POWER STEERING SYSTEM

• HEADINGS
  • Power Steering
    • Special Tools
    • Component Location Index
    • Symptom Troubleshooting Index
    • Symptom Troubleshooting
      • Hard Steering
    • Steering Wheel Rotational Play Check
    • Power Assist Check
    • Steering Linkage and Gearbox Inspection
    • Pump Pressure Test with T/N 07406-0010001
    • Pump Pressure Test with T/N 07406-001000A or T/N 07406-001A101
    • Fluid Leakage Inspection
    • Fluid Replacement
    • Power Steering Hose, Line, and Pressure Switch Replacement
    • Pump Replacement
    • Pump Overhaul
      • Exploded View
    • Steering Wheel Removal
    • Steering Wheel Disassembly/Reassembly
    • Steering Wheel Installation
    • Steering Column Removal and Installation
      • Removal
      • Installation
    • Steering Column Inspection
    • Steering Lock Replacement
    • Rack Guide Adjustment
    • Steering Gearbox Removal
    • Steering Gearbox Overhaul
      • Exploded View
    • Steering Gearbox Installation
    • Tie-rod Ball Joint Boot Replacement
    • Gearbox Mount Cushion Replacement
• FIGURES
  • Fig. 1: Identifying Special Tools
  • Fig. 2: Identifying Steering Component Location
  • Fig. 3: Checking Steering Wheel Rotational Play
  • Fig. 4: Checking Steering Wheel With Spring Scale
  • Fig. 5: Identifying Steering Linkage And Gearbox Components
  • Fig. 6: Connecting P/S Joint Adapter (Hose) To P/S Pressure Gauge W/Torque Specification
  • Fig. 7: Identifying Shut-Off Valve And Pressure Control Valve
  • Fig. 8: Identifying Pump Outlet Hose From Pump Outlet W/Torque Specification
  • Fig. 9: Identifying Shut-Off Valve
  • Fig. 10: Identifying Fluid Leakage Components
  • Fig. 11: Identifying Reservoir
  • Fig. 12: Identifying Return Hose
  • Fig. 13: Identifying Power Steering Hose, Line And Pressure Switch W/Torque Specifications
  • Fig. 14: Identifying Drive Belt, Pump Pulley, Pump Inlet Hose With Pump Outlet Hose W/Torque Specifications
  • Fig. 15: Identifying Drive Belt Installation Position
  • Fig. 16: Exploded View Of Pump Overhaul W/Torque Specifications
  • Fig. 17: Holding Power Steering Pump In Vise With Soft Jaws
  • Fig. 18: Identifying Pressure Control Valve
  • Fig. 19: Checking Flow Control Valve
  • Fig. 20: Submerging Pressure Control Valve In Steering Fluid Or Solvent
  • Fig. 21: Inspecting Ball Bearing
  • Fig. 22: Identifying Pump Seal
  • Fig. 23: Positioning Driveshaft In Pump Housing
  • Fig. 24: Identifying O-Ring
  • Fig. 25: Coating Pump Cover Seals With Power Steering Fluid
  • Fig. 26: Aligning Outer Case With Pump Cover Roll Pin Hole
  • Fig. 27: Aligning Slot With Slot In Outer Case
  • Fig. 28: Identifying Rotor And Cam Ring
  • Fig. 29: Aligning Roll Pin Set Hole With Roll Pin
  • Fig. 30: Installing Pump Housing Over Pump Cover Assembly
  • Fig. 31: Aligning Bolt Holes In Pump Cover with Threaded Holes With Torque Specification
  • Fig. 32: Pushing In Cam Ring From Pump Housing Cap Hole
  • Fig. 33: Identifying Pump Preload Spring W/Torque Specification
  • Fig. 34: Identifying Pressure Control Valve Spring W/Torque Specification
  • Fig. 35: Coating O-Ring With Power Steering Fluid W/Torque Specification
  • Fig. 36: Identifying Pulley Nut W/Torque Specification
  • Fig. 37: Identifying Cable Reel Subcord Connector And Steering Wheel Bolt
  • Fig. 38: Identifying Commercially Available Steering Wheel Puller On Steering Wheel
  • Fig. 39: Identifying Steering Wheel With Bolt
