1997 HONDA CIVIC Shaft

lntermediate Shaft
Reassembly (cont'd)
1. Press the intermediate shaft bearing into the bear-ing support using the special tools and a press asshown.
Prass
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DRIVER ATTACHMENT,52x55mm07746 - 001 0(X)
Seat the internal circlip in the groove of the bearingsuppon.
Press the intermediate shaft into the shaft bearingusing the special tools and a press.
Praa.r
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INTERMEDIATE SHAFT
DRIVER ATTACHMENT,35 mm LD.
16-22
Seat the external circlip in the groove of the inter-mediate shaft.
Install the outer seal into the bearing support usingthe special tools as shown.
NOTE: Install the seal ftush with the bearing sup-port.
Pre$
t HANDr.r DRTVER- 0011r(x)0
Pack the Interiorof the ouler seal.2.0- 3.5 g {0.07 -0.12 ozl
OUTEN SEAL
Install the new set ringgroove.
ORIVER ATTACHMENT,52x55mm077i16 - 0010/O0
in the intermediate shaft

lnstallation
1. lnsert the intermediate shaft assembly into the dif-
ferential.
CAUTION: Hold the intermodiate shaft horizontal
to prevent damag€ to the difterential oil seal'
NOTE: Clean the areas where the intermediate shaft
contacts the transmission (differential) thoroughly
with solvent or carburetor cleaner, and dry with com-
Dressed air,
2. Install the three dowel bolts, then tighten them'
DOWEL BOLTS10 x 1.25 mm39 N.m {i1.0 kgf'm, 29 lbf'ftl
lz
16-23

Inspection and Adjustment
Steering Operation
Steering Wheel Rotational Play
Place the front wheels in a straight ahead position andmeasure the distance the steering wheel can be turnedwithout moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm (0 - 0.4 in)
lf the play exceeds the service limit, perform rack guide
adjustment (see page lT-5).
lf the play is still excessive after rack guide adjustment,inspect the steering linkage and gearbox as descrjbed
Detow.
Steering Linkage and Gearbox
TIE.ROO LOCKNUTCheck for loose locknut.
BOOTInspect for damage and deterioration.
STEERING JOINTSCheck for loose joint
END BALL JOINTInspect for faulty movementano oamage.
GEABBOX MOUNTINGInspect f or deterioration.GEABBOX ASSEMBLY
Ste€ring Effort Check
Raise the front wheels off the ground.
Turn the steering wheel with a spring scale and check itsreaorng,
Standard: 15 N (1.5 kgf, 3.3 lbll maximum
lf it reads more. perform rack guide adjustment (see
page 17-5).
COLUMNInspect for loose columnmounting bolts and nuts.
PINION SHAFT GROMMETfor damage and deterioration.
BALL JOINT BOOTInspect for damage and deterioration.See pago 17-68 tor replacement.
ao-\---------U
17-4
Inspect for loose mounting bolts.

Steering Gearbox
Removal(cont'd)
Remove the cotter pin from the castle nut ('96 - '97
models) or nut ('98 - '00 models) and remove the nut.
Installthe 10 mm hex nut on the ball joint.
Be sure that the 10 mm hex nut is flush with the balljoint pin end, or the threaded section of the ball joint
pin might be damaged by the balljoint remover.
NOTE: Remove the ball joint using the special tool,
Refer to section 18 for how to use tho ball joint
remover.
Separate the tie-rod ball joint and knuckle using the
specialtool.
CAUTION: Avoid damaging the ball ioint boot.
Remove the left tie-rod end, then slide the rack all
the way to the right.
Separate the exhaust pipe A or TWC (see section g).
Disconnect the shift linkage (see section 13 or sec-
tion 14).
Remove the stiffener plate.
7.
'10.
11.
12.
Replace.
17-6
13. Remove the mounting bracket,
Pull the steering gearbox all the way down to clear
th€ pinion shaft from the bulkhead, then remove thepinion shaft grommet,
Move the steering gearbox to right so the left rack
end clears the rear beam, then tilt the left side down
to remove it from the car.
t5.
STEENING GEARBOX
PINION SHAFT GROMMET

