-ft) No. 2 PROPELLER SHAFT ‘Check for damage, No. 2 PROPELLER SHAFT PROTECTOR s2row/ sour & ne ae Salmo Siam, 24m 16-29Propeller Shafts p Removal © No. 1 Propeller Shaft NOTE: body. Nore: 10 x 1.25 mm FLANGE BOLTS 12.POINT 10 mm UNIVERSAL SOCKET Mark the shafts end joints for reassembly. 1. Remove the No. 1 propeller shaft protector. ‘No. 1 PROPELLER SHAFT PROTECTOR 8 x 1.25 mm FLANGE BOLTS 2. Disconnect the No. 1 propeller shaft and viscous coupling (No. 2 propeller shaft). 3, Remove the front center bearing support from the Use 12 point Box Wrench for other portions. 12-POINT BOLT 8x 1.25 mm 4, Remove the No. 1 propolier shaft. NOTE: Use 12 Point Box Wrench for other portions. 12-POINT 10 mm UNIVERSAL SOCKET 12.P0INT BOLT Bx 1.25 mm © Viscous Coupling (No. 2 Propeller Shaft) and No. 3 Propeller Shaft. 5. Remove the No. 3 (INTRAC: No. 2) propeller shaft protector. 8 x 16 mm BOLTS No. 3 PROPELLER SHAFT PROTECTOR 16-306. Disconnect the No. 3 (INTRAC: No. 2) propeller Shaft and rear differential NoTe: Use 12 Point Box Wrench for other portions. ARK 12.POINT 10 mm UNIVERSAL, socKET 12-PoInT Bout 8x 1.25 mm 7. Remove the rear center bearing support from the body, then remove the viscous coupling (No. 2 Propeller shaft) and No. 3 propeller shaft (Except INTRAC). 10 x 1.25 mm FLANGE BOLTS CENTER BEARING ‘SUPPORT r No. 1 Propeller Shaft Disassembly 5 NOTE: Make the shaft and hub before disassembly. 1. Remove the hub nut from the No. 1 propeller shaft, using the special tool to prevent the shaft from turning 2. Remove the propeller shaft hub. PROPELLER SHAFT HUB PROPELLER SHAFT HUB NUT 221.5 mm COMPANION FLANGE HOLDER 07HAB—sD90101 3. Remove the rear center bearing support seal REAR CENTER BEARING ‘SUPPORT SEAL Replace. PROPELLER SHAFT HUB. (cont'a) 16-31Propeller Shafts 4. Holding the center bearing support with one hand, lightly tap on the shaft end with a soft hammer until the shaft is clear of the bearing support. NOTE: If difficulty is encountered in removing the shaft, use ‘a puller. Replace the bearing support with anew one when a puller is used to remove it. CENTER BEARING SUPPORT See - No. 1 Propeller Shaft Disassembly (cont'd) 5. Remove the front center bearing support seal. FRONT CENTER BEARING SUPPORT SEAL Replace. 6. Unscrew the boot bolts from the joint housing of the No. 1 propeller shaft. Boor BOLT 6x. 1.0 mm 10 Nem (1.0 kg-m, 7 1A) 16-32Pull the joint housing off propeller shaft. NoTE: © Mark the housing and shaft before separating them. © Be careful not to let the rollers fall off the spider during disassembly, JOINT, HOUSING MARKS Pry off the 26 mm circlip and separate the spider from the propeller shaft, NOTE: Mark the spider and shatt before separating them, Remove the stopper ring. STOPPER RING 26 mm CIRCLIP MARKS 10. Raise the boot band locking tabs. 11, Remove the boot, boot band and best ring from the propeller shaft. BOOT RING BOOT BAND Replace. Boot 16-33Propeller Shafts 1. Remove the viscous coupling (No. 2 propeller shaft) from the No. 3 propeller shaft. viscous couPLING (No. 2 propeller shstt) No. 3 PROPELLER SHAFT 12-POINT BOLT 8x 1.25 mm 2. Remove the hub nut from the viscous coupling (No. 2 propeller shaft) using the special tool to prevent the shaft turning. NOTE: Mark the shaft and hub before disassembly. 3. Remove the propeller shaft hub. PROPELLER SHAFT HUB NUT 22x 1.5 mm Replace. L& PROPELLER SHAFT HUB. COMPANION FLANGE HOLDER 07926~sp90000 4 5, [— Viscous Coupler (No. 2 Propeller Shaft), No. 3 Propeller Shaft Disassembly — Remove the rear center bearing support seal. REAR CENTER BEARING SUPPORT SEAL Replace. Holding the cetner bearing support with one hand, lightly tap on the shaft end with a soft hammer until the shaft is clear of the bearing support. CENTER BEARING SUPPORT 16-34Propeller Shafts eS _ —— 5 No. 1 Propelier Shaft Reassembly 5 NOTE: Hf difficulty is encountered in removing the shaft, use a puller. Replace the bearing support with a new one when 2 puller is used to remove it. CENTER BEARING SUPPORT BEARING PULLER 6. Remove the front center bearing support seal from the bearing support 7. Remove the ring from the viscous coupling (No. 2 propeller shaft) FRONT CENTER BEARING ‘SUPPORT SEAL Foplace. Rina CENTER BEARING ‘SUPPORT 1. Slide the boot band, boot ring and boot onto the No. 1 propeller shatt. 2. Position the boot on the shaft s0 the raised area of the boot is aligned with the shaft groove. 800T at BOOT BAND 3. Seat the stopper ring in the shaft groove. 4. Install the spider on the propeller shaft making sure the marks made during disassembly are aligned: NOTE: Do not interchange the rollers between the roller shafts on the spider. 5. Install the 26 mm circlip in the shaft groove. STOPPER RING ‘caRCUP (cont’a) 16-35Propeller Shafts 6. Pack the rollers and joint housing with molybdenum disulfide grease. ‘Amount: 60-70 g (2.1—2.5 o2) 7. Slide the spider and rollers into the joint housing mak ing sure that the marks are aligned. 8. Attach the boot ring to the joint housing with the boot bolts. 9. Install the new boot band and bend the lug of the boot band toward the locking tabs. 10. Secure the lug with the locking tabs on the boot. LocKINe TABS Boor BoLT 10 Nem (1.0 kg-m, 7 tb-ty JOINT HOUSING 11. Install the front and rear bearing support seal, bear. ing support 12. Position the hub on the propeller shaft with the marks, aligned, and install with the hub nut. PROPELLER SHAFT HUB, 60 Nem (6 kg-m, 43 Ib-f), BEARING SUPPORT COMPANION FLANGE HOLDER Alin marks. O7HAB—SD90101 - No. 1 Propeller Shaft Reassembly (cont'd) ————————————_———__ 13. Peen the nut over the shaft end to lock in place. 16-361. Temporarily install the ring, front center bearing sup- ort seal, bearing support, hub and hub nut on the viscous coupler. RING FRONT CENTER BEARING yn SEAL viscous ‘COUPLER Q 2. Hold the hub with the special tool, and torque the hhub nut to force the bearing support into position, 60 Nem (6.0 kg-m, 43 Ib-f) COMPANION FLANGE HOLDER (079265090000 [ Viscous Coupler (No. 2 Propeller Shaft), No. 3 Propeller Shaft Reassembly 5 Remove the hub nut and hub. Install the rear center bearing support seal on the bearing suppor. Position the hub on the propeller shatt with the marks aligned, and install with the hub nut. REAR CENTER BEARING SUPPORT SEAL 60 Nm (6.0 kg-m, 43 Ib-f) Align marks. 6. Pen the nut over the shaft end to lock in place Peen over, (cont'd) 16-37Propeller Shafts .- Viscous Coupler (No.2 Propeller Shaft), |- Installation No. 3 Propeller Shaft Reassembly (cont'd) © Viscous Coupling (No. 2 Propeller Shaft) end No. 3 Propeller Shatt. 7. Temporarily connect the viscous coupling (No. 2 1. Inetall the rear center bearing support on the frame propeller shaft) and No. 3 propeller shaft with the T2-point bolts and yoke nuts. 8. Torque the all bolts and nuts 12-POINT BOLT 8x 1.25 mm 33 Nem (3.3 kgm, 24 Wb-f) 40 Nem (4.0 kg-m, 29 Io-tt) No. 3 PROPELLER SHAFT 2. Temporarily connect the propeller shaft and rear differential using the 12-point bolts and yoke nuts. 3. Torque all bolts and nuts. NOTE: Use 12 Point Box Wrench for other portions. Align marks. 12-20INT 10 mm UNIVERSAL SOCKET 33 Nem (3.3 kam, 24 tb-f) 16-386) 4 Install the No. 3 propeller shaft protector. ‘No. 3 PROPELLER SHAFT PROTECTOR © No. 1 Propeller Shaft 5, Temporarily connect the propeller shaft and front differential using the 12-point bolts and yoke nuts. Torque all bolts and nuts, NoTE: Use 12 Point Box Wrench for other protions. Align marks. 12-POINT 10 mm UNIVERSAL SOCKET 33 Nem (3.3 kgm, 24 lb-ft) 7. Install the front center bearing support on the freme. Temporarily connect the No. 1 propeller shaft and viscous coupling (No. 2 propeller shaft) using 12-point bolts. 33 Nim (3.3 kg-m, 24 Ib-tt) 12.POINT 10 mm UNIVERSAL SOCKET NOTE: Use 12 Point Box Wrench for other portions, 8. Torque all bolts. 9. Instal the No. 1 propeller shaft protector. No. 1 PROPELLER SHAFT PROTECTOR 1.25 mm BOLTS 22 Nem (2.2 kgm, 16 Ibett) 16-39SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (if steering wheel and column sen required) 1g are ‘Some models of the CIVIC include a driver's side airbag, located in the steering wheel hub, as pert of a Supplemen- tal Restraint System (SRS). Information necessary to safely service the SRS is included in this service manual. Items marked * on the contents page include, or are located near, SRS components. Servicing, disassembling or replacing these items will require special cautions and tools, and should therefore be done only by an authorized HONDA dealer. rr ‘To avoid rendering the SRS inoperative, which can lead to personal injury or death in the event of a severe fron: tal collision, all maintenance on this system must be performed by an authorized HONDA deale! © Improper maintenance, including incorrect removal and installation of the SRS, and replacing with wrong parts, can lead to personal injury caused by unitentional activation of the airbag. © AIISRS electrical wiring hamesses are covered with yellow outer insulation. Related components are located in ‘the steering column, the dashboard, and behind the dashboard lower cover. Do not use elec ment on these circuits. © Servicing, disassembling or replacing nearby the steering wheel, under the dash, or related to the wire harnesses nearby the under-dash fuse box may affect the SRS and must therefore be performed by an authoriz- ‘ed HONDA dealer. I test equip-Steering 17-1 17-29 Manual Steering . Power Steering .Manual Steering Special Tools .. - 17-2 Component Location Index ... On-Car Checks Steering Wheel Rotational Play ... Steering Effort Check ... Steering Gearbox Adjustment Steering Gearbox Gearbox Removal . Illustrated Index . Steering Gearbox Overhaul Gearbox Installation . Ball Joint Boot Replacement Steering Wheel (With SRS) Removal .... Disassembly/Inspection Installation ... Steering Wheel (Without SRS) Removal . Disassembly/Inspection Installation ... Steering Column Removal . Inspection Installation ... . 17-3 17-4 17-4 17-4 17-5 17-8 17-9 17-14 17-17 . 17-18 17-19 17-20 17-22 17-22 . 17-22 17-23 17-25 17-26Special Tools Ret. No. Tool Number Description | ary | Page Reference @ | FO7NAZ—SRI0100 | Lockwasher Pilot Cinch 1 | v2 @ | -O7Mac—st00200 | Ball Joint Remover, 28 mm fa 176 3 +0746 0020100 Inner Handle 8 1 17411 ® -97916—SA50001 Locknut Wrench, 40 mm 1 17-4, 12 ® 07974—SA50600 | Pinion Dust Seal Guide 1 a7at © 107974—SA50800__| Ball Joint Boot Clip Guide 1 4747 @ ® ® ® 17-2Component Location = Index NOTE: © LH drive shown. RH drive is similar. © If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see section 23), Before removing the gearbox, remove the ignition key to keep the steering shaft from turning. © After installing the gearbox, check the wheel alignment and adjust if necessary. © The tilt steering column is shown; the conventional steering column is similar except for the titt mechanism. CAUTION (with SRS) © All SRS electical wiring harnesses are covered with yellow outer insulation. ‘© Replace the entire affected SRS harness assembly it it has an open circuit or damaged wiring, © Before disconnecting the SRS wiring harnes: the ignition switch off, positive battery cables, and wait at least minut ‘STEERING WHEEL Steering wheel positioning, ‘Se0 Suspension/Alignment Disassombly/Reassembly, page 17-19 SRS AIRBAG ASSEMBLY. Removal, page 23-350 Installation, page 23-351 IGNrmion swiTcH Switch Test/Removalinstallation, see Electrical Section ‘STEERING COLUMN Removal, page 17-23 Inspection, page 17-25 Instaiation, 17-26 STEERING GEARBOX Removal, page 17-5 Stooring Gearbox Overhaul, page 17-9 Ingtallation, page 17-14 17-3On-Car Checks [- Steering Effort Check 1. Raise the front wheels off the ground. 2. Tum the steering wheel with @ spring gauge and check its reading 3. If the reading exceeds the service limit, adjust the steering gearbox as shown below, Service Limit: 15 N (1.5 kg, 3.3 Ibs) r— Rack Guide Adjustment [— Steering Wheel Rotational Play — 1. Place the front wheels in a straight ahead position ‘and measure the distance the steering wheel can be tured without moving the front wheels. 2. Ifthe play exceeds the service limit, check all steer- ing components, Service Limit: 10 mm (0.4 in} (0—10 mm (0-0.4 in} 1. Loosen the rack guide screw locknut with the special tool 2. Retighten the rack guide screw until it compresses the spring and seats against the rack guide. RACK GUIDE SCREW LOCKNUT WRENCH, 40 mm 07916-50001 RACK GUIDE SCREW 3. Back off the rack guide screw and install the Tocknut on the rack guide screw. Back the rack guide screw off about: 50° = 10° 4. Check for tight or loose steering through the com- plete turning travel 5. Recheck steering effort. 17-4Steering Gearbox [~ Gearbox Removal NOTE: ‘© Before removing the steering gearbox, align the front wheels straight ahead. © Disconnect the battery negative terminal and then disconnect the positive terminal 1. Raise the front of car and support on safety stands in the proper locations. 2. Remove the front wheels. 3. Remove the steering joint cover. STEERING JOINT COVER CLAMPS 4. Remove the steering joint lower bolt, and move the joint toward the column. 8, Manual transmission model only: © Remove the shift extension from the transmis: ‘SHIFT EXTENSION © Slide the boot at the connecting position of the {gear shift rod. © Drive out the spring pin with @ punch, then disconnect the shift rod. SHIFT ROD PIN RETAINER (cont'd) 17-5Steering Gearbox — Gearbox Removal (cont’d) 6. Automatic transmission only: ‘¢ Remove the shift cable holder SHIFT CABLE HOLDER © Disconnect the shift cable from the shift control shaft. SHIFT CABLE Lock WASHER Replace. 7. Separate the catalytic converter by removing the self-locking nuts, CAUTION: Replace tho exhaust gasket and solf- locking nuts when you reinstall the pipe. SELF-LOCKING NUT CATALYTIC CONVERTER SELF-LOCKING NUT Replace. 8. Remove the cotter pin from the tie-rod ball joint nut and remove the nut. 9. Install the 10 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 ball joint remover. NOTE: Remove the ball joint using the Ball Joint Remover, 28 mm {07MAC—SLO0200). Refer to page 18-12 for how to use the ball joint remover. 