  • Fig. 40: Disassembly/Reassembly Of Steering Wheel
  • Fig. 41: Identifying Cable Reel
  • Fig. 42: Identifying Cancelling Sleeve Tabs
  • Fig. 43: Identifying Steering Wheel Bolt W/Torque Specification
  • Fig. 44: Identifying Steering Joint Cover
  • Fig. 45: Holding Lower Slide Shaft On Column With Piece Of Wire
  • Fig. 46: Identifying Combination Switch Assembly And Cable Reel Components W/Torque Specifications
  • Fig. 47: Identifying Steering Column Joint Position
  • Fig. 48: Identifying Joint Bolt W/Torque Specification
  • Fig. 49: Identifying Steering Joint Cover
  • Fig. 50: Inspecting Steering Column
  • Fig. 51: Drilling Shear Bolts
  • Fig. 52: Identifying Shear Bolts And Hex Heads
  • Fig. 53: Identifying Rack Guide Screw
  • Fig. 54: Identifying Rack Guide Screw
  • Fig. 55: Tightening Rack Guide Screw W/Torque Specification
  • Fig. 56: Identifying Steering Joint Cover
  • Fig. 57: Holding Lower Slide Shaft On Column With Piece Of Wire
  • Fig. 58: Identifying Steering Joint Bolt
  • Fig. 59: Identifying Center Guide, Steering Joint Cover And Cover Seal
  • Fig. 60: Identifying Harness Clamp And Hose
  • Fig. 61: Identifying Clamp Bracket
  • Fig. 62: Identifying Engine Hanger Adapter (VSB02C000015) To Threaded Hole In Cylinder Head
  • Fig. 63: Identifying Engine Support Hanger (AAR-T-12566) To Vehicle
  • Fig. 64: Identifying Tie-Rod Ball Joint Nut Cotter Pin
  • Fig. 65: Identifying P/S Heat Shield
  • Fig. 66: Identifying Splash Shield And Bolts
  • Fig. 67: Lifting Front Suspension Subframe
  • Fig. 68: Identifying Inlet Line Holder Mounting Bolt
  • Fig. 69: Identifying Flare Nut And Inlet Line
  • Fig. 70: Identifying Front Suspension Subframe Right Mid Mount Bolts
  • Fig. 71: Identifying Front Suspension Subframe Left Mid Mount
  • Fig. 72: Identifying Steering Stiffener Plate
  • Fig. 73: Identifying Front Suspension Subframe Front Bracket
  • Fig. 74: Identifying Front Suspension Subframe Rear Bracket And Mounting Bolt
  • Fig. 75: Identifying Gearbox Mounting Bracket And Cushion
  • Fig. 76: Identifying Pinion Shaft Grommet
  • Fig. 77: Applying Vinyl Tape Or Equivalent Material To Brake Lines
  • Fig. 78: Identifying Steering Gearbox Assembly
  • Fig. 79: Removing Steering Gearbox
  • Fig. 80: Exploded View Of Steering Gearbox W/Torque Specifications
  • Fig. 81: Identifying Boot Bands And Tie-Rod Clips
  • Fig. 82: Identifying Lock Washers
  • Fig. 83: Holding Flat Surface Sections Of Steering Rack With Wrench
  • Fig. 84: Identifying Rack Guide Screw And Locknut
  • Fig. 85: Removing Cylinder Lines From Gearbox
  • Fig. 86: Identifying Valve Body Unit From Gearbox Housing
  • Fig. 87: Identifying Drill Hole
  • Fig. 88: Holding Gearbox Housing Using C-Clamp
  • Fig. 89: Identifying Commercially Available Bearing Separator On Gearbox Housing
  • Fig. 90: Identifying Cylinder Seal
  • Fig. 91: Identifying Cylinder Seal And Backup Ring
  • Fig. 92: Identifying Piston Seal Ring And O-Ring
  • Fig. 93: Applying Vinyl Tape To Splines Of Pinion Shaft
  • Fig. 94: Checking Inner Wall Of Valve Housing
  • Fig. 95: Checking Sleeve Grooves For Wear, Burrs And Other Damages
  • Fig. 96: Identifying Snap Ring And Sleeve From Pinion Shaft
  • Fig. 97: Identifying Seal Ring
  • Fig. 98: Identifying Valve Seal Ring And O-Ring
  • Fig. 99: Identifying Valve Oil Seal And Wave Washer
  • Fig. 100: Removing Valve Oil Seal And Roller Bearing
  • Fig. 101: Applying Vinyl Tape To Stepped Portion Of Pinion Shaft
