1999 HONDA CIVIC ac line

Power Steering Hoses, Lines
Fluid Leakage Inspection
HOSES and LINES
. Inspect hoses for damage, leaks, interference or
twisting.
. Inspect tluid lines for damage, rusting and leakage.
. Inspect for leaks at hose and line joints and connec-
tions.
POWER STEERINGswtTcH12 N.m {1.2 kgt.m,9lbt.ft}
CYLINDER HOUSING-to.CYLINDER LINES28 N.m (2.7 kgf.m, 20 lbf.ft)
VALVE BODY UNIT-to-CYLINDER LINES'17 N.m {1.712 tbl.ftl
VALVE BODY UNIT-Io-FEED/RETURN LINES
Feed line: 14 x '1.5 mm llare nut
37 N.m {3.8 kgJ.m, 27 lbf'tt)
Return Line Joint 16 x 1.5 mm flare nut
28 N m 12.7 kgf.m,20 lbtft)
HOSE CLAMP:
. Position the hose clamps at the points indicated (b) in
the drawing above.
. Slide the hose over the line until it contacts the stop.
8()07Check for leaks.
OUTLET HOSE11 N.m
G€AR8OX and VALVE BODY UNITCheck for leaks at the mating surfaceand flare nut connections,
tbt(Double Ring Typei
CAUTION: Check all clamps for deterioration or delor-
mation; replace with the clamps new ones il necessary.
(1.1 kgf.m,8
PUMP ASSEMBLYCheck for leaks at the pump
seal, inlet and outlet fiftings.
Replacement
NOTE:
. Connect each hose to the corresponding pipe securely
until it contacts the stop on the line. Install the clamp
or adiustable clamp at the specified distance from the
hose end as shown.
. Add the power steering fluid to the specified level on
the reservoir and check for leaks.
ADJUSTABLE HOSE CLAMP:
. Position the adiustable hose clamps at the points
indicated (a) in the drawing above.
. Slide the hose over the line until it contacts the stop.
2.5 - 5.5 mm{0.01 - 0.22 in)2.0 - 4.0 mm(0.08 - 0.16 in)
2.5 - 5.5 mm(0.01- 0.22 in)1.,
17-39

Power Steering Pump
RemovaUlnstallation
NOTE: Eefore disconnecting the hoses from the pump,
Dlace a suitable container under the vehicle.
1. Remove the belt by loosening the pump mounting
bolts and adjusting bolt ('99 -'00 models: 81642
Engine Type only).
OUTLET LINE11 N.m {1.1 kgf'm,8
L
PUMP MOUNTING BOLT24 N.m (2.4 kgl.m, 17 lbf ft)
2. Cover the Ay'C compressor with several shop towels
to protect it from spilled power steering fluid.
3. Disconnect the inlet hose and the outlet line from
the pump, and plug them.
NOTE: Take care not to spill the fluid on the body
or parts, Wipe off any spilled fluid at once.
4. Remove the pump mounting bolts and adjusting
bolt ('99 -'00 models: 816A2 Engine Type only),
then remove the pump.
NOTE:
. Do not turn the steering wheel with the pump
removeo.
. Wrap the opening of the pump with a piece of
tape to prevent foreign material from entering
the pump.
17-40
1.
8.
Connect the inlet hose and the outlet line. Tiqhten
the pump fittings securely.
Loosely install the pump in the pump bracket with
mounting bolts and adjusting bolt ('99 -'00 models:
81642 Engine Type only).
Installthe pump belt.
CAUTION:
. Make sure that the power steering belt is prop-
orly positioned on the pulleys.
. Do not get power stoering tluid or grease in the
power steering bsh or pulley faces. Clean off any
fluid or grease before installrtion.
Adjust the pump belt (see page 17-32).
Fill the reservoir to the upper level line (see page

Steering Gearbox
)
Removal
NOTE: Using solvent and a brush, wash any oil and dirt
off the valve body unit its lines. and the end if the gear-
box. Blow dry with comPressed air.
1. Drain the power steering fluid as described on page
2. Raise the front of vehicle, and support it on safety
stands in the proper locations (see section 11.
3, Remove the front wheels.
4. Remove the driver's airbag assembly, and steering
wheel (see page 17-35)
5. Bemove the steering joint cover.
6. Remove the steering joint lower bolt, and loosen
the steering joint upper bolt. Disconnect the steer-
ing joint by moving the ioint toward the column
tJ
17-47
TIE.ROD END
7. Remove the cotter pin from the castle nut {'96 -'97
models) or nut ('98 - '00 modslsl and remove the nut.
BALL JOINT REMOVER.28 mm07MAC - SLqI2|X)
'98 - '00 mod.b:NUT
8.
COTTER PINSRepl6ce.
lnstall the t0 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 special tool.
NOTE: Remove the ball joint using the special tool.
Refer to section 18 for how to use ths ball joint
remover.
Seoarate the tie-rod ball joint and knuckle using the
specialtool.
CAUnON: Avoid damaging tho 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 9).
Disconnect the shift linkage (see section 13 or section
14).
(cont'd)
9.
10.
11.
12.