10. Separate the tie-rod ball joint and knuckle using the special tool CAUTION: Avoid damaging the ball joint boot. —~— eat JOINT REMOVER, 28 mm ‘O7MAC—SL00200 17 611, Remove the left tie-rod end, then slide the rack all the way to the right NOTE: Remove the performance rod, if it is equipped. 12. Remove the steering gearbox assembly mounting bolts and pinion shaft gromet. MOUNTING BOLTS 13. Pull the steering gearbox assembly all the way down to clear the pinion shaft from the bulkhead. 14, Move the steering gearbox assembly to the right so the left rack end clears the rear beam, 18. Hold the steering gearbox assembly and slide the rack all the way to the left, place the left rack end below the rear beam. 16. Move the steering gearbox assembly to the left and tilt the left side down to remove it from the car. 17-7Steering Gearbox Mlustrated Index and Inspection NOTE: LH drive shown. RH drive is similar. PINION SHAFT GROMMET oor PINION DUST SEAL Replace. 8007 BAND Replace. SNAP RING 35 mm PINION oa Inspect for wear, scoring, or damaged teeth, and ball bearing cam Locknut of. aunve ‘SCREW SPRING DISC WASHER 5 pack cue cYLINDEA HOUSING 39m fea tgm, 43 bt —nge™ (3.9 kom, 28 tte) BOOT BAND Roplace. nécK Inspect for damaged tocth or scoring place. ‘TNE-ROD Lock A p S ack évo 17-8cS) r- Overhaul 1. Carefully clamp the gearbox in a vise with soft jaws. Romove the tie-rod assembly. THE-ROD LOCKNUT TieROD 3. Remove the boot bands and tube clamps. Pull the dust seals away from the ends of the gearbox Boor BAND Replace. bust Seat ‘Tue CLAMP 4. Hold the steering rack with a 19 mm wrench and unscrew the rack end with a wrench, RACK END “TIE-ROD LOCK WASHER Replace. [STEERING RACK 5. Push the right end of the rack back into the eylinder housing so the smooth surface that rides against ‘the seal won't be damaged. 6. Loosen the rack screw locknut and remove the rack guide screw. 7. Remove the disc washer, spring and rack guide from the gear housing, \ disc waster RACK GUIDE SCREW LocknuT (cont'd) 17-9Steering Gearbox [- Overhaul (cont'd) 8. Remove the pinion dust seal, and 35 mm snap ring, then pull the pinion assembly out of the gearbox. NOTE: Hold the pinion shaft with a vise securely. Remove the pinion assembly by tapping around the flanged section of the gearbox with a plastic ham- mer evenly. Do not reuse the removed pinion assembly. CAUTION: Do not tap on the steering rack. @ ‘STEERING PINION ‘SEAL SNAP RING 35 mm ‘CYLINDER HOUSING 17-10 10. Remove the rack end bushing GEARBOX CUSHION ROUND PROJECTION RACK END BUSHING 11, Replace the gearbox cushion if necessary. © To remove the cushion, use a sharp knife and make a cut down the length of the cushion. Be careful not to damage the paint on the cylinder housing. Remove the old cushion. ‘© Apply weatherstrip adhesive to the inside of the ew cushion. Install the cushion onto the cylinder housing and position it 19 + 1 mm (0.74 = 0.04 in} from the end of the cylinder housing 8s shown. GEARBOX CUSHION ae) le 1921 mm (0.74 20.04 in) NOTE: After installing the cushion, wipe off any excess adhesive that may have dripped into the in side of the cylinder housing.@ 12. Apply a thin coat of grease to the inside surface of the rack end bushing Grease quantity: 1—3 g (0.1 oz) CAUTION: Do not fil the slots with grease; they must remain open to serve as alr passages. 13, Install the rack end bushing by aligning the round Projection on the bushing with the hole in the cylinder housing, ROUND PROJECTION RACK END BUSHING 14. Apply grease to the steering rack. 15. Install the steering rack into the cylinder housing carefully to avoid damaging the steering rack sliding surface. a STEERING RACK CYUNDER HousiNG 16, Install the steering pinion in the gear housing with the special tools. 17. Install the 35 mm snap ring securely in the gear housing groove. 18. Apply grease the surface of the special tool, and in- stall it on the pinion shaft. Then grease the sealing lip of the steering pinion seal, and install it into the ‘gear housing. Remove the special tool. INNER HANDLE B 077460020100 uf a STEERING PINION. SEAL \<— SNAP RING 35 mm PINION DUST SEAL GUIDE. (07974-SA50600 [STEERING PINION 19. Coat the rack guide with grease. 20. Install the rack guide, spring, disc washer and rack guide screw on the gear housing. ee RACK cue | SIDE SPRING RACK GUIDE SCREW LocknuT. (cont’a) 17-11Steering Gearbox [- Overhaul (cont'd) 21, Tighten the rack guide screw until it compresses ‘the spring and seats against the rack guide. 22. Back off the rack guide screw and install the locknut on the rack guide screw. Back the rack guide screw off about: 50° + 10° 23. Tighten the locknut while holding the rack guide screw with the special tool. RACK GUIDE SCREW (07916—Sa50001 25 Nem (2.5 kg-m, 18 ft) 24. Install the new lock washer in the groove in the steering rack 25. Hold the steering rack with a wrench and tighten the rack end to 55 Nem (5.5 ka-m, 40 Ib-ft) RACK END Lock WASHER RACK END 26. After tightening the rack end stake the four section of lockwasher with the special tool and hydraulic press. NOTE: Set the V-block on the press table. Set the lock washer section of the rack end on the V-block securely. — Be sure that the pressing direction, special tool, and each lockwasher stake position are in line. — Stake the lockwasher in the center of the flat section of the joint housing, (The bottom end of ‘the stake must be in that position.) See below. STAKE POINT “¥". LockwasHER JOINT HOUSING { LockwasHER PILOT CLINCH (07NAZ—~SR30100 v-eLock on FONT HOUSING Center of the ASSEMBLY TocKWashEr 17-12@ 27. Apply steering grease to the circumference of the rack end housing. NOTE: Coat the rack end groove and inside of the boot with silicone grease. Kaas SILICONE GREASE Cost the sing surface of the rack ond, >) So ‘STEERING GREASE (Honda P/N 0873380708) 28. Install the boots on the rack end with the tube clamps. NOTE: Install the boot band with the rack in the straight ahead position (i.e. right and left tie-rods are equel in length. 29, Install the boot band so that the lacking tabs of the band (stake points) are in the range shown below. (Tabs should face up and slightly forward.) CAUTION: Stake the band locking tabs firmly. Left Oust Sea! Band (Wiewed trom the Band wind tot sige) * a S Front. en: Offaat shaft Right Dust Seal Band (iewed from the Stake. right side) 30. Install new boot bands on the boot and bend both sets of locking tabs. 31. Lightly tap on the doubled-over portions to reduce ‘thelr height, LOCKING TABS Band winding direction Stake points Offeet shaft centerline 17-13Steering Gearbox 1 2 6. [ Gearbox Installation Slide the cack all the way to the tight. Pass the right side of the steering gearbox assembly above and through the right side. Hold the steering gearbox assembly and slide the rack all the way to the right. Raise the left side of the steering gearbox assembly above and through the left side of the rear beam. Install the pinion shaft grommet and insert the pin- ion shaft up through the bulkhead, Install and tighten the gearbox mounting bolts. 59 Nim (6.9 kg-m, 43 Itt) NOTE: Install the performance rod, equipped, it it is 7. Reconnect the tie-rods to the steering knuckles, tighten the ball joint nut to the specified torque, and install new cotter pins. CAUTION: Torque the castle nut to the lower tor- que specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening. CASTLE NUT 50-60 Nem (5.0-6.0 kgm, 36—43 itt) On reassembly, bend the cotter pin as shown, 8. Install the catalytic converter with the new gaskets and self-locking nuts. 34 Nem (3.4 kg-m, 25 Ib) 34 Neri (3.4 kg-m, 25 ttt) 17-149. Manual transmission model only: © Connect the shift rod to the transmission and drive the spring pin with a punch, then install the pin retainer. Be sure that the projection on the pin Is in the hole, SHIFT ROD. © Install the shift extension on the transmission SHIFT EXTENSION 10. Automatic transmission model only: ‘© Connect the shift cable end to the shift control shaft, and bend the lock washer securely. © Install the cable bracket. SHIFT CABLE Tock WASHER © Install the cable holder. CABLE HOLDER (cont'd) 17-15Steering Gearbox [- Gearbox Installation (cont'd) 11, Slip the lower end of the steering joint onto the pin- fon shaft (line up the bolt hole with the groove ‘around the shaft) and loosely install the lower bolt. CAUTION: Bofore tightening the steering joint bolts pull the steering joint to make sure that the steering joint is fully seated. 12. Tighten the steering joint bolts to the specified torque. STEERING GEARBOX PINION LOWER BOLT 22 Nem (2.2 kg-m, 16 tot) 13, Install the steering joint cover with the clamps and lip, STEERING JOINT 14, After installation, perform the following checks, = Check the front toe. — Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary 17-16Ball Joint Boot Replacement 1, Remove the circlip and the boot, CAUTION: Do not contaminate the boot installa- tlon section with grease. 2. Pack the interior of the boot and lip with grease. 3. Wipe the grease off the sliding surface of the ball pin, then pack the lower area with fresh grease. ‘grease off the boot installation section and the tapered section of the ball pin. © Do not allow dust, dirt, or other foreign materials to enter the boot. BALL ‘SECTION Wipe the grease. ‘TAPERED ‘BOOT INSTALLATION SECTION Wipe the grease. 4, Install the boot in the groove of the boot installation section securely, then bleed air. BALL JOINT BOOT CUP GUIDE 07974—SAs0800 ‘Adjust the depth by turning the bot. CAUTION: After installing the boot, check the bi pin tapered section for grease contamination and wipe it if necessary. 17-17Steering Wheel (With SRS) f- Removal Airbag Assembly Removal Store a removed airbag assembly with the Pad surface up, if the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury. cauTion: © Before beginning work related to the SRS system, turn the ignition switch off, disconnect the negative and positive battery cables, and wait three minutes. © Do not install used SRS parts from another car. ‘When repairing an SRS, use only new parts, © Carefully inspect the airbag assembly before install- ing it. Do not install an airbag assembly that shows ians of being dropped or improperly handled, such as dents, cracks or deformation. © Do not disassemble or tamper with the assembly. © Special bolts are necessary for installing the airbag assembly. Do not use other bolts. irbog NoTe: © Make sure the wheels are aligned straight ahead. Remove the left airbag assembly mounting TORX bolt first (the safety switch will automatically turn off. 1. Turn the ignition switch off, then disconnect the negative and positive battery cables, and wait three minutes. 2. Remove the airbag assembly (page 23-350) Remove the steering wheel nut. Remove the steering wheel by locking it slightly from side-to-side as you pull steadily with both ands. STEERING WHEEL NUT Roplace. 17-18[- Disassembly/Reassembly EERIE] store» removed airbag assembly with the ad surface up. Ifthe airbag is improperly stored fa Gown, accidental deployment could prope the wait woah fnough force to cause serious injury, NOTE: If an intact airbag assembly has been removed from @ scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see page, 23-352) STEERING WHEEL NUT 50 Nem (5.0 kg-m, 36 bt) ToRX® BOLT 10 Nem (1.0 kgm, 7 te) @ ‘caution: bag assombly before install- bag assembly that shows signs of being dropped or improperly handled, such ‘as dents, cracks or deformation. © Do not disassemble or tamper with the assembly. 17-19Steering Wheel (With SRS) Installation 1. Install the steering wheel on the column, NOTE: Be sure the steering wheel shaft engages the slip ring and canceling sleeve. CANCELING SLEEVE [STEERING WHEEL 50 Nem (5.0 kg-m, 36 tot) 2. Install the sirbag assembly (See page 23-351) CAUTION: ‘© Be sure to install the SRS wiring so that it is not pin- ched oF interfering with other car parts. © Be sure the battery cables are disconnected. 3. After installing the airbag assembly, confirm proper ‘system operation: ‘© Turn the ignition to ON: the instrument panel SRS in- dicator light ehould go on for about 6 seconds and then go off. © The SRS self diagnosis indicator (LED) should blink. ‘one time with the ignition switch ON. 17-2017-21Steering Wheel (Without SRS) - Removal ——H#—_ Installation 1. Remove the center pad. 1. Install the steering whee. NOTE: Be sure the steering wheel shaft engages: 2. Remove the steering wheel nut. the turn signal canceling sleeve, 3, Remove the steering wheel by rocking it slightly from side-to-side a8 you pull steadily with both a hands. ‘TURN SIGNAL CANCELING SLEEVE Install the center pad. STEERING L 50.Nem (5.0 kg-m, 36 bf -- Disassembly/Reassembly 50 Nem (5.0 kg-m, 36 tote) Replace. 17-22Steering Column (~ Removal CAUTION (with SRS): © All SRS electrical wiring harnesses are covered with yellow outer insulation. sssembly if It has an open circuit or damaged wiring, © Before disconnecting the SRS wiring harnesses, turn the ignition switch off, isconnect the negative and ‘at least three NOTE: LH drive shown. RH drive is similar. 1. Remove the steering wheel (17-18) 2, Remove the lower cover. 