  • Fig. 102: Applying Vinyl Tape To Splines And Stepped Portion Of Shaft
  • Fig. 103: Applying Power Steering Fluid To Surface Of Valve Seal Ring
  • Fig. 104: Applying Power Steering Fluid To Surface Of Sleeve Seal Ring Guide
  • Fig. 105: Applying Power Steering Fluid To Seal Rings On Sleeve
  • Fig. 106: Applying Power Steering Fluid To Surface Of Pinion Shaft
  • Fig. 107: Applying Power Steering Fluid To Seal Ring Lip Of Valve Oil Seal
  • Fig. 108: Applying Vinyl Tape To Pinion Shaft
  • Fig. 109: Pressing Pinion Shaft/Sleeve Into Valve Housing
  • Fig. 110: Positioning O-Ring And Piston Seal Ring On Piston Seal Ring Guide
  • Fig. 111: Coating Piston Seal Ring And Inside Of Piston Seal Ring Sizing Tool With Power Steering Fluid
  • Fig. 112: Placing Seal On Cylinder Seal Slider With Its Grooved Side
  • Fig. 113: Coating Surface Of Steering Rack With Power Steering Fluid
  • Fig. 114: Identifying Backup Ring On Steering Rack
  • Fig. 115: Applying Multipurpose Grease To Steering Rack Teeth
  • Fig. 116: Inserting Appropriate Size Deep Socket Wrench Onto Steering Rack
  • Fig. 117: Placing Seal On Cylinder Seal Slider With Grooved Side
  • Fig. 118: Coating Inside Surface Of Cylinder Seal Slider And Steering Rack With Power Steering Fluid
  • Fig. 119: Holding Gearbox Housing Using C-Clamp
  • Fig. 120: Tightening Cylinder Locknut W/Torque Specification
  • Fig. 121: Coating O-Ring With Multipurpose Grease On Valve Housing W/Torque Specification
  • Fig. 122: Tightening Flange Bolts W/Torque Specifications
  • Fig. 123: Identifying Rack Guide Screw W/Torque Specification
  • Fig. 124: Identifying Lock Washer W/Torque Specification
  • Fig. 125: Identifying Lock Washer
  • Fig. 126: Applying Multipurpose Grease To Circumference Of Rack Joint Housing
  • Fig. 127: Identifying Tie-Rod Clips And Boots
  • Fig. 128: Aligning Tabs With Holes Of Band
  • Fig. 129: Closing Portion Of Band
  • Fig. 130: Identifying Mount Cushion Mating Surfaces
  • Fig. 131: Identifying Pinion Shaft Points Upward
  • Fig. 132: Identifying Pinion Shaft Grommet
  • Fig. 133: Identifying Mounting Cushion W/Torque Specification
  • Fig. 134: Identifying Steering Stiffener Plate W/Torque Specifications
  • Fig. 135: Identifying Inlet Line Holder And Return Hose On Gearbox Mounting Bracket W/Torque Specification
  • Fig. 136: Tightening Return Line Flare Nut W/Torque Specifications
  • Fig. 137: Supporting Front Suspension Subframe W/Torque Specifications
  • Fig. 138: Identifying Front Suspension Subframe Front Bracket W/Torque Specifications
  • Fig. 139: Identifying Front Suspension Subframe Left Mid Mount Bolts W/Torque Specifications
  • Fig. 140: Identifying Front Suspension Subframe Right Mid Mount Bolts W/Torque Specification
  • Fig. 141: Identifying Splash Shield And Bolts
  • Fig. 142: Identifying P/S Heat Shield W/Torque Specification
  • Fig. 143: Identifying Tie-Rod Ball Joints And Knuckles W/Torque Specification
  • Fig. 144: Identifying Cover Seal W/Torque Specification
  • Fig. 145: Positioning Steering Column Joint
  • Fig. 146: Aligning Bolt Hole On Steering Joint With Groove W/Torque Specification
  • Fig. 147: Identifying Steering Joint Cover
  • Fig. 148: Identifying Grease Applying Area
  • Fig. 149: Identifying Tie-Rod Ball Joint Boot With Front Hub Disassembly Tool
  • Fig. 150: Identifying Socket Wrench On Flange
  • Fig. 151: Identifying Socket Wrench
• TABLES
  • TROUBLESHOOTING CHART

