1996 HONDA CIVIC Air

Steering Gearbox
Reassembly (cont'dl
LApply a thin coat of grease to the inside surface of
the rack end bushing.
Grease quantity: 1 - 3 S 10.04-0.1 ozl
CAUTION: Do not till the slots with greas€; th€y
must remain open to serve as air passages,
Install the rack end bushing by aligning the round
projection on the bushing with the hole in the cylin-
der housing
4.
Grease the steering rack teeth.
Install the steering rack into the cylinder housing
carefully to avoid damaging the rack end bushing.
CYLINDER HOUSING
17-10
11. Adjust the rack guide screw (see page 17-5).
Drive in the steering pinion in the gear housing with
the soecial tools.
ORIVER.22 mm l.D.o7716-qr20100SNAP RING, 35 mm
PINION DUSTSEALReplace.
Vinyltape
STEERINGPINION
7.
Install the 35 mm snap ring securely in the gear
housing groove.
Apply vinyl tape to the pinion shaft, then coat the
vinyltape with grease.
Install the pinion dust seal on the gear housing until
it seats properly, then remove the tape.
Grease the sliding surface of the rack guide, and
install it on to the gear housing.
Install the spring, disc washer and rack guide screw
on the gear housing.
NOTE: Install the disc washer with its convex side
facing in.
LOCKNUT
SPRING RACK GUTDE
RACK GUIOE SCREW
10.
Dtsc w,
a(-\
l1 *l
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Component Locations
I
lndex
Power Steering:
NOTE:
. li an intact airbag assembly has been removed trom a scrapped vehicle or has been found defective or damaged dur-
ing transit. storage or service, it should be deployed (see section 24).
. Before removing the gearbox, remove the driver's airbag assembly and steering wheel.
. After installing the gearbox, checkthewheel alignmentand adjust if necessary.
SRS components are located in this area. Review the SRS component locations. precautions, and procedures in the SRS
section {24} before performing repairs or service.
STEERING WHEELRemoval/lnstallation, page 17-35
Disassembly/Feassembly, page 17-36
DRIVER'S AIRBAG ASSEMBLYRemoval/lnstallation, see section 24
STEERING GEAREOXRack Guide Adiustment, page 17'33
/
Removal, page 17 47Disassembly, page 17-49Reassembly, page 17-55Installation, page 17-65VALVE EODY UNITOverhaul, page 17 52
COLUMNFemoval/lnstallation, page 17-37Inspection, page 17-38CASLE REELRemoval/lnstallation, see section 24
IGNITION SWITCHSee section 23
POWEF STEERING PUMPPump Belt Inspection, page 11-32Pump Belt Adiustmenl, page 11'32Pump Pressure Check, page 17 34Removal/lnstallation, page 17'40Disassembly/Reassembly, page 17-41
TIE.ROD END BALL JOINTBallJoint Boot Replacement, page 17-68
1,,
17-15

Pressure Control
Low assist at higher speeds:
WhensteeringresistanceIsIow,suchaswhendrivingathighspeeds,orwhendrivingstraightahead,theinputshaftis
near or in the neutral position, so there is little or no fiow ro any of the power cylinder orifices. Most oI the feed pressure
fromthepumpisbypassedtothereservoir.Becauseofthis,thepressurestaysthesameinbothsidesofthepowercy||n-
der, resulting in low or no asslst
VALVE From PUMP
SECTION A-A
RETURN PASSAGElTo RESERVOIRI
POWER CYLINDER
STEERING GEARBOX
High assist at lower speeds:
When steering resistance is high. such as when driving at low speeds' or when turning the wheel wirh the vehicle
stopped,thedifference|nang|ecreatedbetweentheinputshaftandtheVa|veopensthef|uidpassageononeside,and
c|osesthefluidpassageontheotherside,ateachpairoforifices'Thef|uidpressureincreasesinthesideo|thepower
cy|inder|edbythe|argerf|uidpassage'Thisincreasedpressurepushesontherackpiston,a|lowingthesteeringwhee|to
be turned with light effort. on the other side of the power cylinder, the return passage opens allowing the steering tluid to
returnthroUghtheinputshafttothereservoir'Thef|uidpassagestothepowercy|inderautomatica||ychangeins|ze,
increasing as the steering resrstance increases. In other words, the passages become larger and power assist increases
when the steering effort would normally be high, (for example' when parking or making low speed turns)' and the pas-
sagesbecomesma||erandpowerassistdecreaseswhenthesteeringeffortwou|dnorma||ybe|ow,(forexamp|e,when
driving at high speeds or straight ahead).
FLUIO PASSAGE TO
POWER CYLINDER
/t=\\a!-4,))
=YjJ
RESERVOIR
SECTION A-A
l'
{High fluid Pressure}