3. Remove the upper column and lower colum covers. UPPER COLUMN COVER Lowen coLuMN: coven 6, Pull out the connector lock, then disconnect the ‘SRS main harness 6-P connector from the slip ring NOTE: Dispose of the connector lock, it is not to be reused. Remove the slip ring from the combination switch assembly. ‘SRS MAIN HARNESS 5: CONNECTOR SUP RING MouNTING SCREWS Remove the turn signal canceling sleeve and the combination switch assembly. NOTE: After removing the combination switch assembly, place it on the floor gently so that it does not hinder you in service. Do not disconnect the harnesses from the combination switch assembly. ‘TURN SIGNAL SS CANCELING { SLEEVE COMBINATION swiTcH ASSEMBLY (cont’a) 17-23Steering Column r- Removal (cont’d) 7. Disconnect the ignition switch connectors from the tunder-dash fuse box. 8. Remove the steering joint cover. STEERING JOINT COVER 9. Remove the steering joint bolts, and move the joint toward the column, sree tar aL \ . \ 10. Remove the steering column assembly by removing the attaching nuts and bolts. COLUMN HOLDER, 17-24r- Inspection NOTE: © Check the tilt mechanism, steering joint bearings and steering shaft for proper movement and damage. Replace as an assembly if damaged or faulty, © The tilt steering column is shown; the conventional steering column is similar except for the tilt mechanism, ‘STEERING COLUMN ABSORBING aman, aera, G a serane {Chock for damage 22. Nem (2.2 kgm, 16 Ay mervocnanr 8 o! SEH ance Kor 8x 1.25 mm cdtumw HoLoeR 16 N-m (1.8 kgm. 12-1) FLANGE BOLT 39 Nem (3.9 kg-m, 28 tote) ‘© Attach a spring scale to the knob of the tilt lever. ‘Measure the force required to move the lever. Preload: 70—90 N (7—9 kg, 15~20 Ibs) If the force measured is not within the specification, loosen the lock bolt, then the stopper, until the cor- rect force can be obtained. (oan) 17-25Steering Column ight ahead and that the angle is correct. If minor spoke angle adjustment is necessary do ¢0 only by adjustment of the tie rods, not by removing and repositioning the st wheel 1. Slip the upper end of the steering joint onto the col- umn shaft (line up the bolt hole with the flat on the shaft) and loosely install the upper bolt. UPPER BOLT Bok must fine up with fat on sate STEERING OWT 2, Slip the lower end of the steering joint onto the pin- jon shaft (line up the bolt hole with the groove around the shaft) and loosely install the lower bolt. NOTE: Be sure that the lower bolt is securely in the groove in the steering gearbox pinion. STEERING GEARBOX PINION LOWER BOLT Final torque, 22 Nim (2.2 kg-m, 16 ttt) r- Installation CAUTION: 3. Install the steering column assembly with the nuts © Aftor reassombly, confirm that the whe and column holder. 4, Tighten the upper and lower steering joint bolts loosely installed in step 2. COLUMN ASSEMBLY ‘coun: HOLDER 160m (ekg, 12 wt 39.Nem (3.9 kom, 28 b-F0 5. Install the steering joint cover with the clamps and lip. [STEERING JOINT 17-26COMBINATION swiTcH ‘ASSEMBLY 8, Connect the wire connectors from the ignition Switch to the under-dash fuse box. Install the combination switch assembly and turn signal canceling sleeve onto the steering column, NOTE: Be sure the wires are not caught or pinched by any parts when installing the combination switch. ‘TURN SIGNAL CANCELING SLEEVE Install the slip ring on the steering column, then connect the SRS main herness 5-P connector to the slip ring. ‘SAS MAIN HARNESS. 5:P CONNECTOR SUP RING (CABLE REEL WIRE 9. Install the upper column cover and lower column UPPER CQLUMN COVER 10. Install the lower cover. 11, Install the steering wheel and airbag assembly (page 17-20). 17-27Power Steering Special Tools .. Component Location Index (LHD) Index (RHD) System Description (LHD) Fluid Flow Diagram Steering Pump Fluid Reservoir/Filter Control Vaive .. Full-Lock Unloader System ‘System Description (RHD) Fluid Flow Diagram ‘Steering Pump Fluid Reservoi Steering System Troubleshooting (LHD) General Troubleshooting Noise and Vibration . . 17-30 17-32 17-33 17-34 17-35 17-36 17-37 17-39 17-40 17-41 17-43 17-44, iter 17-47 17-50 17-61 Troubleshooting (RHD) General Troubleshooting Noise and Vibration ..... Fluid Leaks Maintenance Pump Belt Adjustment ..... On-Car Checks Rack Guide Adjustment . Fluid Replacement Pump Pressure Check ‘Steering Wheel Rotational Play .. Power Assist Check with Car Parked ... - 17-52 17-56 - 17-68 - 17-60 - 17-61 17-62 17-63 - 17-64 17-64 Steering Wheel (with SRS) Removal ... Disassembly/Inspection Installation ‘Steering Wheel (without SRS) Removal : assembly/Inspection Installation Steering Column Removal Inspe Installation .. Steering Pump Mustrated Index .. Replacement Pulley Replacement .... Contro! Valve Inspection and Replacement assembly Reassembly ... Steering Gearbox (LHD) Valve Body Unit Overhaul .... Gearbox Removal Mustrated Index .. Gearbox Overhual . Gearbox Installation Steering Gearbox (RHD) Gearbox Removal Mlustrated Index .. Gearbox Overhual . Gearbox Installation Ball Joint Boot Replacement .. . 17-65 17-66 - 17-67 17-69 . 17-69 . 17-69 17-70 17-72 s+ 17-73 esses W775: 17-76 17-76 -17-77 17-79 17-82 17-84 17-89 17-92 17-93 17-106 17-109 17-113 17-114 17-128 17-132Special Tools LHD | Toot Numb Description ary | Page Reteronce 17-30 ® @ ‘O7GAF—S040700 Hub Dis/Assembly Base 1 | 17-81, 94 “07GAG—SD40100 | Piston Seal Ring Guide 1 | 17-99 07GAG—$040200 | Piston Seal Ring Sizing Tool + | 17-99 | -O7GAG—S040400 | Gyiinder End Seal Guide 1 | azt02 “974660010100 | Belt Tension Gauge 1 | 17-60 “Q7MAC-$L00200 | Ball Joint Remover, 28 mm 1 | 17-90 | ¥07NAak—sR3011A P/S Joint Adapter (Pump) 1 | 17-63 *O7NAK—AR3O12A PIS Joint Adapter (Hose) 1 17-63 | ¥o7Naz—sr30100 Lockwasher Pilot Clinch | 1 17-104 | 07406~0010001 P/S Pressure Gauge 1 | 1763 O1 ~07406—0010300 Pressure Control Valve | 1 17-63 @2 | -07406—0010400 | Pressure Gauge 1 | i763 ® £07725 0030000 | Universal Holder 1 | 17-76 o 077460020100 Inner Handle B {ot | 82 @ | 077480010300 | Attachment, 42 x 47 mm 1 | 1794 @® | 07749-0010000 Driver | 1 | 1797 @ — | v07916—sas0001 | Locknut Wrench, 40 mm 1} 17-61, 103 ® ~07974—SA50600 | Pinion Dust Seal Guide | oa | i788 @ _| -07974—SA50800 _| Ball Joint Boot Clip Guide || 3432 < ===) Ss @ ®S RHD Ref. No. ‘Too! Number Description [ory | Page Reference @ O7GAF—SD40700 _ | HubiDis Assembly Base 1) a7an7, v8 @ ©7466—0010100 | Belt Tention Gauge + | 17-60 @ 07MAC—SLO00200 Ball Joint Remover, 28 mm 1 17-110, ® ©7NAD—SR30100 | Handle Driver a | 7416 ® O7NAD—SR30200 | Packing End Remover + | i716 © O7NAG—SR30200 | End Packing Setting Tool 1 | aria ® o7NAG—SR30300 | End Packing Slider + | rzaaa ® 07NAG-SR30400 | Piston Seal Ring Guide | 1 | 17-120 ® 07NAG—SR30500 | Piston Seal Sizing Tool 1 | 17-420 @ 07NAG—SR30600 | Sloove Seal Sizing Too! 1 | a7at9 ® O7NAG—SDB0400 | Sleeve Seal Guide 1 | avzar8 @ 07NAG—SR30800 End Seal Guide 1 17-122 ® O7NAG—SR30800 | Valve Sea! Sizing Too! + | arate ® O7NAK—SR3011A | PIS Joint Adapter (Pump) + | 1763 ® O7NAK—SR3012A | P/S Joint Adapter (Hose) 1 | 1763 ® O7NAZ—SA30100 | Lockwasher Pilot Clinch + | 25 @ 07406-0010001 | PIS Pressure Gauge + | 1763 on 074060010300 | Pressure Control Valve 1 | 1763 @2 07406-0010400 | Pressure Gauge 1 | 1763 @ 072250030000 | Universal Holder 1 | 1776 @ 077460010100 | Attachment, 32 x 35 mm + | a7ate ® 07748 -0010700 | Attachment, 24 x 26 mm 1 | oaza7 ® 07746-0020100 | nner Hnale 8 + | 1782 @ 077490010000 | Briver 1 | waz a8 @ 07916—SA50001 Locknut Wrench, 40 mm | 1 17-61, 124 ® 07974~SA50800 | Ball Joint Boot Guide Loa | i192 @ = e ® eed f Hesse 17-31Component Location index (LHD) NOTE: © If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during tansit, storage or service, It should be deployed (see section 23). © Before removing the gearbox, remove the ignition key to keep the steering shaft from turning © After installing the gearbox, check the wheel alignment and adjust if necessary. CAUTION (with SRS} © All SRS electrical wiring harnesses are covered with ellow outer insulation, tire affected SRS harness assombly if it has an open circuit or damaged wiring. ‘© Botore disconnecting the SRS wiring hamesses, turn, the ignition switch off, disconnect the negative and positive battery cables, and wait at least three utes. STEERING WHEEL Steering wheel positioning, ‘SRS AIRBAG ASSEMBLY Removal, page 23-350, Inctallation, page 23-351 ‘STEERING COLUMN Removal, page 17-70 Inspection, pege 17-72 Installation, page 17-73 IGNITION swiTcH ‘Stooring Lock Replacement and Switch Test, see Electrical Section POWER STEERING OIL PRESSURE SWITCH Troubleshooting, soe section 11 VALVE BODY UNIT Overhaul, page 17-84 STEERING GEARBOX Rack Guide Adjustment, page 17-61 Removal, page 17-83, Index, page 17-92 Overheul, page 17-93 Installation, page 17-108 BALL JOINT BOOT Replacement, page 17-132 RESERVOIR Fluid Replacement, Control Valve Inspection and Roplacoment, page 17-77 Disassembly, page 17-79 47-32 Reassombiy, page 17-82iS) Index (RHD) NOTE: © Before removing the gearbox, remove the ignition key to keep the steering shaft from turning. © Han intact ais smbly has been removed from a scrapped car or has been found defective or damaged during ansit, storage or service, it should be deployed (see section 23). © After installing the gearbox, check the wheel alignment and adjust if necessary, CAUTION (with SRS): © AILSRS electrical wiring harn yellow outer insulation. © Replace the entire affected SRS harness assembly if it has an open circuit or damaged wiring, © Bofore disconnecting the SRS wiring harnesses, turn the ignition switch off, disconnect the negative and positive battery cables, and wait at least three minutes. SRS AIRBAG ASSEMBLY Removal, page 23-350 Installation, page 23-351 18 are covered with STEERING COLUMN Removal, page 17-70 Inspection, page 17-72 Installation, page 17-73 IGNITION switcH Steering Lock Replacement ond Switch Test, see Electrical Section ‘STEERING WHEEL Steering wheel positioning, ‘500 Suspansion/Alignment Disessembly/Reassembly, page 17-66 POWER STEERING OIL PRESSURE SWITCH Troubleshooting, see section 17, Ws oS SK WSS STEERING GEARBOX WS ack Guide Adjustment, page 17-61 BS Removal. page 17-109, as tedex, page 17-113 “t Overhaul Install Pump Belt Adjustment, page 17-60 Fluid Replacemont, page 17-62 Pump Pressure Check, page 17-63 Pump Replacement, page 17-76 Control Valve Inspection and pom Replacement, page 17-132 Reaseombly, page 17-82 17-33System Description (LHD) [- Fluid Flow Diagram The reservoir supplies power steering fluid to the pump; the pump pressurizes the fluid to about 8000 kPa (1200 psi), and delivers it through a high pressure hose to the control unit on the gearbox. The control valve {in the control unit) controls the direction of the turn by shifting fluid to the left or right side of the piston on the rack (in the power cylinder). The cut-off valve, slso in the control unit, controls the amount of assist by regulating the stroke of the control valve. Fluid returning from the power cylinder flows back through the control valve and out to the reservoir through the cooler. om Cooter, STEERING WHEEL —-— — Gearsox PINION, 7 HOLDER | STEERING PINION conraow unit conTRoL. 17-34@ [- Steering Pump Construction ‘The pump is a vane-type incorporating a flow control valve (with an integrated relief valve) and is driven by @ V-belt from the crank pulley. The pump features 10 vanes. Each vane performs two intake/discharge operations for every rota- tion of the rotor. This means that the hydraulic fluid pressure pulse becomes extremely small during discharge. INLET PORT ROTOR CAM RING FLOW CONTROL VALVE DRIVE SHAFT VANE fen pulley rotates the rotor through the drive shaft. As the rotor rotates, the hydraulic pressure is applied {0 the vane chamber of the rotor and the vanes will rotate while being pushed onto the inner circumference of the cam ring, ‘The inner circumference of the cam ring has an extended portion with respect to the center of the shaft, so the rollers move downward in the axial direction as the carrier rotates. As a result of this roller movement, the internal volume of. the vane chamber will change, resulting in fluid intake and discharge. START OF FLUID INTAKE FLUID INTAKE FLUID MOVEMENT FLUID DISCHARGE i DISCHARGE PORT “The vanes are pushed onto the The volume of the vane cham: inner eveumference of the cam ‘ing, a The sucked:in fluid moves Increases so that fluid is toward the discharge port ed in feturn tothe their Of the vane lecreases so the uid is discherged trom the dis charge port. (cont'd) 17-35System Description (LHD) @ Fluid Reservoir/Filter [- Steering Pump (cont'd) Flow Control Fluid from the pump runs through a metering orifice to ‘the control unit. This creates a pressure difference be- tween the pump and control unit sides of the orifice. When pressure in the pump side is higher than the force of the spring holding the flow control valve closed, it pushes the valve down (open), and excess fiuid returns to the pump inlet. The combined effect of the metering orifice and the flow control valve provides a relatively constant flow of fluid to the control unit. METERING ‘ORIFICE Pressure Relief As pressure on the control unit side builds up it pushes the relief valve ball {inside the flow control valve) up ‘against its spring, and excess fluid returns to the pump inlet. As the pressure under the flow control valve drops, the relief valve ball is closed by its spring, and the flow control valve is forced down again, allowing excess fluid from the pump side to return to the inlet. This flow con trol valve-reliaf valve cylinder keeps pump output pres- sure between 7845-8826 kPa (80-90 kg-cm?, 1138-1280 psi. RELIEF VALVE OPEN PUMR, FLow contaot—>| VALE RELIEF VALVE BALL’ DANPING ORIFICE Aone piece reservoir and filter is attached to the fender apron on the left side of the engine compartment. The fluid and the filterireservoir should be replaced if the sys- ‘tem is opened for repairs, orf the fluid gots water or dirt init CAUTION: Use only Honda Power Steering Fluid-V. The use of other fluid such as A.T-F., or other manufacturer's power steering fluid will cause damage to the system, T rven ra fon rn, Lowen ere ~ From Controt Unit Jy To Steering Pump Reservoir Capacity ... 