2004-08 STEERING

Steering - TSX

Power Steering

Special Tools

Fig. 1: Identifying Special Tools
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Component Location Index

Fig. 2: Identifying Steering Component Location
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Symptom Troubleshooting Index

Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause.

TROUBLESHOOTING CHART

Symptom	Procedure(s)	Also check for
Hard steering	Troubleshoot the system (see HARD STEERING ).	Modified suspension Damaged suspension Tire sizes, tire varieties, and air pressure
Assist (excessively light steering at high speed)	Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ).	Front wheel alignment (see WHEEL ALIGNMENT )
Shock or vibration when the steering wheel is turned to full lock	Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). Check the drive belt for slippage (see DRIVE BELT INSPECTION ). Check the power steering pump fluid pressure with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ), T/N 07406-001000A or T/N 07406-001A101 (see PUMP PRESSURE TEST WITH T/N 07406-001000A OR T/N 07406-001A101 ). Overhaul the steering gear box (see STEERING GEARBOX OVERHAUL ).
Steering wheel will not return smoothly	Check cylinder lines for deformation. Check upper and lower ball joints for binding. Check wheel alignment (see WHEEL ALIGNMENT ). Overhaul the steering gearbox (see step 2 ).
Uneven or rough steering	Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). Check the drive belt (see DRIVE BELT INSPECTION ). Check for low or erratic engine idle speed (see IDLE SPEED INSPECTION ). Check for air in the power steering system due to air entering inlet side of pump. Check for low fluid level in the power steering reservoir due to possible leaks in system. Overhaul the steering gearbox (see step 2 ).
Steering wheel kicks back during wide turns	Check the drive belt (see DRIVE BELT INSPECTION ). Check the power steering pump fluid pressure with T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ), T/N 07406-001000A or T/N 07406-001A101 (see PUMP PRESSURE TEST WITH T/N 07406-001000A OR T/N 07406-001A101 ).
Humming noise from the power steering system	Check when the noise occurs: If the noise is heard during the first 2-3 minutes after starting the engine in cold weather, this is normal. If the noise is heard when the wheel is turned with the vehicle stopped, this is normal due to fluid pulsation. Check for the high-pressure hose touching the subframe or body. Check for automatic transmission converter noise. Check for air bubbles in the power steering fluid, leak on inlet side of pump. Check for particle contamination of fluid and restricted filter in the reservoir.	Pump pressure
Power steering rack rattle or chattering	Check for loose steering components (tie-rod and ball joints). Tighten or replace as necessary. Check the steering column shaft for wobbling. If the steering column wobbles, replace the steering column assembly (see STEERING COLUMN REMOVAL AND INSTALLATION ). Check the rack guide adjustment (see RACK GUIDE ADJUSTMENT ). Check the power steering pump pulley: If the pulley is loose, tighten it (see step 46 ). If the pump shaft is loose, replace the Pump (see PUMP REPLACEMENT ).
Hissing from the power steering system/foaming fluid	Check the fluid level. If low, fill the reservoir to the proper level and check for leaks. Check the reservoir for leaks. Check for crushed inlet hose or loose hose clamp allowing air into the suction side of the system (see FLUID LEAKAGE INSPECTION ). Check the power steering pump shaft oil seal for leaks.	Air in the P/S fluid
Noise from the power steering pump	Compare the pump noise at normal operating temperature to another like vehicle (pump noise for 2-3 minutes after starting the engine in cold weather is normal). Remove and inspect the pump for wear and damage (see PUMP REPLACEMENT ).	P/S pump pressure Air in the P/S fluid
Squeaking from the power steering pump	Check the drive belt (see DRIVE BELT INSPECTION ).
Fluid leaks from the steering gearbox	Fluid leaks from the top of the valve body unit: Overhaul the valve body unit (see STEERING GEARBOX OVERHAUL ). Fluid leaks from the driver's side boot. Replace the valve oil seal on the pinion shaft. Replace the cylinder end seal on the gearbox side. Fluid leaks from the passenger's side boot. Replace the right cylinder end seal. Fluid leaks from pinion shaft near the lower steering joint bolt. Overhaul the valve body unit. Fluid leaks from the steering damping valve covers on the valve body unit. Replace the valve housing.
Fluid leaks from the power steering line	Fluid leaks from the cylinder line connections (flare nuts). Tighten the connection and retest (see POWER STEERING HOSE, LINE, AND PRESSURE SWITCH REPLACEMENT ). Fluid leaks from damaged cylinder lines. Replace the cylinder line (see POWER STEERING HOSE, LINE, AND PRESSURE SWITCH REPLACEMENT ). Fluid leaks from the pump outlet hose or return line fitting on the valve body unit (flare nuts). Tighten the fitting and retest. If it still leaks, replace the hose, the line, or valve body unit as necessary.
Fluid leaks from the power steering pump	Fluid leaks from the front oil seal. Replace the front oil seal. Fluid leaks from the power steering pump housing. Replace the leaking O-rings or seals (see PUMP OVERHAUL ), and if necessary replace the power steering pump (see PUMP REPLACEMENT ).
Fluid leaks from the power steering reservoir	Fluid leaks from around the reservoir cap because the fluid level is too high. Drain the reservoir to the proper level. If the fluid is aerated check for an air leak on the inlet side of pump. Fluid leaks from reservoir. Check the reservoir for cracks and replace as necessary.
Fluid leaks from the power steering pump outlet hose (high-pressure)	Check the fitting for loose bolts. If the bolts are tight, replace the fitting O-ring. Fluid leaks at the swaged joint. Replace the outlet hose.
Fluid leaks from the power steering pump inlet hose (low-pressure)	Check the hose for damage, deterioration, or improper assembly. Replace or repair as necessary.

