1999 HONDA CIVIC ect

Steering Gearbox
Disassembly (cont'dl
10. Slide the steering rack out of the cylinder housing.
CAUTION: Be carelul not to damage the bushing in
the cylinder housing.
11. Remove the rack end bushing.
GEARBOX MOUNTING CUSHION
Inspect inner wall tor wear or damage.
17-8
12. Replace the gearbox mounting 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 outside of the cylinder
housing. Remove the old cushion.. Apply weatherstrip adhesive to the inside of the
new cushion. Install the cushion onto the cylinder
housing and position it 20 - 22 mm (0.79 - 0.87 in)
from the end of the cylinder housing as shown.
NOTE: After installing the cushion, wipe off any
excess adhesive that may have dripped into the
inside of the cylinder housing.
20 - 22 mm 10.79 - 0.87 in)

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
\, ,/
\

It
12.
13.
lnstall the new lock washer in the groove in the
steering rack.
Installthe steering rack end into the rack
LOCK WASHER RACK END 54 N m ts.s kgf'm, 40 lbtft)
Replace.
TAB
(l*v
14.
15.
RACK END
Hold the steering rack with a wrench and tighten
the rack end with another.
CAUTION: Be careful not to damage the tack sur-
fac€ with the wrench.
After tightening the rack ends, stake the four sec-
tions of the lock washer with a roll pin 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 flat sections
of the steering rack end before pressing
. Stake the lock washer in the center of the flat
section of the steering rack end.
ROLL PIN DnlFTl(Commorci.lly .Yril.blolSnap-On No. PPRS or oquival.nt
NOTE: This drift has a flat
tip, to prevent puncturing
of metal washer.
srEEatruG nlCr/rl,WOODEN BLOCK
TIE.ROO CLIP
16. Apply grease around the outside ot the rack end
housing.
Apply a light coat of silicone grease to the boot
grooves on the rack ends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rods are
equal in length).
=-..r=-q!q!!.n
SILICONE GREASE
17.
(cont'd)
17-11
NOTE| WiPe grease off
the thread sectlon

)
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
J
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 Gearbox
Installation (cont'dl
Center the cable reel by first rotating it clockwise
until it stops. Then rotate it counterclockwise(approximately two turns) until the arrow mark on
the label points straight up. Reinstall the steering
wheel (see page 17-35).
Install the steering joint cov€r with the clamps and
clrps.
7.
STEERING JOINI COVER
17-14
9. Reconnsct the ti€-rod ends to the steering knuckles,
thon tightsn th€ castle nut ('96 -'97 models) or nut('98 -'00 models) to the specified torque, and install
new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contamination from the ball joint
tapered section and threads.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque
spocification, th€n tighton it only tar anough to
align the 3lot with tho pin hob. Do not align the
nut by loosening ('96 - '97 modcls onlyl.
TIE.ROD
COTTER PINSR6plac6.On rgassombly, b6nd
'96 - 37 model3:
cotter prn as shown.'98 - '00 modol3:
NUT4a N.m(4.5 kgf.m,33 lbr.ftl
CAST1T NUT,O - ilt N'm{4,0 - 4.8 kgf.m.29 - 35 tbtftl
10.Installthe exhaust pipe A or TWC (see section 9).
Connect the shift linkage (see section 13 or section
14).
Install the front wheels.
After installation, perform the following checks.
. 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 equally.
ll.

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

System Description
Fluid Flow Diagram
The system is a compact rotary-valve-type power steering, connected to the steering gearbox. The fluid pressure is pro-
vided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressure is regulated by
the flow control valve built into the pump. The fluid pressure from the pump is delivered to the valve body unit around the
pinion of the steering gearbox. The valve inside the valve body unit controls the hydraulic pressure and changes the direc-
tion of the flow. The fluid then 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.
RESERVOIR
VALVE BOOY UNIT
SUB.VALVE
FLOW CONTROL VALVESTEERING GEARBOX
17-16

)
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
J