0.4 ter (0.42 U.S. qt., 0.35 Imp. at.) 1.4 tar (1.17 U.S. at, 0.97 Imp. at) 17-36iS Mounted on the upper side of the gearbox is a control valve that is moved horizontally by a pin on the pinion holder to shift fluid pressure to the right or left side of the Power Cylinder when the steering wheal is turned. {thas thrust pins at both ends, and two inter-connected reaction chambers, one on each side. Each reaction chamber contains a pair of spring loaded plungers that rise against right and left thrust pins. ‘The valve body fluid passages are controlled by the control valve. f- Control Valve cur-oFF VALVE CONTROL. RESERVOIR VALVE =. = ->_ side Transit Ce) (SECTION Aa — coNTRoL, (cont’a) 17-37i) In the power steering unit, the method used to direct a single source of fluid pressure in either of two directions (for left or right turns) involves the pinion gear transferring a " of direction to the fluid 4-way valve. The pinion is mounted slightly off-center in a pair of bearings, which are in turn mounted in a Pinion Holder cylinder that rotates, centered in its own outer bearings. At the top of the Pinion Holder is a pin, which fits in a slot in the 4-way valve. As the pinion is tumed (to turn left or right), because itis off-center, it also moves slightly along the rack. This movement is transferred to the holder. The pin in the holder then moves the 4-way valve, to direct fluid pressure to either side of the rack in the Power Cylindei The back edges of the pinion holder (facing away from the rack) hit the stops cast into both sides of the gear housing {0 avoid pushing the control valve too far in either direction. The front edge of the pinion holder cuts off assist at full lock as described on the next page. System Description (LHD) - Control Valve (cont'd) away CONTROL VALVE PINION HOLDER Pin NEEDLE ROLLER BEARING BALL BEARING PINION PINION. HOLDER CENTER PINION HOLDER CENTER Ce ee \qGH | << STEERING RACK INiON HOLDER PIN, contaot, VALVE 17-38r—~ Full-Lock Unloader System The 4-way valve shifts the direction of fluid flow when the steering wheel is turned right or left. However, when the wheel is turned to the right or left lock at parking speed, the edge of the pinion holder rides up on the end of the rack, moving the pin in the opposite direction which pulls the 4-way valve back to neutral. ‘This keeps pump pressure from building up (which could cause idle speed to drop), and improves steering feel by increasing resistance at left and right lock. Control in “assist” position Control valve moves back to “neutr * position 17-39System Description (RHD) (- Fluid Flow Diagram ‘The power steering of thes car contrals the power assistane with no stage. It is @ compact rotary valve-type power steer- ing which is excellent in hydraulic pressure sensing performance with the gearbox built in and equipped with the vane- type pump. ‘As the power assistance is automatically controled in compliance with the reaction force of the road surface and car speed, i.e. the system makes the steering wheel light to turn when driving at low speed or when turning the wheel with the car stopped and it makes the steering wheel rather heavy to turn when driving at high speed, the driver feels the best and natural steering responses at all speeds. In addition, the driver can grasp the road congition well, too, as the reaction force of the road surface is adequately transmitted to the steering wheal, The pump driven by the crank pulley pressurizes the steering fluid and delivers it is the valve unit around the pinion of the steering gearbox with the amount of fluid and pressure regulated by the flow control valve built in the pump, The rotary valve of the valve unit controls the hydraulic pressure and changes the direction of the flow, and the fluid flows to the power cylinder where rack thrust is generated, Fluid returning from the power cylinder flows back to the reservoir, where the fluid is “filtered” and supplied to the pump again. STEERING GEARBOX VALVE UNIT RESERVOIR Panton, GEAR RACK FLOW CONTROL VALVE POWER CYLINDER ‘STEERING WHEEL 17-40iS - Steering Pump Construction ‘The pump @ vane-type which gives the driver better steering response thanks to the large discharge volume of the Pump and it has small hydraulic fluid pressure pulse during discharge. This reduced the “beat” noise caused by the pres- ‘sure pulse during discharge making the pump being quiet while operation. The pump is incorporated with the flow control in the pump. valve and controls the discharge volume and pressure iencone CAM RING FLOW CONTROL VALVE DRIVE SHAFT oO. VANE ROTOR ‘The vane-type pump consists of the vanes moving around the rotating rotor and the cam ring fixed outside the vanes. As the rotor rotates, the hydraulic pressure is applied to the vane chamber of the rotor and the vanes will rotate while being pushed onto the inner circumference of the cam ring. The vane chambers move in the rotating direction of the rotor changing the internal volume of the vane chambers according to the shape of the Inner circumference of the cam fing, resulting in fluid intake and discharge. ‘The following drawings show the sequential movement of vane chambers from the intake to discharge operations. The same operation is made at the two facing vane chamber: in other words, each vane chamber performs two intake/dis- ‘charge operations for every rotation of the rotor. START OF FLUID INTAKE FLUID INTAKE FLUID MOVEMENT FLUID DISCHARGE DISCHARGE PORT ‘The internal volume of @ ‘The intomnal volume of @ The internat volume of a vane chamber starts to in- vane chamber keaps in- vane chamber decreases ac- Cracse and a vane chamber creasing and the steering _—‘the sucked.in fluid moves cording to tho shape of the ‘comes to the inlet port. fluid is euckea into the toward the dlecharge port. cam ring and the fluid in the ‘chamber through the iniet ‘Vane chamber Is pressurized port ‘and discharged from the dis- charge port. 17-41System Description (RHD) [- Steering Pump (cont'd) Flow Control The flow control valve in the pump performs the follow- ing steps @ through @ to control the flow of fluid, ie to increase the discharge volume when engine speed is low and to decrease it when the engine speed increases. The assistance thrist of the steering gearbox changes in compliance with the change in the discharge volume. When the engine starts, fluid discharged from the discharge port starts to run through the metering orifice in the pump. The discharge volume increases a the engine speed increases. ® Asthe flow has already been regulated by the meter- ing orifice when the engine speed is at or near the idle speed, a constant and regulared amount of fluid is discharged until the engine speed reaches the mid- dle speed range. As the engine speed increases, pressure difference between the ends of the metr- ing orifice increases. The pressure difference is creat- ed between the top and bottom ends of the flow control valve, too, pushing the flow control valve to ‘open the by-pass passage. This allows the excess fluid to return to the inlet port preventing pressure at the discharge port from rising excessively. @ As the engine speed increases more, the flow con- ‘tol valve is pushed back further. With the engine ‘speed reached at a given speed, the return passage ‘outside the metering orifice is connected to the let port and the opening to the inlet port widens proportion to increase of the engine speed. This ‘makes part of fluid regulated by the metering orifice return to the inlet port of the pump; thereby dis- charged fluid from the pump is decreased slowly by this amount. ® The flow of fluid discharged from the pump is regu- Jated and maintained at a given level until and en gine speed reaches to the high speed range thanks to the orifice in the return passage FLOW CURVE FLOW OF FLUID PUMP P.M, DISCHARGE PORT mereRING ORIFICE g iol EJ Flow conrrou METERING ORIFICE “F perdnw wassace 17-42Pressure Ri f Pressure outside of the metering orifice is directed to the bottom of the flow control valve. When the pressure bullds up, the relief valve in the flow control valve opens to relieve the pressure. As the flow control valve is pushed back by the pressure difference thes time, the flow of fluid in the bypass passage increases controlling the pressure outside the metering orifece. The above operations are repeated to provide constant discharge pressure from the pump, METERING ORIFICE | = RELIEF VALVE DAMPING ORIFICE (Decreases excossive Vibration in the valve.) iS) ‘Aone piece reservoir and filter is attached to the fender apron on the left side of the engine compartment. The {uid and the filter/reservoir should be replaced if the sys- ‘tem is opened for repairs, or ifthe fluid gets water or dirt init r- Fluid Reservoir/Filter CAUTION: Use only Honda Power Steering Fluid-V. ‘The use of other fluid such ae A.T.F.. of other manufacturer's power steering fluid will caust damage to the system. 4 UPPER LeveL From Control Unit Lower > LEVEL _— To Steering Pump + 0.4 ter (0.42 U.S. at. 0.35 Imp. at.) 1.0 titer (1.07 U.S. at, 0.87 Imp. at.) ‘System Capacity 17-43System Description (RHD) - Steering System ‘The rack-and-pinion type steering gearbox is simple in structure which has the vaive unit controlling the steering fluid pressure incorporated with the pinion. Steering fluid from the pump is regulated by the valve unit and is sent through the cylinder pipe to the power cylinder, where the rack thrust is generated. While, steering fluid in another power cylinder returns through the cylinder pipe and valve unit to the reservoir. ‘VALVE UNIT CYLINDER PIPE To POWER CYLINDER POWER CYLINDER Valve Unit Inside the valve unit is the valve which is coaxial with the pinion and controls the steering fluid pressure. The valve unit case is connected with the oil pipe from the pump, return pipe to the pump, and the two cylinder pipes from the respec tive power cylinder. The pinion is double structured with the input shaft connected to the steering shaft equipped with the pinion gear, both of whieh 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 the valve. Becomes of this construction, difference in angle in the circumferential direction between the input shaft and valve be- ‘comes large according to the torsional strength of the pinion or reaction force of the road. However, maximum torsion between the shafts is regulated by the engaged splines of the shafts at the pin engagement section to hold the torsion bar within the set value. This allows the steering system to function as the ordinal rack-and: rized because of the faulty pump. inion type steering when steering fluid is not pressu- To RESERVOIR From PUMP VALVE TORSION BAR INPUT SHAFT CONVEX ON VALVE CONCAVE IN VALVE Pi ‘To POWER, CYLINDER ENLARGED CROSS SECTION (a—A") INPUT SHAFT 17-44@ Pressure Control No reaction force of the road surface: When there is no reaction force of the road surface, the input shaft is in the neutral position, i.e. right and left orifices between the input shaft and the valve are equal. As each orifice is equal in length and fully open, feed pressure from the pump is bypassed to the reservoir. Because of this operation, pressure in the power cylinder does not increase, resulting in small power assistance when reaction force of the road surface is small such as when driving at high speed or when driving straight forward. AFT INPUT SH wvauve nerunw passace ADS To RESERVOIR From PUMP Large reaction force of the road surface: ‘When reaction force of the road surface is large such as when driving at low speed or when turning the wheel with the car stopped, difference in angle is created between the input shaft and valve opening the oil passages of one side and closing the oil passages of the other side. Oil pressure in the power cylinder of the enlarged oil passage side increases to produce the rack thrust; thereby the steer- ing wheel can be operated with light force. While, the return passage from another power cylinder opens to return the steering fluid in the return passage in the input shaft to the reservoir. ‘The oil passages to the power cylinder automatically changes in size according to the reaction force of the road surface; in other words, the passages enlerge and power assistance increases when reaction force of the road surface is large While the passages become small and power assistance decreases when reaction force of the road surface is small Olt PASSAGE TO POWER CYLINDER lL PASSAGE FROM POWER CYLINDER ‘To POWER CYLINDER RETURN FROM POWER CYLINDER ‘To RESERVOIR {cont'd 17-45System Description (RHD) r- Steering System (cont‘d) Hydraulic performance of power cylinder: Though pressure from the pump is maintained at a constant valve, the steering system is designed to discharge large volume of fluid when pump speed. This change in discharge volume changes the hydraulic performance of the power cylinder, too. Where the areas of orifice of the valve unit are equal, prossure in the power eylinder is proportional to the pump discharge volume squared. ‘Therefore, the steering response is light when the discharge volume is large and the steering response is heavy when the discharge volume is small. The combined effect of these characteristics provides the best steering performance. FLOW VOLUME AT LOW SPEED FLOW VOLUME AT MIDDLE SPEED feAcTON FORCE OF ROAD | ow VOLUME AT HIT speeD INPUT TORQUE 17-46Troubleshooting (LHD) tS) [- General Troubleshooting Check the following before you begin: ‘@ Has the suspension been modified in a way that would affect steering? © Aro tire sizes and air pressure correct? © Is the steering wheel original equipment or equivalent? © Is the power steering pump belt properly adjusted? © Is steering fluid reservoir filled to proper level? © Is the engine idle speed correct and steady? Hard Steering Litte or no assist in both directions with car parked, ‘Chock for bubbles in power steer. | Leaking from eylinder end ing tid tigrrod boot, {omit Seeeeeeeeeeen —____1_ ie — 7 It the cylinder end seal leak, remove there are bubbles, check the Wf there are ne bubbles, check if ae the gearbox and overhaul reservoir input side hose and pump sist improves when engine RPM is —r—c—_—r—v—v—vv I front seal for air leake, increased to 3000. Ropair as necessary [ tf no abnormality is found, remove —— the contol valve unit and chack the inion pin for free movement. Ifassist improves, check the pump If assist does not improve, check WOK, check the control valve for flow control valve for interna lak ‘ula pressure, using power st {ree movement (page 17-84). ‘and clean of replace as neces. ing gauge with shutoff valve Repair as necessary, ry tbage 17°77). 