Symptom Troubleshooting

Hard Steering

1. Check the power assist (see POWER ASSIST CHECK ).

   Is the initial turning load more than 29 N (3.0 kgf, 6.6 lbf)?

   YES - Go to step 2.

   NO - Power assist is OK.

2. Connect the P/S pressure gauge T/N 07406-0010001 (see PUMP PRESSURE TEST WITH T/N 07406-0010001 ), T/N 07406-001000A or T/N 07406-001A101 (see PUMP PRESSURE TEST WITH T/N 07406-001000A OR T/N 07406-001A101 ) to the pump.
3. Measure steady-state fluid pressure from the pump at idle.

   Is the pressure 1,470 kPa (15 kgf/cm² , 213 psi) or less?

   YES - Go to step 4.

   NO - Go to step 8.

4. Measure the pump relief pressure at idle.

   Is the pressure 7,850-8,550 kPa (80-87 kgf/cm² , 1,140-1,240 psi) or more ?

   YES - Go to step 5.

   NO - Go to step 9.

5. With a spring scale, measure the power assist in both directions, to the left and to the right.

   Are the two measurements within 2.9 N (0.3 kgf, 0.66 lbf) of each other?

   YES - Go to step 6.

   NO - Go to step 11.

6. Measure the fluid pressure with both pressure gauge valves open (if so equipped), while turning the steering wheel fully to the left and fully to the right.

   Is the pressure 7,850-8,550 kPa (80-87 kgf/cm² , 1,140-1,240 psi) or more?

   YES - Go to step 7.

   NO - Faulty steering gearbox.

7. Adjust the rack guide (see RACK GUIDE ADJUSTMENT ), and retest.

   Is the steering OK?

   YES - Repair is completed.

   NO - Faulty steering gearbox.

8. Check the outlet and return hoses and lines between the pump and the steering gearbox for clogging and deformation.

   Are the lines clogged or deformed?

   YES - Repair or replace the lines.

   NO - Faulty valve body unit.

9. Disassemble the pump (see PUMP OVERHAUL ).
10. Check the pressure control valve for smooth movement and leaks (see step 16 ).

    Is the pressure control valve OK?

    YES - Faulty pump assembly.

    NO - Faulty pressure control valve.

11. Check the cylinder lines for deformation (see POWER STEERING HOSE, LINE, AND PRESSURE SWITCH REPLACEMENT ).

    Are the A or B lines deformed?

    YES - Replace the deformed line.

    NO - Go to step 12.

12. Check for a bent rack shaft or misadjusted rack guide (too tight).

    Is the rack shaft bent or the rack guide adjusted too tight?

    YES - Replace the rack shaft, or readjust the rack guide.

    NO - Faulty valve body unit.