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,
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lnstallation
Slide the rack all the way to the righl
Install the pinion shaft grommet, and insert the pin
ion shaft up through the bulkhead.
NOTE| Align the notch in the pinion shaft grommet
with the tab on the gear housing.
1.
2.
J3. Install the mounting brackets with the two gearbox
mounting bolts on the cushion.
NOTE: The arrow on the bracketpoint toward the front.
STEEBING GEARBOX
{4.0 kgt.m,29 lbf.ftl
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4. Install the stiffener plate with the two gearbox
mounting bolts and stiffener plate attaching bolts.
NOTEr Install the bolts loosely first. then tighten
them securely.
GEARBOX MOUNTING EOLTS43 N.m {4.4 kgf.m, 32 lbf'ftl
5. Center the steering rack within its stroke
6. Slip the lower end ot the steering joint onto the pin
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
steering wheel and steering rack centered
Be sure that the lower steering joint bolt is
securely in the groove in the steering gearbox
pin ion.
lf the steering wheel and rack are not centered,
reposition the serrations at lower end of the
steering ioint.
STEERING JOINT
STEERING JOINTLOWER BOLT22 N.m{2.2 kgf.m, 16lbf'ft}(cont'd)
I t- t5
STIFFENER PLATE
ATTACHING BOLTS38 N.m (3.9 kgf.m.28lbf.ftl

)
Steering Pump
Construction
The pump is a vane-type incorporating a flow control valve (with an integrated relief valve) and is driven by a POLY-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.
/
ROTORVANE CAM RING
Operation
The belt-driven pulley rotates the rotor through the drive shaft. As the rotor rotates, the hydraulic pressure is applied to
the vane chamber of rhe 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 vanes
move downward in the axial direction as the rotor 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:
The vanes are pushed ontothe inner circumference ol the
cam ring,
lhe volume ofthe vane cham- The sucked-in fluid moves
ber increases so that fluid is toward the discharge port.
sucked in.
As the vanes return to the
their original Position on theinner side, the volume of the
vane chamber decreases so
the fluid is discharged from
the discharge port.
(cont'd)
a-t 4-I I- | t
FLOW CONTROL VALVE
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System Description
Steering Gearbox
The rack-and-pinion type steering gearbox has a valve body unit incorporated with the pinion to control the steering fluidpressure. Steering fluid from the pump is regulated by a rotary valve in the valve body unit and is sent through the cylin,der line to the power cylinder, where hydraulic pressure is applied. The steering fluid in the other side of the power cylin,der returns through the cylinder line and valve body unit to the reservoii.
VALVE EODY UNIT
CYLINDER LINE
To RESERVOm +-From PUMP -;
POWER CYLINDER
Valve Body Unit
Inside the valve body unit is the valve, which is coaxial with the pinion shaft, and controls the steering fluid pressure. Thevalve housing is connected with the fluid line from the pump, the return line to the reservoir, and the two cylinder linesfrom the respective power cylinder. The pinion shaft is double - structured with the input shaft connected to the piniongear, both of which 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 thevalve. Because of this construction, the difference in angle in the circumferential direction between the input shaft and thevalve becomes larger according to the torsional strength of the pinion or steering resistance. However, maximum torsionbetween the shafts is regulated by the engaged splines of the shafts at the pin engagement section to hold the torsion barwithin the set value,
This allows the steering system to function as an ordinary rack-and-pinion type steering if the steering fluid is not pressur-
ized because of a faulty pump,
VALVE
Difforence in angle botwoon theinput shaft and pinion shsft
PINION SHAFT
lo
INPUT SHAFT
-l
a
17-20
INPUT SHAFT