Troubleshooting
General Troubleshooting
Check the following before you begin:. Has the suspension been modified in a way that would affect steering?. Are tire sizes, tire variety and air pressure correct?. lsthe steering wheel original equipment or equivalent?. lsthe powersteering pump belt properlyadiusted?
. ls steeringfluid reservoirfilledto proper level?. ls the engine idle speed correct and steady?
Hard Steering (Check the powor assist. se€ page 17-3o. lfthe torce is over 29 N (3.0 kgf, 6.6lbo, Procede with this troubleshootinq.)
Abnormallluid pressure
{fluid pressureis too high)
Faulty valve body unit
Relief pres-sure too low
Abnormal
Faulty llow control valve(Replace the pump es anassembly)
Ch€ck the feed snd return circuit lin€s ano nosebetw6€n the gearbox and pump for clogging andd€lormation.
Normal line and hose
Check the pump fluid pressure(soe page 17-34).l/easure steady-state tluid pres-s!re while idling with the bothvalves tully open.It should be 1.500 kPa (15 kgf/cmr,213 psi) or below.
Normal
Check th€ flow control vslve (see page 17-42).. Chock the valvo lor smooth movement in the hous-ing.. Check the reliefvalve for leaks.
Check the pump fluid pressure
{see page 17-34).Measure pump relief pressurewhile idling with the pressure con-trol valve Iully closed.It should be 6,400 - 7,400 kPa (65 -
75 kgflcm,,920 - 1,070 psi)
Normal relisf pressure
17-22
Go to page 17-23Faulty pump assembly

I
AbnormalDeformed
Faulty cylinder lines
Adiustment OK
Faulty valve body unit
Normal
IICompair the steering to another alike
vehicle.
/
Check the force required to turn
the wheel (see Page 17 30i
Start the engine and measure the
force required to turn the wheel
to the right and left. Difference of
the lorce required to turn the
wheel to the right and to the Ieft
should be 2.9 N 10 3 kgf, 0.7 lbf)
or below.
Check for bent rack shaft
Check rack guide adiustment (see
page 17-33).
(cont'd)
17 -23
1,,

/
Uneven or rough steering
Steering wheel kicks back
during wide t!rns.
ll,
)
Adjust the rac* guide (see page 17-3).
lf the problem is not corrected bY
adjusting the rack guide, replace
the gearbox.
Adiust the belt tension. Feplace the
belt, il necessary (see Page 17 32).
lfthe engine stalls when the wheel
is turned while car is stopped or
moving at low speed, adjust the
idle spe€d (see section 11)
ldle speed low or erratic.
Check power sleering fluid level lf
the level is excessively low, check
lor leaks in the system. Add lluid
to the specified level.
Air in reservoir, or check Powersteering Iluid level.
lf ltuid level is OK, check O-rings
and seals on both ends of thepump inlet hose, and the P/Spump housing mating surfaces
and the pumP shaft oil seal for
suction leaks. RePlace Parts as
nocessary.
Adjust the belt tension (see Page17 32)or replace belt.Pump belt sliPPing on PLrlleY(pump stops momentarilY)
Check if pump press{rre is normal
and the gauge needle travel is 500
kPa (5 kgl/cm?, 7l Psi) or less.
Chock the flow control valve if the
needle travel exceeds 500 kPa (5
kgflcm', 71 Psi). l{ the flow control
valve is normal, replace the PumPas an assemoly.
Install the power steering pressure
gauge, Close the Pressure contrcl
valve fully and m6ssure the PumPpressure {s€e page 17-34}.
17 -25,

)
Pump noaseGrating noisefrom pump
Pump gear nois€
Check the tluid level.
lf low, fill the reservoir to the
proper level, and check lor leaks.
Tighten or replace as nocessary.
Cavitation caused bY air bubbles
in the fluid.
Check lor a crushed suction hose
or a loose hose clamp allowing
air into the suction side of the
sy$em.Tighton or roplace as necossary.
NOTE: Pump noise uP to 2 - 3
minutes alter starting in cold
weather is normalCompare pumP noise at operating
temperature to simular vehicle.
lf pump nois€ is abnormallY loud,
remove and inspect the PUmP for
w6ar and damage (see Page 17-
41).
lz/
Rattle or chattgring
17-27
Tighten or replace the Pulley.lf shatt is loose, rePlace thepump.
tr

Pump outlet line(high pressure,
/
Pump inlet Iine(low-pressure)
Replace the housing O-rings
lf the housing still leaks, rePlace
the pumP.
Reservoir is overfilledPull off the hose and drain the
reservoit to the Proper level.
Air leak in suction side ofthe sys'
tem (reservoir, inlet hose, tront
pump seal).
Tighten the fifting. lI it's still leak-
ing, replace the O-ring or feed line.Leaking at the threaded fitting
Leaking at the swagged joint.
Leaking because ol damage, dete_
rioration, or imProPer assemblY.Reolace or rePair as necessarY.
tJ
17-29