1997 HONDA CIVIC For

)
41.Coat the inside surface of the new cylinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston'
Push in the cylinder end seal with your finger'
CAUTION: When installing the cylinder end sesl'
be carelul not damage the sealing face ot the seal
with the threads and burrs at the staked position oI
the cylinder housing.
trCYLINDES END SEAL
Replace.Make sure the sPring
is in the cylincler end seal
CYLINDER END
SEAL
Remove the vinyl tape from the steering rack'
NOTE: Remove any residue oftape adhesive
Hold the steering gearbox using a C-clamp as shown'
GEARBOX
C-CLAMP:
l-,
46.
47.
Coat the inside surface of the cylinder end with
power steering fluid, then installthe cylinder end by
screwing it into the cylinder housang.
Remove the C-clamp from the steering gearbox'
After tightening the cylinder end' stake the point of
the cylinder housing shown below For'98 -'00
models go to step 51.
NOTE: Stake the cylinder in the position opposite
from where the stake was removed during disas-
semoly.
Be careful not to damage
the bushing when inserting
the cylinder end.
49. Select the 32 mm shim(s) ('96 -'97 model only)'
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shatt, valve housing, and gear
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
lows.
Shim selection:
a. Set the four 32 mm shims on the bearing surface of
the gearbox housing. Total thickness of the four
shims should equal no more than 0 70 mm'
Shim set: four 32 mm shims (Thickness: 010 mm'
0.15 mm, 0.20 mm, 0.25 mm respectivelyl
CAUTION: Th€ four 32 mm shims do not have
thickness identification marks Measure the thick-
ness of each shim using a micrometsr, and mark
the shim lor identification.
(cont'd)
17-61
Stake point. Depth: 1 0 mm (0.04 in)

)
55. Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder lines A and B
thoroughly. The joints must be free of foreign
materlal.
. Install the cylinder lines A and B by tighting the
flare nuts by hand first, then tighten the flare
nuts to the specified torque.
56.
57.
Grease the sliding surface of the rack guide, and
install it onto the gear housing
36 - '97 models:
Apply a thin coat of grease to the new O-ring, and
install it on the rack guide screw.
38 - '00 models:
Remove the old sealant off of the threaded section,
then apply new sealant all around the threads
Install the spring, rack guide screw and locknut on
the gear housing.
Adjust the rack guide screw (see page 17-33)'
NOTE: After adjusting, check that the rack moves
smoothly by sliding the rack right and left'
'1 l:.r1
58.
-GlO.BINGReplace.
17 N.m {1.7 kgt'm, 12 lbl.ft)
28 N.m (2.7 kgf m,20 lbf ftl
CYLINDER LINE 8 CYLINDER LINE A
l/LOCKNUTS
60, lnstall the new lockwasher in the groove in the
steering rack.
61. Screw each rack ends into the rack'
62. Hold the steering rack with a wrench ('98 -'00 mod-
els: left end onlY), and tighten the rack ends'
CAUTION: Bo cateful nol to damage ihe rack sur-
face with the wranch.
NOTE: '96 -'97 model is shown.
STEERING RACK END
54 N'm t5 5 kgt m' 40 lbl'ft)
STEERING RACK
After tightening the rack ends, stake the four sec-
tions of lock washer with a drift and a mallet.
Place the wood block on the press table. then set
the lock washer section of the rack end on the
wood block securelY.
Be sure the tool is aligned with the flst sections
of the steering rack end belore pressing.
Stake the lock washer in the center ot the flat
section of the steering rack end.
LOCK WASHER
NOTE: This drift has a flat,
to prevent puncturing
WOODEN BLOCK
{cont'd}
17-63