1 the valve closed (page 17-63) aeewnvvw— SIS: Fluid pressure below 7845 kPa Fluid pressure 78458826 kPa (0 kgiem?, 1138 psi) (80-80 kglem?, 1138-1280 —_ a — | psi. (Chock the pump flow control vaive ‘Stoering effort above. Check the al leaking, and clean or cutoff valve for sticking oF 3 (age 17-77), logged orifice: cieen or replace the Ifthe valveis OK, replace the pump. valve as necessary (page 17-81). ___TVTE—_—ee the cut-ott valve 1g OK, check the pinion pin for free movement. If Seized or binding overhaul the ing gearbox: (cont'd) 17-47Troubleshooting (LHD) [ General Troubleshooting (cont'd) [gon sipping on puey. | Adivet bet tension. Replace bol, {Bet stoping on put oe ae ee ee necessary (page 17-60), Cutoff valve sticking or leaking Feplace the cut-off valve or contrat | Le Unit _——— If the engine stalls when wheal is turned while cer is stopped or mov- ing at low speed, adjust idle speed (oe Fuel Section) —f jae speed iow or erratic. Uneven or rough steering ————— ‘Check power steering fluid level. v0 tank, or check pow- level is excessively low, check for ing Muid level leaks in the system, Ade fd to the td specified level fia \K, check O-rings ing. surfaces. for suction leaks. Replace parts as necessary. ——| improperty adjusted rack guide. |— Adjust rack guide (nage 17-61), If the rack guide adjustment is OK, ‘check the pinion bearings for wear for damage. Replace thom 03 17-48‘Shock or vibration when whes turned to Yul lock, Stocring kicks back during wide Wheel will not return smoothly. Pump bet slipping on pulley (pump stops momentary). ‘Set the power steering pressure __| gauge: Ciose the shutoff valve fly ‘and measure the pump pressure (see page 17-63) J —[ Pump belt stipping pump a6 an acsombly ‘Adjust belt tonsion (page 17-60) or replace bett ‘Adjust belt tension (page 17-60) oF replace belt. (Check if pump pressure ie within the range 7845-8826 kPa {80-90 Kglem?, 1138-1280 psi) ‘and the gauge neodle travol is "= 490 kPa (5 kglem?, +70 psi) fr less. Chack the flow control Valve if the needle travel exceeds ‘2490 kPa ("5 kg/em?, 70 psid {see page 17-77). If the flow con frat valve ig normal, replace the Sticking cutoff valve or control | Replace cut-off valve or control valve, ack guide adjusted (00 loose. ‘Adjust rack guide (page 17-61). [| Tee pressure 100 low. Improper front whee! alignment. \_f improperty sajusted rack guide. | replace parts as necessary, { ‘Adjust rack guide (page 17-6 Inflate to correct presture. Readjust front wheel alignment oF 17-49Troubleshooting (LHD) [- Noise and Vibration NOTE: Pump noise in first 2—3 minutes after starting in cold weather (~ 20°C, ~4°F or colder) is normal Humming due to pulsation of fluis ie normal, particularly when wheel is turned with car stopped Humming ———_——________——+—— mission, the hum could be torque | 1 Confirm by jporarity o pump bel. ‘converter or pump noise. frame. —[ Bete slipping. Tighten or replace belt a Pinion shaft geal not lubricated. |—| Grease it. | Squeaking - Horn contact not lubricated, or un Grease the contact, or bend it to | jor too much pressure, reduce the pressure, 4 hr a pt | Burrs on the pinion gear Replace the pinion gear. NOTE: A single ‘clunk” may be a normal amount of linkage clearance. To dis: tinguish thie type of clunk, turn the wheel back and forth with the engine OFF. ‘Tighten or replace pulley Ifshaftis loose, replace the pur. ump pulley. Rattle of chattering Loos steering shaft connector, te Chock and tighten, or replace parts rod, oF bal joint as necessary. Column shaft wobbling ~ LJ Replace cotumn assembly Lines or hoses from the control unit Reposition lines so they don’t touching each other touch. Hissing aaaise | Noise from control valve Replace the control unit. ——= NOTE: Pump noise up to 2-3 minutes after starting in cold weather (= 20°C, ~4°F or colder) ig normal. ‘Compare pump noise at operating temperature to another car It pump noise Is abnormally toua, —| check the pump ball bearing and other parts (page 17-80), Pump gear noise [ check tui tevet. low, fil reservol to proper lex ~ [| and check for leaks. rnin note tom pump Bi eeormey aol fluid (Check for erushed suction hose or 2 loose hose clamp allowing air into the system. | Tignton or replace as necessary. 17-50r Fluid Leaks Leaking rom ovinder end sentinto |__ oa go aa age tie-rod boots, Leaking from lett sid rr Remove the control valve and in- Leaking fom rah aie. pect the 1 mm Oring and the ————— port housing bore for pits, burrs or | Reseal geerbox and inspect the rack scratches (page 17-86). sealing surface betwean the steer Repair as necessary. ing tack piston and the Fight end = (page 17-921 If-no abnormality i found, replace ‘the O-ring, teseal the gearbox and NOTE: When flud leaks from one side inspect the steering rack sealing of the rack the balance tube transfers surface for burs oF seratchos be ‘the fluid to the other side, giving the tween the steering rack gear toot Steoring gearbox be aa aetna none appearance that both side releaking, and the piston. Inspect the sea! To troubleshoot, remove both boots, tainer bore In the gearbox housing clean the rack and locate the leak. for proper chamfer and sharp edges (page 17-92). Leaking from control unit meting Tighten attaching bolts or replace surfaces, valve body or port housing. Leaking from either side of valve Roplace all control unit seals and body. Ovrings, Leaking from diiled passage plug (steel bal Replace control valve body. Front eoal leaking. Replace front seal Pump _ J replece nosing O-rings. ‘| _Pump housing leaks at ether end. | — Ifthe housing stl leak, replace the | _—_e | pump. Roservair overtiled Pulloff the hose and drain to proper level. Reservoir ————__________T eatcing from around cap. ‘Ar leak in suction side of system (roservoir, inlet hose, front pump i piesa asses tina — Tilo, fina Ws Pump outlet tine | (nigh pressure) Leaking at sagged joint. Roploce hose. Leaking because of damage, deter Replace oF repair a8 necessar ration, or improper assembly. e eB a Low pressure hoses | Leaking at of Tighten connector. if stil leaking, ee (at flare put, replace the pipe oF control unit. 17-51Troubleshooting (RHD) - General Troubleshooting Check the following before you begin: © Aro tire sizes and air pressure correct? @ Is the steering wheel original equipment or equivalent? @ Is the power steering pump belt properly adjusted? @ Is stoering fluid reservoir filled to proper level? Is the engine idle speed correct and steady? Steering ‘Check pump fluid pressure, | Measure steady-state fuid pressure while idling with the shut-off valve fully open, It should be 785 kpa (8 kg/em?, 114 psi) or below (page 17-63). Abnorm fluid pressure Normal CCheck pump fluid pressure ‘Measure pump relief pressure while idling with the shutoff valve fully 63), 393-6374 kpe 782924 psi Too low relief pressure Normal reli if pressure ’ Go to page 11-53 > Fluid ore '@ Has the suspension been modified in a way that would affect steering? ure is t09 low: Check the return eicuit pipe and ho gearbox and pump fer clogging and 00 high hd hose connected from the pump 10 the gearbox for clogging and deformation, between the formation Normal pipe and hose Faulty control valve unit Check the flow contol valve. * Check the valve for smooth movement in the housing * Check the relief valve for leaks Normel ‘Abnormal , Faulty pump assembly Faulty flow control valve 17-52Check force required to turn the wheel (page 17-64) Start the engine and measure force required to turn the wheel to the Hight ‘and left. Difference of the force required to turn the whe the right and to the loft should be 25 Ni2.5 kg, 5.5 Ib) oF below. |— Abnormat_ ——{ Cheek the gearbox cylinder pipe A and 8 for deformation Normat 17-63) ‘Turn the steering wheel fully to the fight and loft while idling with the ‘shut-off valve fully open, and meas Ure the fluid pressure. I¢ should be 53936374 koa (55—65 kglem, 782~824 pai). Check pump fluid pressure (page i Not deformed Deformed , ' Faulty valve unit Faulty oylinder pipe [— Abnormal ——e Faulty gearbox comp Normal Check the gearbox. Fiemove the goarbox and measure the pinion torque. ‘The torque shoul be; "0.71.2 Nem (712 kgem, 6.07—10.41 bin) with the steoring rack in the straight Gtriving position + 1.3 Nem (13 kg-cm, 11.28 tb- in) with the steering rack in the ‘ther positions. Normal | Check the other parts but the goarbox-ralated parts for | proper rotation. Abnormal ——s ™ Improper rotation ofthe steering column-related partis) * Faulty steering joint + Faulty * Interference in the steering system ‘Adjust the rack guide (page 17-61). ‘Adjust the rack guide and recheck. the pinion torque, [— Norms! = —* improp ty adjusted rack guide Normal Faulty gearbox (cont'd) 17-53Troubleshooting (RHD) Whee! wi - General Troubleshooting (cont'd) ‘Assist (excessively light steering) at high specs. = Shock or vibration when wheels {ured to full lock. not return smoothly. ___| Fiaise the engine speed to 3.000 rpm Park the ear on dry paved surface. ‘and measure force required to turn the wheel ‘When force is 25 N (2.8 kg, 5.5 Ib) cr below, replace the control valve tit 28 an assembly, | Force is proper. [Fore ere [ Aatiust the rack guide (page 17-64). If the problem is nat corrected by ad. justing the rack guide, replace the ‘earbox comp. »_[ heck the rack guide for proper ad justment (page 17-61) Flack guide is adjusted properly ‘Check the belt for slip and adjust as essary (page 17-60) Rack guide was backed off exces sively ‘Adjust. If the problem is not corrected by ad justing the rack guide, replace the gearbox comp. Check the cylinder pipe A and 8 for If either one or both of the cylinder Setormation pipe A and Bisare deformed, replace, fj Ifthe cylinder pipe A and B are nor smal, remove the gearbox from the ‘tame and measure the pinion torque ‘on the gearbox. We should be 0.71.2 Nem (712 kgrom, 6.07— 10.41 Ib-in) or below with the steering rack inthe straight Griving position, and 1.3 Nem (13 kkg-om, 11.28 Ibn) or below with the steering rack in the other positions. | Wf the measurements are out of | specications, adjust the rack guid, If the problem is not corrected by ad- Justing the rack guide, replace the ‘Gearbox comp, 17-54Une, 7 oF tough steering Stoering kicks back during Wide turns 7 improperiy adjusted ck guide ‘Adjust rack guide (page 17-61) | Bett stipping on pulley. If the problem is not corrected by adjusting the rack guide, replace the ‘gearbox comp. ‘Adjust bett tension. Replace bet, if necessary (page 17-60), Idle speed low or erratic is when wheel is ‘car is stopped or mov- Ar in reserve tank, or check pow. er steering fluid level Pump bet slipping on pulley (pump stops momontariy). ‘gauge. Close the shutoff valve fully ‘and measure the pump pressure (soe page 17-63) Check power steering fluid level. level is excessively low, check for leaks inthe system. Add fluid tothe specified level — —— Uf fluid lever is OK, check O-rings | {and seals on both ends of the pump ‘Adjust bett tension (page 17-60) or _] eewtace tot. {Check if pump pressure ie within the range 5393-6374 kPa (85~65 kglom?, 782—824 psi) land the gauge needle travel is + 490 kPa (8 kgicm?, *70 psi) or less. Check the flow control valve if the needle travel exceeds =490 kPa (25 kglem?, =70 psil (see page 17-77). It the flow control Walve is normal, replace the pump | | 25-an essombly. 17-55Troubleshooting (RHD) F- Noise and Vibration Humming NOTE: Pump noise in first 2~3 minutes after starting in cold weather (20°C, —4°F or colder) is normal Humming due te pulsation of fluid le normal, particularly when wheelie tuned Squeaking Rattle oF chattering Hissing with car stopped. 1f equipped with Automatic trans- mission, the hum could be torque |—] Converter oF pump noise | Confirm by temporarily removing pump belt. High pressure line touching the |__[Repostion he ine. frame, — Pinion shaft seal not lubricated. { Grease i Grease the contact, or bend It to reduce the prossurs. Loose steering shatt connecter, tie- |__[ Check and tighten, or replace parts fed, or bal joint. [os necessary ‘Check the rack guide for proper justmant (page 17-61). ‘Adjust, necessary, Rattling sound and feeling when turning the steering wheel right and left with ‘the engine OFF is a sound when the velve unit contacts the stopper. This Is normal ‘Striking sound when turning the steering wheel fully right or lets @ sound when the rack end contacts the stopper. This Is normal {Pump noise, though nat lous the stoering wheel ight or {from the control valve can be heat ft. This ls normal when turning 17-56—— Check fui level vitation caused by air bubbles in low, fill resorvair to proper level, ftom pump fn T | ane check tor oaks. | LTiamen'or replace os necassa (Check for crushed suction hose or {8 lo0s@ hose clamp allowing air into the system, Tighten oF rep necessary, I pump noise is abnormally loud, cheek the pump ball bearing and any parts. (page 17-60) ‘weather (= 20°C, ~4°F of colder i normal Compare pump neise at operating Pump gear noise 1 17-57Troubleshooting (RHD) - Fluid Leaks © Check the gearbox assembly for faulty oll seals/seal leaks carefully. Oil can leak out of various points, depending on location of the 198. Check the following before removing the gearbox fram the frame. Leaking from the olf seal on the top Replace the valve oll seal from the | apa of the valve housing valve housing. Leaking from cylinder end into right FRoplace the valve oi seal from the tle-rod boot. pinion shai L, Replace the cylinder pecking A. Leaking from eylinder end into left Replace the cyinder packing Bor O- ring of the seal holder PS Sie Tighten attoching bolts or replace [J the ‘contrat vaive ‘unit or gear [_Uniemousing mounting section ako Proes 7 Connection: tartare rath | replace the pipe, cylinder or control Leaking caused by damaged pipe A 8. Replace the pipe A or 8. Tighten connector. if stil leaking, replace the pipe oF control valve. Leaking from feed pipe and ret pipe of the control valve. [at rut) 17-58Pump Reservoir Pump outlet tine (high preesura) Low pressure hoses Pines { Front soa eaking _} Replace front sea. Replace housing O-rings. Pump housing pump. Reservoir overfle. —{ Leaking trom around esp. ithe housing stlleaks, eeplace the a) Pulloff the hosa and drain to proper seal ‘Ar leak in suction side of system (reservoir, inlet hose, front pump Tighten iting. HF stil Leaking at threaded fiting replace hose. Leaking at swagged joint. Replace hose. Leaking because of damage, deter oration, oF improper assembly. Leaking at geetbox connection Tighten connector. I stil (at fare nut. Replace or repair as necessary. replace the pipe oF contol unit, King, 17-59Maintenance -- Pump Belt Adjustment 1. Apply @ force of 100 N (10 kg, 22 ib) and measure the deflection between the P/S pump and the crankshaft pulleys. Deflection: Used Belt: D16A Engine 8.0-12.0 mm (0.31—0.47 in) Other 3.0 — 12. engine (31-1 New Belt: D16A Engine 5.5—9. (0.221 Oth 6.0-9.5 mm engine (0.24— NOTE: If there are cracks or any damage evident on the belt, replace it with a new one. POWER STEERING PULLEY Test by the Belt Tension Gauge; 07JGG— 0010100. Attach the tension gauge to the belt and ‘measure the tension of the belt Tension: Used Belt: D16A Engine 350~500 N (35-50 kg, 77—110 Ib) Other 350—500 N engine (35-50 kg, 77—110 Ib) New Belt: D16A Engine 550—750 N (55-75 kg, 121-165 we) Other 500—700 N engine (60-70 kg, 110-154 >) NOTE: © If there are cracks or any damage evident on the belt, replace it with a new one. © See the instructions for the tension gauge. POWER STEERING PULLEY _—_BELT TENSION GAUGE , 075660010100 ‘CRANKSHAFT PULLEY \_ ) 2. Loosen the P/S pump mounting bolts. 