Steering Wheel Rotational Play Check

1. Turn the front wheels to the straight ahead position.
2. Measure how far you can turn the steering wheel left and right without moving the front wheels.
   • If the play is within the limit, the gearbox and linkages are OK.
   • If the play exceeds the limit, adjust the rack guide (see RACK GUIDE ADJUSTMENT ). If the play is still excessive after rack guide adjustment, inspect the steering linkage and gearbox (see STEERING LINKAGE AND GEARBOX INSPECTION ).

   Rotational play: 0-10 mm (0-0.39 in.)

   Fig. 3: Checking Steering Wheel Rotational Play
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Power Assist Check

NOTE:

This test should be done with original equipment wheels and tires at the correct tire pressure.

1. Check the power steering fluid level (see FLUID REPLACEMENT ).
2. Start the engine, let it idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid.
3. Attach a commercially available spring scale to the steering wheel. With the engine idling and the vehicle on a clean, dry floor, pull the scale as shown and read it as soon as the tires begin to turn.
   • If the scale reads no more than the specification, the gearbox and pump are OK.
   • If the scale reads more than the specification, troubleshoot the steering system (see SYMPTOM TROUBLESHOOTING ).

   Initial turning load: 29 N (3.0 kgf, 6.6 lbf)

   Fig. 4: Checking Steering Wheel With Spring Scale
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Steering Linkage and Gearbox Inspection

Fig. 5: Identifying Steering Linkage And Gearbox Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Pump Pressure Test with T/N 07406-0010001

Special Tools Required

• P/S joint adapter (pump) 07VAK-P8A011A
• P/S joint adapter plate (pump) 07ZAK-S7CA100
• P/S joint adapter (hose) 07ZAK-S7CA200
• P/S pressure gauge 07406-0010001

Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox.

1. Check the power steering fluid level (see FLUID REPLACEMENT ).
2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the P/S joint adapter (pump) on the pump outlet (B) with the P/S joint outlet plate.

   Fig. 6: Connecting P/S Joint Adapter (Hose) To P/S Pressure Gauge W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump outlet hose to the P/S joint adapter (hose).
4. Install the P/S pressure gauge to the P/S joint adapter (pump).
5. Fully open the shut-off valve (A).

   Fig. 7: Identifying Shut-Off Valve And Pressure Control Valve
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Fully open the pressure control valve (B).
7. Start the engine and let it idle.
8. Turn the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (70°C).
9. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the pressure should be no more than 1,470 kPa (15.0 kgf/cm² , 213 psi). If the pressure is too high, check the outlet hose or valve body unit (see Steering System Troubleshooting).
10. Raise the engine speed to 3,000 rpm, and measure the fluid pressure. If the pump is in good condition, the pressure should be at least 1,470 kPa (15.0 kgf/cm² , 213 psi). If the pressure is too high, repair or replace the pump.
11. Lower the engine speed and let it idle. Close the shut-off valve, then close the pressure control valve gradually until the pressure gauge needle is stable. Read the pressure.

    NOTE:

    Do not keep the shut-off valve closed more than 5 seconds or the pump could be damaged by over-heating.

12. Immediately open the shut-off valve fully. If the pump is in good condition, the pressure gauge should read at least 7,850-8,550 kPa (80-87 kgf/cm² , 1,140-1,240 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

Pump Pressure Test with T/N 07406-001000A or T/N 07406-001A101

Special Tools Required

• P/S joint adapter (pump) 07VAK-P8A011A
• P/S joint adapter plate (pump) 07ZAK-S7CA100
• P/S joint adapter (hose) 07ZAK-S7CA200
• P/S pressure gauge 07406-001000A or 07406-001A101

Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox.

1. Check the power steering fluid level (see FLUID REPLACEMENT ).
2. Disconnect the pump outlet hose (A) from the pump outlet with care so as not to spill the power steering fluid on the frame and other parts, then install the P/S joint adapter (pump) on the pump outlet (B) with the P/S joint outlet plate.

   Fig. 8: Identifying Pump Outlet Hose From Pump Outlet W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Connect the P/S joint adapter (hose) to the P/S pressure gauge, then connect the pump outlet hose to the P/S joint adapter (hose).
4. Install the P/S pressure gauge to the P/S joint adapter (pump).
5. Open the shut-off valve (A) fully.