Steering Gearbox
Reassembly (cont'dl
64. Apply grease to the circumference of the rack endhousing.
RACK END GROOVE
=^.#-q!:s!!H
SILICONE GREASE
Apply a light coat of silicone grease to the bootgrooves on the rack ends.
lnstall the boots in the rack end with the tie-rodclips.
NOTE: Install the boots with the rack in the straightahead position (right and left tie-rods are equal inlength).
66.
RACK END
NOTE: Wipe the grease offthe thread section.
17-64
TIE.ROD CLIP
67. Adjust the air hose fitting position of the boots bvturning it as shown below.
LEFT BOOT(Viewed from theleft side)
RIGHT BOOT{Viewed from theright side)
AIR HOSE FITTING
Install new boot bands on the boot, and bend bothsets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
Lightly tap on the doubled-over portions to reducetheir height.
Slide the rack right and left to be certain that theboots are not deformed or twisted.

71.Connect the air tube between the right and left
boot.
lnstall the clips on the cylinder lines' then clamp the
air tube with the cliPs.
l./
CYLINDER LINE A
CLIP
l-,
lnstallation
CAUTION: Be carelul not to bend or damage the feed
line and cylinder lines when installing the gearbox'
1, Before installing the gearbox, slide the rack all the
way to right.
2. Install the mounting cushion on the steering gear-
DOX.
Install the pinion shaft grommet, then insert the pin-
ion shaft up through the bulkhead.
NOTE: Align the notch in the pinion shaft grommet
with the tab on the valve housing.
Install the mounting bracket over the mounttng
cushion, then installtwo gearbox mounting bolts'
MOUNTING BRACKET
cusHroN
39 N.m(4.0 kgj m, 29 lbtftlNOTE: Install the bracket
with the arrow Pornllngtoward the front.(cont'd)
17-65

)
1?
12, Install the steering joint cover with the clamps and a
clrp.
Reconnect the tie-rod ends to the steering knuckles,
tighten the castle nut ('96 -'97 models) or nut ('98 -
'OO models) to the specified torque, and install new
cotter plns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint tapered
section and threads.
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening {,96 -'97 models only).
COTTER PINSReplace.On reassembly, bend
the cotter Pin 6s shown.'96 -'97 models:'98 -'00 mod€ls:
tr
CASTLE NUT40 - a8 N'm(4.0 - 4.8 kgf'm,29 - 35 lbf.ftl
NUT&l N.m{a.5 kgf'm, 33 lbl'ftl
NE-ROD END
(l-,
17-67
14.
15.
16.
17.
18.
Install the exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
lnstall the front wheels
Fill the system with power steering fluid, and bleed
air from the system (see page 17-331
After installation, perform the following checks
. Start the engine, allow it to idle, and turn the
steering wheel from lock-tolock several times to
warm up the fluid. Check the gearbox for leaks
(see page 17-39).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the right and left tie-rods equallv

Ball joint Boot Replacement
'96 - '97 models:
1. Remove the boot set ring and the boot.
CAUTION: Do not contaminate the boot installa.tion section with grsase.
2. Pack the interior of the boot and lip with grease.
3. Wipe the grease off the sliding surface of the ballpin, then pack the lower area with fresh grease.
CAUTION:
. Keep grease off the boot installation seciion andthe tapered s€ction ot the ball pin.
. Do not allow dust, dirt, or oth6r foreign materi-
als to 6nt8r the boot.
LIPEALL PIN TAPEREDSECTIONWipe off the grease.
INSTALLATION
SECTIONWipe off the grease.
Install the boot in the groove of the boot installation
section securely, then bleed the air from the boot.
-6lrBOOTSECTIONWipe off the grease
4.
ADJUSTING BOLTAdjust the depthby turning the bolt.
SET RING
Adjust the special tool with the adjusting bolt untilthe end of the tool aligns with the groove on theboot. Slide the set ring over the tool and into posi-
UOn.
CAUTION: After installing the boot, qhsck the ballpin tapered section for grease contamination andwipe it it necGsary.
17-68
'98 - '00 models:
CAUTION: Do not contaminato the boot installation sec-tion with grease.
1. Remove the boot from the tie-rod end, and wiDe theold grease off the ball pin.
2. Pack the lower area ofthe ball pin with fresh grease.
3. Pack the interior of the new boot and liD with freshgrease.
CAUTION:
. Keop groasc ott tho boot installalion sestion andth. iapored s.ction if th€ ball pin.
. Do not allow dust. dirt, or other foreign materials
to entor tho boot.
BOOT INSTALLASECTIONWipe off the gr€ase,
Install the new boot using the special tool as shownbelow.
NOTE: The boot must not be a gap atthe boot installation sections.
LtP .6r
J_/
ru
CAUTION: Aftor installing the boot, chock the batlpin tapgred section tor grgase cortamination. andwipe it it n€ces3ary.
FRONT HUBDIS/ASSEMBLY TOOL07965 - SA5o500