3. Turn the adjusting bolt to get the proper belt ten- sion, then retighten the bolts. 4. Start the engine and turn the steering wheel from lock-to-lock several times, then stop the engine and recheck the deflection of the belt. ‘ADJUSTING BOLT SPECIAL BOLTS 45. Nem 17-60On-Car Checks r- Rack Guide Adjustment LHD: 1. Loosen the rack guide screw locknut with the special tool. 2. Tighten, loosen and retighten the rack guide screw two times to 4 Nem (0.4 kg-m, 2.9 Ib-ft), then back It off 20°°8°, 3. Tighten the locknut to about 25 Nem (2.5 kg-m, 18 lb-ft) while preventing the guide screw from turning. LOCKNUT WRENCH, 40 mm 07916-50001 RACK GUIDE SCREW 4. Check for tight or loose steering through the com- plete turning travel 5. Recheck steering assist (page 17-64) @ RHO: 1. Loosen the rack guide screw locknut with the ‘special tool 2. Tighten, loosen and retighten the rack guide screw tow times to 5 Nem (0.5 kg-m, 3.6 lb-ft, then back it off 25°. 3, Tighten the locknut to about 68 N-m (6.8 kg-m, 48 lb-ft) while preventing the guide screw from turning. LOCKNUT WRENCH, 40 mm 07916—Sas0001 RACK GUIDE SCREW 4. Check for tight or loose steering through the com- plete turning travie. 5. Recheck steering assist (page 17-64) 17-61On-Car Checks r- Fluid Replacement Check the reservoir at regular intervals, and add fluid as necessary, CAUTION: Use only GENUINE HONDA Power Steering Fluid-V. Using other fluids such as ATF or other manufacturer's power steering fluid will damage the system. Fluid Roplacomont ‘SYSTEM CAPACITY: LHD: 1.1 liter (1.17 U.S.qt, 0.97 Imp at) RHD: 1.0 liter (1.07 U.S.qt, 0.87 Imp at) RESERVOIR CAPACITY: 0.4 liter (0.42 U.S.qt, 0.35 Imp at) Raise the reservoir and disconnect the hose that goes to the oil cooler. Connect @ hose of suitable diameter to the discon- nected hose that goes to the oil cooler and put the hose end in a suitable container. CAUTION: Take care not to spill the fluid on the body and parts. Start the engine, letitcun at idle, and tuen 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. HOSE (From the oll cooler) HOSE Refit the return hose on the reservoir. Fill the reservoir to the upper level mark. Start the engine and run it at fast idle, then turn the steering from lock-to-lock several times to bleed air from the system, Recheck the fluid level and add some if necessary. CAUTION: Do not fill the reservoir beyond the up- per level mark. 17-62f- Pump Pressure Check Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox. NOTE: First check the power steering fluid level and pump belt tension, CAUTION: Disconnect the with care so as not to spill the power st fon the frame and other parts, igh pressure hose ing fluid 1. Disconnect the outlet hose from the pump outlet fitting, and install the pump joint adaptor on the pump outlet 2. Connect the hose joint adaptor to the power steer: ing pressure gauge, then connect the outlet hose to the adaptor. 3. Install the power steering pressure gauge to the pump joint adaptor as shown. HOSE ATTACHING BOUT PIS JOINT ADAPTOR (HOSE) ‘O7NAK—SR3O12A PIS PRESSURE GAUGE (07408—0010001 (Part of tool PIS JOINT ADAPTOR (PUMP) O7NAK—SR3O11A 4. Open the shut-off valve f 5. Open the pressure control valve fully. @ Start the engine and let i idle. Turn the steering wheel from lock-to-lock several ‘times to warm the fluid to operating temperature, Close the shut-off valve, then close the pressure control valve gradually until the pressure gauge needle is stable. Read the pressure. Immediately open the shut-off valve fully. CAUTION: Do not keep the shut-off valve closed more than 5 seconds or the pump could be dam- aged by over-heating If the pump is in good condition, the gauge should read at least. A low reading means pump output is too low for full assist. Repair or replace the pump, LHD: 7845—8826 kpa (80-90 kg/em?, 1138—1280 psi) 5393-6374 kpa (55—65 kglem?, 782-924 psi) RHI P/S PRESSURE GAUGE 074080010007 PRESSURE CONTROL VALVE 17-63On-Car Checks 1. Place the front wheels in a straight ahead position and measure the distance the steering wheel can be turned without moving the front wheels. 2. Ifthe play exceeds the service limit, check all steer- ing components. 0-10 mm (0-0.4 in) [- Steering Wheel Rotational Play —— - Power Assist Check with Car Parked 1. Check the power steering fluid level and pump belt 2. Start the engine, allow it to idle, and turn the steer- ing wheel from lock-to-lock several times to warm, up the fluid 3. Attach a spring scale to the steering wheel. With the engine idling and the car on a clean, dry floor, pull the scale as shown and read it as soon as the tires begin to turn. Specifications: LHD: 30 N (3.0 kg, 6.6 Ib) maximum RHD: 26 N (2.5 kg, 5.5 Ib) maximum 4, If the reading is out of specifications, check the gearbox and pump. 17-64Steering Wheel (With SRS) -- Removal @ irbog Assembly Removal rn ‘Store a removed ait ad surface up. if the airbag is improperly stored face ‘down, accidental deployment could propel the unit with ‘enough force to cause serious injury. CAUTION: ‘turn the ignition switch off, disconnect the negative and positive battery cables, and wait three minutes. © Do not install used SRS parts from another c When repairing an SRS, use only new parts. © Carefully inspect the airbag assembly before install- 19 it. Do not install an airbag assembly that shows ‘signs of being dropped or improperly handled, such as dents, cracks or deformation. © Do not disassemble or tamper with the airbag assembly. © Special bolts are necessary for installing the airbag assembly. Do not use other bolts. NOTE: © Make sure the wheels are aligned straight ahead. Remove the left airbag assembly mounting TORX bolt first (the safety switch will automatically turn off. 1. Turn the ignition switch off, then disconnect the negative and positive battery cables, and wait three minutes 2. Remove the jrbag assembly (page 23-350) 3. Remove the steering wheel nut. 4. Remove the steering wheel by locking it slightly from side-to-side as you pull steadily with both hands. STEERING WHEEL NUT Replace. 17-65Steering Wheel (With SRS) assembly/Reassembly enough force to cause serious injury. NOTE: If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see page, 23-352). ee STEERING WHEEL NUT 50 Nem (5.0 kg-m, 36 ibe) AIRBAG ASSEMBLY TORX® BOLT 10 Nem (1.0 kgm, 7 ete) ESR CAUTION: mbly before install- ing. Do not install an airbag assembly that shows signs of being dropped or improperly handled, such ‘as dents, cracks or deformation. © Do not disassemble or tamper with the airbag assembly. 17-66cS r—Installation 1. Install the steering wheel on the column. NOTE: Be sure the steering wheel shaft engages the slip ring and canceling sleeve. CANCELING SLEEVE [STEERING WHEEL SHAFT X tn HOLE 50 N-m (6.0 kom, 36 tb-fe) 2. Install the airbag assembly (see page 23-351). ‘CAUTION: © Bo sure to install the SRS wiring so that it ched or interfering with other car parts. © Bo sure the battery cables are disconnected, not pin- 3. After installing the airbag assembly, confirm proper ‘system operation: ‘© Turn the ignition to ON: the instrument panel SRS in- dicator light should go on for about 6 seconds and then go off. © The SRS self ‘one time with the ig 17-6717-68Steering Wheel (Without SRS) [~ Removal Installation 1. Remove the center pad 1. Install the steering wheel 2. Remove the steering wheel nut. NOTE: Be sure the steering wheel shaft engages the turn signal canceling sleeve. 3. Remove the steering wheel by rocking it slightly from side-to-side as you pull steadily with both hands. 2. Install the center pad. ‘TURN SIGNAL STEERING CANCELING SLEEVE (EEL 50 Nem (5.0 ka-m, 36 toot ,- Disassembly/Reassembly 50 Nom (5.0 kg-m, 36 tb-ft) Replace. 17-69Steering Column -— Removal CAUTION (with SRS): © All SRS electrical wiring harnesses are covered ‘© Replace the ontire affected SRS harness assembly if it has an open circuit or damaged wiring. © Before disconnecting the SRS wiring harnesses, tum the Ignition switch off, disconnect the negative and positive battery cables, and wait at least three minutes. NOTE: LH drive shown. RH drive is similar 1, Remove the steering whee! (17-65) 2. Remove the lower cover. ‘Lower cover 3. Remove the upper column and lower column ‘UPPER COLUMN COVER Lowen sa ‘COVER 4, Pull out the connector lock, then disconnect the ‘SRS main harness §-P connector from the slip ring. NOTE: Dispose of the connector lock, it is not to be reused. ‘5, Remove the slip ring from the combination switch assembly. ‘SRS MAIN HARNESS. 5:P CONNECTOR SUP RING MOUNTING SCREWS 6. Remove the turn signal canceling sleeve and the combination switch assembly. NOTE: After removing the combination switch ‘assembly, place it on the floor gently so that it does not hinder you in service. Do not disconnect the harnesses from the combination switch assembly. ‘TURN SIGNAL COMBINATION SWITCH CANCELING ASSEMBLY SLEEVE 17-706. Disconnect the ignition switch connectors from the. under-dash fuse box. 8. Remove the steering joint bolts, and move the joint toward the column. 7. Remove the steering joint cover. STEERING JOINT COVER STEERING JOINT 9. Remove the steering column assembly by removing the attaching nuts and bolts COLUMN ASSEMBLY COLUMN HOLDER 17-71Steering Column Inspec Nore: © Check the tilt mechanism, steering joint bearings and steering shaft for proper movernent and damage. Replace as an assembly if damaged or faulty. © The tilt steering column is shown; the conventional steering column is similar except for the tilt mechanism. ‘STEERING COLUMN nasonaove LATE o PLATE GUIDE Check for damage, ie ; mur =/ mn fe) Bae COLUMN HOLDER FLANGE NUT. FLANGE BOLT 8x12 mm 39 Nem (3.9 kg-m, 28 1b-f) 18N-m (1.8 kgm, 12 6-40 ‘© Attach a spring scale to the knob of the tilt lever. Measure the force required to move the lever. Pr Joad: 7090 N (79 kg, 15—20 Ibs) If the force measured is not within the specification, loosen the lock bolt, then the stopper, until the cor- rect force can be obtained. oie 17-72cS r- Installation ‘cauTiON: ‘© After reassombly, confirm that the wheels are stil straight ahoad and that the steering wheel spoke angle is correct. If minor spoke angle adjustment is necessary do s0 only by adjustment of the tie rod not by removing and repositioning the steering wheel. 1. Slip the upper end of the steering joint onto the col- ‘umn shaft (line up the bolt hole with the flat on the shaft) and loosely install the upper bolt. Final torque: UPPER BOLT 22 Nem (2.2 kg-m, 16 tot) oft must ne up with STEERING SONT: 2. Slip the lower end of the steering joint onto the pin- jon shaft (line up the bolt hole with the groove around the shaft) and loosely install the lower bolt. NOTE: Be sure that the lower bolt is securely in the ‘groove in the steering gearbox STEERING GEARBOX PINION LOWER BOLT Final torque! 22 Nem (2.2 kg-m, 16 bt) 3. Install the steering column assembly with the nuts and column holder. 4. Tighten the upper and lower steering joint bolts loosely installed in step 2. COLUMN ASSEMGLY HOLDER, 29Nm 16 Nm (3.9 kgm, 2B (1.6 kgm, 12 FO 5. Install the steering joint cover with the clamps and clip, STEERING JOINT cover (cont'd 17-73Steering Column [— Installation (cont'd) 6. Connect the switch to thi f@ connectors from the ignition \der-dash fuse box. 7. Install the combination switch assembly and turn signal canceling sleeve onto the steering column. NOTE: Be sure the wires are not caught or pinched by any parts when installing the combination ‘switch. COMBINATION SwiTCH ‘TURN SIGNAL CANCELING ASSEMBLY SLEEVE 8. Install the slip ring on the steering column, then connect the SRS main harness 5-P connector to the slip cing. SRS MAIN HARNESS. '5:P CONNECTOR SLIP RING 9. Install the upper column cover and lower column cover. UPPER COLUMN COVER 10. Install the lower cover. LOWER COVER 11. Install the steering wheel and airbag assembly (page 17-67). 17-74Steering Pump iS) r— Illustrated Index CAUTION: Pump components made of aluminum. Be careful not to damage them when servicing, NOTE: © Clean all of the disassembled parts thoroughly. '® Replace all O-rings and seals. Do not dip new O-rings and seals in solvent; coat O-rings with steering grease before in- stallation, and make sure they stay in place during reassembly. © If any part denoted with an asterisk is worn or damaged, replace the complete pump. ROLLER “PUMP CAM RING 5x 26.8 mm Check for damage Pump cover and wear Check for damage to {S108 puare sealing foce. heck for damage . “PUMP VANES and wear crm nous (10 plates) 54 x 1.9 mm ling faces. Checi for mage ea JER \ 24 wear Replace ee Drive iG 16.8 x 1.9 mm o-nING / DRIVE, HK y pee Check for damage PRELOAD and wear SPRING BALL PUMP SEAL FLANGE BOLT bint BEARING 20 Nem Cheek for (2.0 Kg. 14 we Soh Co noir play. Rouen Inter yor oF 35% 49.8 mm pou 68.5 x1.9'mm ‘8 ~ erin o } 0: Replace. “PUMP ROTOR 13.1.9 mm Check for damage O-RING ‘CONTROL VALVE and wear Replace ‘Check for pressure FLANGE BOLT TNs (1.1 kgem, 8 lb-ft), VALVE SPRING S58 21.9 mm 221119 mmonmo-“eap 88819 O-RING PULLEY’ Replace, Replace. ‘Check for distortion ‘and cracks: FLANGE BOLT PULLEY NUT eee’ V1 Norm (1.1 kg-m, 8 tb-fe) 65 Nem (6.5 kg-m, 47 Ibe) 17-75Steering Pump Replacement 1. Drain the fluid from the system (page 17-62). 