   Fig. 9: Identifying Shut-Off Valve
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Start the engine and let it idle.
7. Turn the steering wheel from lock-to-lock several times to warm the fluid to operating temperature at 158°F (709°C).
8. Measure steady-state fluid pressure while the engine is idling. If the pump is in good condition, the pressure should be no more than 1,470 kPa (15.0 kgf/cm² , 213 psi). If the pressure is too high, check the outlet hose or valve body unit (see Steering System Troubleshooting).
9. Raise the engine speed to 3,000 rpm, and measure the fluid pressure. If the pump is in good condition, the pressure should be at least 1,470 kPa (15.0 kgf/cm² , 213 psi). If the pressure is too high, repair or replace the pump.
10. Lower the engine speed and let it idle. Close the shut-off valve gradually until the pressure gauge needle is stable. Read the pressure.

    NOTE:

    Do not keep the pressure control valve closed more than 5 seconds or the pump could be damaged by over-heating.

11. Immediately open the shut-off valve fully. If the pump is in good condition, the pressure gauge should read at least 7,850-8,550 kPa (80-87 kgf/cm² , 1,140-1,240 psi). A low reading means pump output is too low for full assist. Repair or replace the pump.

Fluid Leakage Inspection

Fig. 10: Identifying Fluid Leakage Components
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fluid Replacement

Check the reservoir (A) at regular intervals, and add the recommended fluid as necessary. Always use Acura Power Steering Fluid. Use of any other type of power steering fluid or automatic transmission fluid can cause increased wear and poor steering in cold weather.

NOTE:

If the fluid is contaminated, the screen in the reservoir may be partially blocked. Replace the reservoir if necessary.

System capacity: 1.1 L (1.16 US. qt) at disassembly

Reservoir capacity: 0.32 L (0.42 US. qt)

Fig. 11: Identifying Reservoir
Courtesy of AMERICAN HONDA MOTOR CO., INC.

1. Raise the reservoir, then disconnect the return hose (A) to drain the reservoir. Take care not to spill the fluid on the body and parts. Wipe off any spilled fluid at once.

   NOTE:

   Inspect the reservoir screen for any debris. If the reservoir screen is clogged, replace the reservoir.

   Fig. 12: Identifying Return Hose
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Connect a hose (B) of suitable diameter to the disconnected return hose, and put the hose end in a suitable container.
3. Start the engine, let it run at idle, and turn the steering wheel from lock-to-lock several times. When fluid stops running out of the hose, shut off the engine. Discard the fluid.
4. Reinstall the return hose on the reservoir.
5. Fill the reservoir to the upper level line (C).
6. Start the engine and run it at idle, then turn the steering from lock-to-lock several times to bleed air from the system.
7. Recheck the fluid level and add some if necessary. Do not fill the reservoir beyond the upper level line.
8. If the fluid is contaminated, dark, or discolored, repeat procedure as necessary.

Power Steering Hose, Line, and Pressure Switch Replacement

Note these items during installation:

• Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown.
• Check all clamps for deterioration or deformation; replace the clamps with new ones if necessary.
• Add the recommended power steering fluid to the specified level on the reservoir and check for leaks.

  Fig. 13: Identifying Power Steering Hose, Line And Pressure Switch W/Torque Specifications
  Courtesy of AMERICAN HONDA MOTOR CO., INC.

Pump Replacement

1. Place a suitable container under the vehicle.
2. Drain the power steering fluid from the reservoir (see FLUID REPLACEMENT ).
3. Remove the drive belt (A) from the pump pulley (see DRIVE BELT INSPECTION ).

   Fig. 14: Identifying Drive Belt, Pump Pulley, Pump Inlet Hose With Pump Outlet Hose W/Torque Specifications
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Cover the auto-tensioner, alternator, and A/C compressor with several shop towels to protect them from spilled power steering fluid. Disconnect the pump inlet hose (B) and the pump outlet hose (C) from the pump (D), and plug them. Take care not to spill the fluid on the body or parts. Wipe off any spilled fluid at once. Do not turn the steering wheel with the pump removed.
5. Cover the opening of the pump with a piece of tape to prevent foreign material from entering the pump.
6. Remove the pump mounting bolts (E).
7. Connect the pump inlet hose and the pump outlet hose onto the new pump with a new O-ring (F).
8. Loosely install the pump in the pump bracket with the mounting bolts, then tighten the pump fittings securely.
9. Tighten the pump mounting bolts to the specified torque.
10. Install the drive belt (A).