Wheel Alignment
,f,
Caster
NOTE: For proper inspection/adjustment of the wheel
alignment check and adjust the following before check-
ing the alignment.
. Check that the suspension is not modified.
. Check the tire size and tire pressure.
. Check the runout of the wheels and tires.
. Check the suspension ball ioints. {Hold a wheel with
your hands and move it up and down and right and
left to check for wobbling.)
Inspection
NOTE: Use commercia lly-available computerized four
wheel alignment equipment to measure wheel align-
ment {caster. camber, toe, and turning angle). Follow
the equiDment manufacturer's instructions.
Check the caster angle.
Caster angle: 1',10' I 1'
lf out of specification, check for bent or damaged
suspensron components.
2.
1.
18-4
Camber
lnspection
NOTE: Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Check the camber angle.
Camber angle:
Front: 0'00' j 1"
Rear:-1"11"
2. lf out ol specification, check for bent or damaged
suspensron components.

?
Front Toe Inspection/Adiustment
NOTE: Use commercially-available computerized four
wheel alignment equipment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Check the tire pressure.
Center steering wheel spokes.
Check the toe with the wheels pointed straight
a head.
Front toe: lN 1 1 2 mm llN l/16 r 1/16 inl
- lf adjustment is required, go on to step 4.
- lf no adjustment is required, remove alignment
equrpmenr.
Loosen the tie-rod locknuts, and turn both tie-rods
in the same direction until the front wheels are in
straight ahead position.
TIE.ROD LOCKNUT'14 x 1.5 mm
4.
tJ
6.
Turn both tie-rods equally until the toe readang on
the turning radius gauge is correct.
After adjusting, tighten the tie-rod locknuts.
NOTE: Reposition the tie-rod boot if it is twisted or
displaced.
4,1 N.m {4.5 kgf.m, 33 lb{.ft)
2.
Rear Toe Inspection/Adiustment
NOTE: Use commercially-available computerjzed Iour
wheel alignment equjpment to measure wheel align-
ment (caster, camber, toe, and turning angle). Follow
the equipment manufacturer's instructions.
1. Release parking brake.
NOTE:
a Measure difference in toe measurements wlth
the wheels pointed straight ahead.
. if the parking brake is engaged, you may get an
incorrect readang,
Rear toe-in: 2 11 mm ttltollllS int
- lf adjustment is required, go to step 2.
- lf no adjustment is required, remove alignment
equipment.
Before adjustment, note the locations of adiusting
bolts on the right and left compensator arms
Loosen the adjusting bolts, and slide the compen
sator arm in or out. as shown, to adjust the toe
ADJUSTING BOLT10 x 1.25 mm
In CoMPENSAToR ARM
4. Tighten the adiusting bolts
. Example:
After the rear toe inspection, the wheel is 2 mm
(0.08 in) out of the specification.- Move the arm so the adjusfing bolt moves 2 mm
(0.08 in) inward trom the position recorded before the
adjustment.- The distance the adjusting bolt is moved should be
equal to the amount out-of-specification.
64 N.m 16.5 ksf m, 47 lbtft)
18-5