2, Disconnect the inlet and outlet hoses from the pump and plug them. 3. Remove the belt by loosening the special bolts and adjusting bolt. 4. Remove the special bolts, then remove the pump. 11. Nem (LT kgm, 8 Fo ADJUSTING BOLT O-RING Roplace. ‘SPECIAL BOLT 45 Nem (4.5 kgm, 33 Ibo 5, Loosely install a new pump on the bracket. 6. Connect the inlet and outlet hoses to the pump, 7. Install and adjust the belt (page 17-60). 8. Fillthe reservoir with new fluid to the UPPER LEVEL on the reservoir. 9. Start the engine and let it run at fast idle while turn- ing the steering wheet iock-to-lock several times to bleed air from the system. 10. Check the reservoir and add fluid if necessary. Pulley Replacement Hold the steering pump in a vise with soft jaws, and hold the pulley with the special tool and remove the pulley nut and pulley. NOTE: Pulley nut has left-hand threads. UNIVERSAL HOLDER PULLEY (077250030000 PuLLey NUT 985 Nem (6.5 ko-m, 47 eA) Hold the pulley with the special tool and tighten the pulley nut. 17-761. Remove the control valve cap by removing the three flange bolts. 2. Remove the control valve spring, control valve and O-rings. CONTROL VALVE VALVE SPRING CONTROL VALVE CAP 22.1 x 1.9 mm O-RING Replace. Replace. 5.8 x 1.9 mm O-RING 3. Check for wear, burrs, and other damage to the ledges of the grooves in the valve. CONTROL VALVE check for Samage to edges. C Lie [- Control Valve Inspection and Replacement cS) 4. Slip the valve back in the pump and check that it, moves in and out smoothly. CONTROL VALVE If OK, go on step 5, if not replace the valve: NOTE: The original valve was selected for a precise fit in the pump housing bore, so make sure the new one has the same identification mark. Outside Diameter IDENTIFICATION MARK Outside Diameter mm (in) 17.991 17.996 (0.7083~0.7085) Mark Part Name A | CONTROL VALVE A 8 | control vatve 6 | ,17-996- 18.001 (0.7085~0.7087) Hf OK, go on step 5, if not, replace the whole pump ‘as an assembly. Attach a hose to the end of the vaive as shown. Hose CONTROL VALVE (cont'd) 17-77Steering Pump 6. Submorge the valve in a container of power steer- ing fluid or solvent, and blow in the hose. If air bub- bles leak through the valve, replace or repair it as follows, ‘AIR PRESSURE ‘At oss 98.1 kPo oe (1 kgiom?, 14.2 pit ff «— ower srecrInc FLUID or SOLVENT 7. Clamp the bottom end of the valve in a vise with, soft jaws. 8. Unscrew the seat in the top end of the valve, and, remove any shims, the relief check ball, relief valve ‘and relist valve spring RELIEF VALVE RELIEF CHECK BALL sHIMS} ti T EeRT 13.Nem (1.3 kgm, 9 b-A Ne Clamp this end in f vise with soft jaws, CONTROL VALVE RELIEF VALVE ‘SPRING r- Control Valve Inspection and Replacement (cont'd) 9. Clean all the parts in solvent, dry them off then reassemble and retest the valve. NOTE: If necessary, relief pressure is adjusted at the factory by adding shims under the check ball seat. If you found shims in your valve, be sure you reinstall as many as you took out 10. Install the control valve in the reverse order of removal, © Apply steering grease (Honda P/N 08733— B070E) to new O-rings. © Coat the control valve with power steering fluid, then install it and valve spring. CONTROL VALVE VALVE SPRING CONTROL VALVE CAP 17-78-- Pump Disassembly CAUTION: The pump components are made of alumi- ‘um. Be careful not to damage them when servicing. 1. Remove the pump from the engine (page 17-76) 2. Remove the pulley (page 17-76). 3. Remove the control valve Ipage 17-77). 4, Remove the inlet joint and O-ring. Replace. 5. Remove the pump cover and O-ring. PUMP COVER 6. Remove the pump cam ting from the pump. housing, PUMP CAM RING 7. Remove the pump rotor and vanes. PuMP ROTOR PUMP VANES. (cont'd) 17-79Steering Pump -— Pump Disassembly (cont’d) 8. Remove the two rollers from the side plate. 9. Remove the side plate and preload spring, ROLLER 5x 26.8 mm I 4.5 x 49.8 mm | PRELORD Senna 10. Remove the O-rings from the side plate. 16.8. 1.9 mm ona Replace. 54 x 1.9 mm I~ o-ring Replace. 11, Remove the circlip, then remove the drive shaft assembly from the pump housing using a plastic hammer. 12, Remove the seal spacer and oil seal. oon pave shart ume SEAL So Z ne place. 13. Check the pump ball bearing for play; if it is good land the grease in itis clean, go on step 14. — If the bearing is noisy or has excessive play, replace the bearing, 17-80Remove the bearing using the special tool and press. Press Hus Dis/AsseMBLY BASE 07GAF—s040700 Install the new bearing using the press and speciat tool. Press Install with the Fd shielded side facing down, HUB DIS/ASSEMBLY BASE (07GAF—sD40700 NOTE: Hold the inner race with the tool securely. 17-81Steering Pump - Pump Assembly 1. Coat the lip of the new oil seal with steering grease (Honda P/N 08733—B070E). 2. Install the new oil seal in the pump housing by hand, then install the pump seal spacer. 3. Install the pump driver shaft assembly with the special tool. 4, Install the 38 mm circlip with its tapered side facing INNER HANDLE B (077460020100 cicuP DRIVE 5. Coat the side plate grooves with power steor ing fluid, then position the 16.8 x 1.9 mm and 84 x 1.9 mm O-rings on the side plate. SIDE PLATE 4, ROLLER 4.5 mm HOLE 10. " Install the preload spring in the pump housing Set the 4.6 x 49.8 mm roller in the 4.8 mm hole in the pump housing. ‘Set the side plate over the roller and install it on the pump housing, Set the 5 x 26.8 mm roller in the 5 mm hole in the side plate, 5 x.49.8 mm 5x26.8mm \ ROLLER 5 mm HOLE SIDE PLATE PRELOAD SPRING ‘Assemble pump rotor to the drive shaft with the ‘mark on the roter facing upward. Set the 10 vanes in the grooves in the rotor. NOTE: Be sure that the round end of the vanes is in contact with the sliding surface of the cam ring Round ond PUMP ROTOR 17-82@ 12. Set the pump cam ring over the two rollers with the 3" mark on the cam ring upward. PUMP CAM RING MARK 13. Install the 68.8 x 1.9 mm O-ring on the pump 14, Align the roller set holes in the pump cover with the rollers. 18. Align the projection on the pump housing and the projection on the pump cover and tighten the four bolts. 20.Nem (2.0 kom, 14 6-10 PUMP COVER 16, Set the 13 x 1.9 mm O-ring on the inlet joint. 117. Install the inlet joint on the pump housing, 11m INLET JOINT 18. Install the control valve (page 17-78). 19. Install the pulley (page 17-76) and check that the pump turns smoothly by turning the pulley. (cont'd) 17-83Steering Gearbox (LHD) Valve Body Unit Overhaul NOTE: If the Valve Body is damaged, it must be replaced as a set, with the Cut-off Valve end 4-Way Control Valve (shaded parts) cauTiON: © Roplace the O-rings and seals with new ones. ‘© Do not dip the O-rings and seals in solvent. © Apply grease in the seal grooves to keep the cap and port seals in place. © Apply grease to the 50 x 2.4 mm and 11 mm O-rings to keep them in place in the valve ports. © _-Samme; STEERING GREASE . Part Number 08733—BO70E (CUT-OFF VALVE VALVE QODY CAP ge ] ‘SPRING CAP SEAL a Ropes, PLUNGERS WG Wm ,t kom, 8 HD RETURN Sy Senives Ti mm O-RING fasloe 7 Rowers vave soov ovo IMON DUST wes (Samy NO 7 0 ea PORT SEAL Replace. 4 i x ones PORT ORIFICES Zo ORIFICE oe Dower pin eo 3.4mm O-RING a roplce rors uSusine en 9.841% mm 12mm omnes ening Rept, Repace 17-84@ 1. Remove the steering gearbox (17-89). 2. Remove the two 8 mm flange bolts and remove the control valve body unit from the gearbox. 3. Remove the O-rings and port orifices from the gearbox. CONTROL VALVE Bopy UNIT 4. Remove the two 6 mm flange bolts, then remove the cap from the valve body. 5. Remove the cap seal from the cap. vawve sooy VALVE BODY CAP cap Seat Replace. 6 mm FLANGE BOLT 6. 7 Remove the cut-off valve and spring from the valve body. CUT-OFF VALVE SS SPRING Check the cut-off valv © Inspect its surface for scoring or scratches. © Slip it back into the valve body, and make sure it slides smoothly without drag and without side play. (CUT-OFF VALVE Check for scoring or ‘scratches, and rough eperation. NOTE: If any part of the valve body is damaged, replace the valve body unit (valve body, 4-way control valve) as an assembly. (cont'd) 17-85Steering Gearbox (LHD) [- Valve Body Unit Overhaul (cont'd) 8. Separate the valve body and port housing. 9, Remove the seal and dowel pins from the port housing. 10, Remove the pinion dust seal and O-ring from the port housing, PINION DUST SEAL PORT HOUSING oplace. VALVE BODY 80x 24 mm ‘O-RING Replace. PORT SEAL Replace 11, Remove the rollers from the control valve by pushing the valve out one side of the valve body, and then the other. NOTE: When removing the rollers, hold the plungers with your fingers to keep them from pop ping out. 11 mm O-RING Replace. 4:WAY CONTROL VALVE ROLLER RETUAN SPRINGS ROLLER 12. Remove the plungers, return springs and 4-way control valve from the valve body. 13, Remove the 11 mm O-ring from the 4-way control valve. 14, Check the plungers. © Inspect their surface for scoring or scratches. © Slip each plunger into the valve body, and make sure it slides smoothly, without drag or side play, If any plunger is damaged, replace it. NOTE: If the valve body is damaged, replace all three parts (valve body, cut-off valve and 4-way control valve) as a set. PLUNGERS. ck for scoring oF snd rough VALVE BODY PLUNGERS Check for scoring or scratches, and rough sliding 15, Check the 4-way control valve. © Inspect its surface for scoring or scratches. © Slip it into the valve body, and make sure it slides smoothly, without drag or side play. NOTE: if any part of the valve body is damaged, replace the valve body unit (valve body, cut-off valve, 4way control valve) as an assembly. away CONTROL VALVE Check for scoring scratches, oF rough operation. 17-86@ 16. If necessary; replace the sensor orifice and O-ring using @ 1.5 mm (1/16"7 dail bit. 3.4 mm O-RING SENSOR ORIFICE Replace. Replace. Valve body side — Coat the new O-ring with the power steering fiuid-V and install the sensor orifice into the valve body by tapping lightly with @ rubber mallet. Assembly: NOTE: ‘© Thoroughly clean all the disassembled parts. © Coat the plungers, cut-off valve and 4-way con- tol valve surfaces with power steering flui 17. Coat the O-ring with grease, and install it on the A-way control valve 18. Install the 4-way control valve, plungers, return Springs and rollers into the valve body. away CONTROL VALVE 11 mm O-RING a Sy Cy | nerve H26000 Semmes rotten Jlage:2 puungens a ROLLER, 19. Install the new pinion dust seat in the control valve body unit by hand. 20. Coat the O-ring and port seal with grease, and in- stall them port housing. 21. Install the dowel pins and valve body on the port housing, PINION DUST SEAL PORT HOUSING 22. Install the cut-off valve spring and cut-off valve. x -OFF VALVE SPRING Dd CUT-OFF vi cur-oFF VaLvE (cont'd) 17-87Steering Gearbox (LHD) [ Valve Body Unit Overhaul (cont'd) 23. Cost the cap seal with grease and install the valve body cap, 24, Install and tighten the 6 mm flange bolts in the con- trol vaive body unit. VALVE BoDY VALVE BODY CAP cap seat =a 6 mm FLANGE BOLT 12N-m (1.2 kgm, 9-H 25. Make sure the control valve moves smoothly, and returns to neutral position, 26. Coat the 9.8 x 1.9 mm O-rings and pinion holder pin with grease, and install them together with the orifices. 27. Apply grease to the surface of the special tool and install it on the pinion shaft, 28. Install the valve body unit on the gear housing with the two 8 mm bolts. 11 Nem (1.4 kgm, 8 t-te CONTROL VALVE BODY UNIT PINION DUST SEAL GUIDE 07974—SA50600 PORT ORIFICES PINION HOLDER PIN =n 29. Remove the special tool. CAUTION: ‘© When installing, be careful not to hit the pinion holder pin © Make sure the O-rings are in place and not pinched. 17-88t- Gearbox Removal NOTE: © Bofore removing the steering gearbox, align the front wheels straight ahead. © Disconnect the battery negative terminal and then disconnect the positive terminal. 1. Drain the power steering fluid as described on page 17-43. 2. Remove the steering joint cover. ‘STEERING JOINT COVER 3. Remove the steering joint lower bolt, and move the joint toward the column, 4. Raise the front of car and support on safety stands In the proper locations. 5. Remove the front wheels. sTecnind JOINT 6. Using solvent and a brush, wash any oll and dirt off the control unit, its lines, and the end of the gear- box. Blow dry with compressed air. (Manual transmission model only) © Remove the shift extension from the transmis- SHIFT EXTENSION © Slide the boot back at the connecting position of the gear shift rod. © Drive out the spring pin with @ punch, then disconnect the shift rod, SHIFT ROD PIN RETAINER (cont'd) 17-89Steering Gearbox (LHD) -— Gearbox Removal (cont'd) (Automatic transmission only) ‘© Remove the shift cable holder SHIFY CABLE HOLDER © Disconnect the shift cable from the shift control shaft. Lock WASHER Replace. 7. Separate the catalytic converter by removing the self-locking nuts, SELF-LOCKING NUT Replace. CATALYTIC CONVERTER SELF-LOCKING NUT Foplace. 8. Remove the cotter pin from the tie-rod ball joint nut and remove the nut. 9. Install the 10 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 ball joint remover. NOTE: Remove the ball joint using the Ball Joint Remover, 28 mm (07MAC—SLO0200). Refer to page 18-12 for how to use the ball joint remover. 10. Separate the tie-rod ball joint and knuckle using the special tool CAUTION: Avoid damaging the ball joint boot. Dy E\Y 16 \ \ Qy BALL JOIN REMOVER, 28 mm ‘o7MAC—st00200 17-9011, Disconnect the three lines from the control unit CAUTION: After disconnecting the hoses and ipes, plug or seal the hoses and pipes with the piece of tape or equivalent to prevent foreign ‘materials from entering the control unit. To reservoir: 12. mm wrench To oil Cooler: 17 mm wrench From pump! 14 mm wrench 12. Remove the left tie-rod end, then slide the rack all the way to the right, NOTE: Remove the performance rod, if it is equipped. 