Steering Gearbox
Removal {cont'dl
Loosen the 14 mm flare nut and disconnect the feed
line.
Loosen the adjustable hose clamp and disconnect
the return hose.
Loosen the 16 mm flare nut and remove the return
hose joint trom the valve body unit.
CAUTION: After disconnecting lhe hos6 and lin6.
plug or seal the hose and line with a pioca ol tapa
or equivalent to prevenl foreign matorials trom
entsring the valve body unit.
NOTE: Do not loosen the cvlinder line A and
between the valve body unit and cylinder.
ADJUSTABLE HOSECLAMP
Remove the stiffener Dlate.
NOTE: Some stiffener plate attaching bolts are also
used as gearbox mounting bolts. The gearbox will
tilt to side when these bolts are removed.
13.
14.
t9.
16.
17-48,
17. Remove the mounting brackets.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead. then remove the
pinion shaft grommet.
Move the steering gesrbox to right so the left rack
end clears the rear beam, then tilt the left side down
to remove it from the vehicle,
CAUTION: Be careful not io bend or damage the
fagd ling and cylindsr lin99 whgn rgmoving thg
ggarbox,
18.
STEERING GEANEOX

Steering Gearbox
Disassembly (cont'd)
8. Remove cylinder lines A and B from the gearbox.
CYLINDER LINE gCYLINOCR LINE A
Drain the fluid from the cylinder fittings by slowly
moving the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body unit from the gearbox. (See page 17-52 forvalve body unit disassembly.)
VALVE BOOY UNITFLANGE BOLT
10.
'96 - '97 mod.ls:32 mm SHIMS98 - '00 modok:WAVE WASHER
17-50
13. Loosen and remove the cvlinder end.
11. Drill a 3 mm (0.12 in) diameter hole approximatety
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the stakedpoint on the cylinder.
cAunoN:
o Do nol allow metal shavings to onter the cylin.
der housing.
. After romoying iha cylinder end, remova any
bur6 at the staksd point.
Dcpthi 2,5 - 3.0 mm {0.10 - 0.12 in}
CYUNDER
12. Hold the steering
snown.
gearbox using a C-clamp as

Steering Gearbox
Disassembly (cont'dl
22. Carelully pry the piston seal ring and O-ring off theprslon rack.
CAUTION| Be caletul not to damage the inside ofseal ring groove and piston edges when removing
the seal rin9,
Replace.
17-52
Valve Body Unii Disassembly
23. Eefore removing the valve housing, apply vinyl tapeto splines of the pinion shaft.
24. Separate the valve housing from the pinion shaft/
valve using a press.
VALVE HOUSING
Vinylt.pe
PINION SHAFT
Check the inner wall of the valve housing where theseal ring slides with your finger. lf there is a step inthe wall, the valve housing is worn. Replace thevalve housing.
NOTE:
There may be the sliding marks from the sealring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.When the valve housing is replaced, jnstall new
shim(s) on the bearing surface of the housing toadjust the thickness.
Check the inside of valve housingwhether the wall is stepped.

)Reassembly
NOTE:
. clean the disassembled parts wrth a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly'
. Apply the recommended power steering fluid to the parts+ndicated in the assembly procedures'
o Do not a||ow dust, dirt, or other foreign materials to enter the power steering system.
a Use the appropriate special tools where necessary'
FLANGE BOLTS20 N.m (2.0 kgt'm, 14lbf ftl
CYLINDER LINE B
VALVE HOUSINGFLARE NUTS
28 N.m (2.7 ksf m,20 lbf ftl
VALVE OIL SEAL
Replace.
CYLINDER END SEAL
Replace.
f itllTllli".",'r'o,.n,ft
''*^'*-1$*€-/s6-,,mode,3:
EUSHINGReplace 'P'\-- BEARING
SLEEVE SEAL RINGS ..-------...... SS
.----
",a"a,,
*---
--,
Replace. lss-, Replace.
Xll,Y5"l'.
"o. --r...- gY------..r.u,
,-f-..-S: _ ,96 _,9? models:
--€l€--------=- ircriip'ii.rt'-l./BACKUPReplace.
I,
wAvE wAsHER d
-.-.-r_ i"pru"".
CYLINDER HOUSING // -\-
, AJ - O.RING
/ ,S-'..- ReDtace.
_ j GEAR HouslNG l.g --'\-
\- t F
tonsrnrr
.,_- s
- 'oo ,,iod"t., -s-'--------- vALvE SEAL R'NG
S_.<---,tj- 97 models onlY:
CYLINDER END SEAL
)@OOD m n"prac".
/'\N,."._nrNG I '98 - 'oo - RACK GUIDE
models:
:scREw I
O.RINGReplace..98 - '00 models:
CYLINDER END69 N.m {?.0 kgt'm,51 lbl'ft)
(cont'd)
17-55
CYLINDER LINE A
tJ

Steering Gearbox
Reassembly (cont'd)
Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl taoe with
the power steering fluid.
2. Install the backup ring ('96 -'97 models) or wavewasher ('98 -'00 models) with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil sealwith power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being
careful not to damage the sealing lip.
Vinyl t.po{Stepped ponion}
Tap6red position.
BACKUPGroove side.
sure the spring isseatod in the oil seal.
'98 - '00 mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Apply vinyl tape to the splines and stepped portion
of the shaft, and coat the surface of the vinyl tapewith the power steering fluid.
Fit the new O-ring in the groove of the pinion shaft.Then slide the new valve seal ring over the shaft
and the groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft,
'96 - '97 models:
lip
7.
VALVE SEAL RIiIGReplace.Do not over-expand.
17-56
8. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
9. Apply power steering fluid to the inside of the spe-cial tool. Set the larger diameter end of the specialtool over the valve seal ring.
10. Move the special tool up and down several times tomake the valve seal ring fit in the pinion shaft.11, Remove the soecial tool.
12. Turn the special tool over, and set the smaller diam-eter end of the special tool over the valve seal ring.Move the special tool up and down several times tomake the valve seal ring fit snugly in the pinion
shaft.
PISTON SEAL BINGSIZING TOOL07NAG - SR:togoAol07NAG - SR3|X)00
(g(m
Use the larger diameterend of the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringfit snugly in the pinionshaft using the other end(smaller diameter end) ofthe specialtool.