13, Remove the steering gearbox assembly mounting bolts and pinion shaft gromet. ‘MOUNTING BOLTS 14. Pull the steering gearbox assembly all the way down to clear the pinion shaft from the blukhead: 15. Move the steering gearbox assembly to the right s0 the left rack end clears the rear beam. 16. Hold the steering gearbox assembly and slide the rack all the way to the left, place the left rack end below the rear beam. 17. Move the steering gearbox assembly to the left and tilt the left side down to remove it from the car. 17-91Steering Gearbox (LHD) Illustrated Index CAUTION: © Before disassembling the gearbox, wash it off with solvent and a brush. ‘© Thoroughly clean all disassembled parts. Always replace O-rings and seals. © Replace parts with damaged sliding surfaces. © Do not dip seals and O-rings in solvent; coat O-rings with g and use appropriate special tools to install them where necessary. © —SGimEN STEERING GREASE . CYLINDER Rousing 50x 2.4 mm O-RING Replace. BACK-UP RING CYLINDER END = Geremgy N bg d a = Part Number 08733—B070E Go 31.5 x 24 mm O-RING: Replace: STON SEAL Ree CYLINDER BARREL STEERING RACK Inspect surface for damage. Inspect inner wall for damage. cYLINDER : END SEAL gusHinG = i Repioce. _ BUSHIN Rp; 27.5 x2 mm 2B. BALL BEARING —"S3 RACK BUSHING B é RETAINING oe 3751.5 mm Seeee orrincs h Replace een — “oS, HousING a Locknut 43.5 x 2 mm Stine uIDE scREW Replace ohne SEH ressune PoPace RACK GUIDE SPRING GEAR HOUSING CAP. 6mm FLANGE BOLT TN Nery (1-7 kgm, 8 bt 17-92Overhaul Disassembly 1. Remove the control 17-84. e unit as described on page 2. Carefully clamp the gearbox in a vise with soft jaws. 3. Remove the tie-rod assembly. ‘THE-ROD LOCKNUT HEROD 4. Remove the boot bands and tube clamps. Pull the dust seals away from the ends of the gearbox. B00T BAND Replace. use CLAMP: 5. Hold the steering rack with a 19 mm wrench and unscrew the rack end with @ wrench. ‘TIE-ROD LOCK WASHER Replace. RACK END STEERING RACK 6. 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. 7. Loosen the rack screw locknut and remove the rack guide screw. 8. Remove the spring and rack guide from the gear housing. RACK GUIDE q< ‘screw Ce tockwur (conta) 17-93Steering Gearbox (LHD) [ Overhaul (cont'd) 9. Remove the steering pinion assembly by removing the circtip. cancur STEERING PINION ASSEMBLY — Check the pinion upper ball bearing for play; if it is good and the grease in it is clean, go on step 10, I the bearing is noisy or has excessive play, replace the bearing, ‘© Remove the 15 mm snap ring. PINION UPPER BALL BEARING 115 mm SNAP RING '® Remove the ball bearing using the special tool HUB DIS/ASSEMBLY BASE 07GAF—SD40700 © Using @ press, install the upper ball bearing on. the pinion. Press PINION UPPER ILL BEARING, pal " ATTACHMENT 42 « 47 mm 07746--0010300 Hue DIS/ASSEMBLY BASE (07GAF—SD40700 17-94@ 10, Remove the four bolts from the end of the cylinder housing, then slide the housing off the rack. 11. Remove the O-ring, back-up ring, steering rack bushing A and cylinder spring. RACK BUSHING A CYLINDER SPRING one Replace. CYLINDER HousiNG 12. Remove the cylinder end seal from the cylinder housing. NOTE: Use you fingers or a wooden stick to avoid ‘damaging the housing. CYLINDER HOUSING END SEAL 13. Remove the cylinder, cylinder seal retainer, cylinder cap and steering rack from the gear housing. cYUNDER CYLINDER SEAL RETAINER CYLINDER CAP GEAR HOUSING 14. Remove the retainer washer from the gear housing, RETAINER WASHER (cont'd) 17-95Steering Gearbox (LHD) f[- Overhaul (cont'd) — Check the pinion holder for free movernen cessive play and rough movement; if it is go on step 15. If itis damaged, or if dirt has gone past the seal into the grease, replace the bearing. © Remove the gear housing cap from the gear housing, GEAR HOUSING \ FR ‘-RING Replace. © Remove the circiip from the pinion holder. circu PINION HOLDER ‘© Remove the pinion holder from the gear housing. © Check the needle roller bearings in the pinion holder and gear housing for damage; if OK, pack the needle roller bearing with grease. If the bear- Ings are damaged, replace them as a set. PINION HOLDEFT NEEDLE ROLLER © Check the lower ball bearing for damage: I itis damage, replace the lower ball bearing. ‘© Remove the pinion lower ball bearing from the ‘gear housing. Lowen BALL BEARING = 17-96© Drive the new lower ball bearing into the gear housing using the special tools. Driver (07749-0010000 ATTACHMENT, 42x 47 mm (07746--0010300 © Install the pinion holder in the gear housing. ‘© Reinstall the circlip with its tapered side facing out. NOTE: Circlip ends must be aligned with the flat © Grease the new O-ring and install it in the groove in the gear housing cap. Install the gear housing cap and tighten the bolts securely. PINION HOLDER, Fiat area. GEAR HOUSING CAP =~) RYO 15, Remove the cylinder and seal retainer from the steering rack. CYLINDER f | ernst SEAL RETAINER (cont'd) 17-97Steering Gearbox (LHD) - Overhaul (cont'd) 16, Remove the O-ring and circlip from the seal re. tainer, then remove the cylinder cap from the seal 17. Remove the O-rings from the eylinder cap. o-nING Replace. grew Oo’, CYLINDER cap one Replace. ‘SEAL RETAINER 18. Remove the bushing stopper ring from the seal retainer. 19. Remove the cylinder end seal BUSHING STOPPER RING CYLINDER END SEAL SEAL RETAINER RACK BUSHING B 20. Carefully pry the piston seal ring and O-ring off the rack. 31.5 x 2/4 mm O-RING PISTON ‘SEAL RING Assembly NOTE: Before reassembling any parts inspect them as discribed on page 17-92 and make sure they are clean. Replace worn or damaged parts. 21. Install a new O-ring on the rack. 31.5 2.4 mm one 17-98@ 22. Coat the piston seal ring guide with power steering fluid, and slide it onto the rack, big end first. 23. Position the new piston seal ring on the special tool, slide it down to big end of the tool, and then pull it off into the piston groove on top of the O- fing PISTON SEAL RING Gute 07GA6—sp40100 ISTON SEAL RING a o.ninc: 31.5x2.4 mm 24, Coat the piston seal ring and inside of the special tool with power steering fluid Carefully slide the tool onto the rack and over the piston ring, then rotate the tool as you move it up ‘and down to seat the piston seal ring, RACK PISTON SEAL RING| | | Ho [piston seat rine (07GAG—8040200 | ‘SIZING TOOL 25. Coat new O-rings with grease and install them on the cylinder cap. San 371.5 mm O-RINGS. cvunbeR cap 26. Slide the cylinder cap onto the seal retainer. 27. Install the circlip and O-ring on the seal retainer. oo 27.5 x 2 mm O-nING | coeur 0 CYLINDER CaP SEAL RETAINER (cont'd) 17-99Steering Gearbox (LHD) [- Overhaul (cont'd) 28. Grease the sliding surface of the steering rack bushing B, and install the bushing on the steering rack with the groove of the bushing facing the steering rack piston. Sao RACK BUSHING 8 29. Grease the sliding surfaces of the new cylinder end seal and the special tool, then place the seal on the special tool with its grooved side facing opposite ‘the slider. BACK-UP RING CYLINDER END SEAL Install end seal with its grooved = a CYUNDER END ‘SEAL SLIDER (07GAG—SD40300 30. Grease the steering rack, and install the special tool, CAUTION: Make sure the rack teeth do not face the slot in the special tool. a ‘STEERING RACK 31. Separate the cylinder end seal from the special ‘tool, then remove the tool from the rack. CYLINDER END SEAL RACK BUSHING CYLINDER END ‘SEAL SLIDER ‘07GAG—SD40300 17-10082. Fit the seal retainer on the steering rack. CYLINDER END SEAL SEAL RETAINER RACK BUSHING 8 33. Push the rack bushing 8 toward the seal retainer by hand until the cylinder end seal is seated in the re: tainer, Fit the seal stopper ring in the groove of the seal retainer securely. Then grease the steering rack. BUSHING STOPPER RING BUSHING STOPPER RING CYLINDER END SEAL cS) 34. Install the retainer washer on the gear housing RETAINER WASHER GEAR HOUSING 35, Place the gear housing on the work bench and in- sert the seal retainer and steering rack into the gear housing. 36. Coat the inside surface of the cylinder with power steering fluid, slide it over the rack and into the gear housing: press it into the housing untill it seats. CYLINDER SEAL RETAINER STEERING RACK GEAR HOUSING (cont’a) 17-101Steering Gearbox (LHD) Overhaul (contd) 37. Install the cylinder spring over the rack, than coat the rack bushing A with power steering fluid and in- stall it on the spring 38, install the special tool, or apply vinyl tape onto the steering rack and coat the special tool or vinyl tape with grease. CYLINDER END SEAL GUIDE ‘07GAG—s040400 Vinyl tape Sasi =| RACK BUSHING A. CYLINDER SPRING. STEERING “— 39. Cost the inside surface of the cylinder with power steering fluid and install the cylinder end seal with its grooved side facing out. CYLUNDER HOUSING CYLINDER END SEAL CYLINDER END SEAL 40. Install the O-ring and back-up ring on the gear housing. 41, Carefully position the cylinder housing on the gear housing and loosely install with four bolts. CAUTION: Be careful not to damage the end seal in the cylinder housing. A Housine 1 evunoen Bours eee rina Qn Sm RING. 42, Remove the vinyl tape or special tool from the steering rack. 43, Tighten the cylinder housing to the gear housing. NOTE: Before tightening the bolts, make sure the mating surfaces of the cylinder and gear housing fit properly by pushing them together; hold them while tightening the bolts. Make sure the O-ring {i in place and not pinches 17-102@ 44. Install the steering pinion in the pinion holder. 45, Install the circlip securely in the pinion holder groove. NOTE: Install the circlip with its tapered side fac- ing out. circu [STEERING PINION PINION HOLDER 46. Install the O-ring on the rack guide screw. 47. Coat the rack guide with grease. 48, install the rack guide, spring and rack guide screw fon the gear housing. Pe LocknuT RACK GUIDE SCREW 49. Tighten the rack guide screw until it compresses the spring and seats against the rack guide, then loosen it. 50. Retighton it to 4 Nem (0.4 kg-m, 2.9 lb-ft, back it off about 20° *§° then install the locknut on the rack guide screw. 51. Tighten the locknut while holding the rack guide screw with the special tool LOCKNUT WRENCH, 40 mm (07916-50001, 25 Nem (2.8 kg-m, 18 bt 52, Install the valve body unit (page 17-88), 53. Install the new lock washer in the groove in the steering rack. 54, Hold the steering rack with @ wrench and tighten the rack end to 55 Nem (5.5 kg-m, 40 Ib-ft). RACK END Lock WasHER RACK END (cont'd) 17-103Steering Gearbox (LHD) [Overhaul (cont'd) 55. After tightening the rack end stake the four section of lockwasher with the special tool and hydraulic press. NOTE: Set the V-block on the press table. Set the lockwasher section of the rack end on the V-block securely ~ Be sure that the pressing direction, special tool, and each lockwasher stake position are in line. ~ Stake the lockwasher in the center of the flat section of the joint housing. (The bottom end of ‘the stake must be in that position} See below. STAKE POINT "¥" LocKwasHER JOINT HOUSING LockwasHER PILOT CLINCH (O7NAZ—SR30100 v-BLock STEERING RACK ASSEMBLY, LockwasHeR 56. Apply steering grease to the circumference of the rack end housing. NOTE: Coat the rack end groove and inside of the boot with silicone grease, =) ‘STEERING GREASE (Honda P/N 08733—B070E) SILICONE GREASE Coat tha slising ‘surface of the rack fond 57. Install the boots on the rack end with the tube clamps, uae CLAMP 17-104iS NOTE: Install the boot band with the rack in the straight ahead position (i.e. right and left tle-rods are equal in length). ‘58. Install the boot band so that the locking tabs of the band (stake points) are in the range shown below. (Tabs should face up and slightly forward.) 59. Install new boot bands on the boot and bend both sete of locking tabs. 60. Lightly tap on the doubled-over portions to reduce their height. CAUTION: Stake the band locking tabs firmly. AIR HOSE CLIP (Viewed from the right side) clamp < Y Front ain HOSE cur 61 62. 63. Install the band cushion and air hose band; position the band as shown and tighten it. Then install the air hose, After assembling, slide the rack right and left to be certain that the boots are not deformed or twisted. Install the right and left tie-rods on the right and left rack ends, BOOT BAND © and wind LOCKING TABS direction a The lorking tabs (stake range: 79° + 10° FF Front. tf c Jor orrser sharr CENTER NE Left Dust Seal Band OFFSET SHAFT CENTER LINE. (0:24 im) ‘Air Hose Band (viewed from the ight side) Band winding age 210° ~ Section 90° = 10° Tue ~ JOINT + Front + Front. ‘clump ‘Lockine Tass The locking tabs (stake points) should bein this Right Dust Seal Band range. (viewed trom the Fight side) OFFSET SHAFT CENTER LINE. 17-105Steering Gearbox (LHD) r- Installation 1. Slide the rack all the way to the right. 2. Pass the tight side of the steering gearbox assembly above and through the right side of the rear beam, 3. Hold the steering gearbox assembly and slide the rack all the way to the right. 4. Raise the left side of the steering gearbox assembly ‘above and through the left side of the rear beam, 5. Install the pinion shaft grommet and insert the pin: jon shaft up through the bulkhead. NOTE: Install the performance rod, if it is equipped, 6. Install and tighten the gearbox mounting bolts, 59 Nem (6.9 kg-m, 43 bt) 39 Nem (3.9 kg-m, 28 Ib) 7 Connect the fluid lines to the control unit. To raservor: 12 mm wrench 48 Nem (1.3 kg-m, 9 1b-f) To ail cooler: 17 mm wrench 29 Nem (2.9 kg-m, 21 ft) rom pump: 14 mm wrench ‘38 Nem (3.8 kg-m, 28 t-te) Reconnect the tie-rods to the steering knuckles, tighten the ball joint nut to the specified torque, and install new cotter pins. CAUTION: Torque the castle nut to the lower tor- que specification, then tighten it only far enough to ‘align the slot with the pin hole, Do not align the nut by loosening. FRONT TIE-ROD ‘50~60 Nem (5.0-6.0 kg-m, 36-43 b-ft) COTTER PIN. Foplace On reassembly, bend the cotter pin as shown, 17-106