    Note these items during belt installation:

    • Make sure that the belt is properly positioned on the pulleys (B).
    • Do not get power steering fluid or grease on the auto-tensioner, alternator, A/C compressor, and drive belt or pulley faces. Clean off any fluid or grease before installation.

      Fig. 15: Identifying Drive Belt Installation Position
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Fill the reservoir to the upper level line (see FLUID REPLACEMENT ).

Pump Overhaul

Exploded View

Replace the pump as an assembly if the parts indicated with an asterisk (*) are worn or damaged.

Fig. 16: Exploded View Of Pump Overhaul W/Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

• Pulley holder 07ZAB-S5A0100
• Attachment, 32 x 35 mm 07746-0010100
• Driver 07749-0010000

Disassembly

NOTE:

Refer to the EXPLODED VIEW as needed during the following procedure.

1. Drain the fluid from the power steering pump (see FLUID REPLACEMENT ).
2. Remove the power steering pump (see PUMP REPLACEMENT ).
3. Hold the power steering pump (A) in a vise with soft jaws (B), hold the pulley (C) with the pulley holder (D), and remove the pulley nut (E) and pulley. Be careful not to damage the pump housing with the jaws of the vise.

   Fig. 17: Holding Power Steering Pump In Vise With Soft Jaws
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Remove the inlet joint and O-ring.
5. Remove the pressure control valve cap, O-ring, pressure control valve, and valve spring.
6. Remove the pump housing cap, O-ring, and pump preload spring.
7. Remove the pump cover and pump cover seals.
8. Pull out the roll pin.
9. Remove the outer case, cam ring, rotor, vanes, and side plate.
10. Remove the rubber seal and slipper seal from the outer case.
11. Remove the O-rings from the bottom of the housing.
12. Remove the snap ring, then remove the driveshaft by tapping the shaft end with a soft face hammer.
13. Remove the pump seal from the pump housing.

    Inspection

14. Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve.

    Fig. 18: Identifying Pressure Control Valve
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

15. Inspect the bore of the pressure control valve on the pump housing for scratches and wear.
16. Slip the pressure control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 17; if not, replace the pump as an assembly. The pressure control valve is not available separately.

    Fig. 19: Checking Flow Control Valve
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Attach a hose (A) to the end of the pressure control valve (B) as shown. Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and apply compressed air in the hose.
    • If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm² , 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately.
    • If the pressure control valve is OK, set it aside for reassembly later.

      Fig. 20: Submerging Pressure Control Valve In Steering Fluid Or Solvent
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B).

    Fig. 21: Inspecting Ball Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

19. Inspect each part shown with an asterisk in the Exploded View. If any of them are worn or damaged, replace the pump as an assembly.

    Reassembly

20. Install the new pump seal (A) (with its grooved side facing in) into the pump housing (B) by hand first, then drive it in using the attachment and the driver until there is no step at the top of the pump seal, and the seal is fully seated in the pump housing.

    Fig. 22: Identifying Pump Seal
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Position the driveshaft (A) in the pump housing, then press it in with the appropriate size socket wrench (B) as shown. Do not apply more than 1,370 N (140 kgf, 308 lbf) of pressure.

    Fig. 23: Positioning Driveshaft In Pump Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Install the 40 mm snap ring (C) with its radiused edge facing out.
23. Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it on the bottom (B) of the pump housing.

    Fig. 24: Identifying O-Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

24. Coat the new pump cover seals (A) and (B) with power steering fluid, then position them into the grooves on the pump cover (C).

    Fig. 25: Coating Pump Cover Seals With Power Steering Fluid
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

25. Install the outer case (A) by aligning the slot (B) inside the outer case with the pump cover roll pin hole (C). Be sure that the slit (D) on the outer case is facing the direction shown.

    Fig. 26: Aligning Outer Case With Pump Cover Roll Pin Hole
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

26. Apply the power steering fluid to the rubber seal (E) (black), and install it in the slot (F) of the outer case.
27. Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you just installed.
28. Install the cam ring (A) with the "." mark (B) facing up. Align the slot (C) with the slot (D) in the outer case.

    Fig. 27: Aligning Slot With Slot In Outer Case
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

29. Insert the roll pin (E) into the slots between the cam ring and outer case, then push the roll pin into the set hole (F).
30. Install the rotor (A) in the cam ring (B).

    Fig. 28: Identifying Rotor And Cam Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

31. Set the 11 vanes (C) in the grooves in the rotor. Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring.
32. Place the side plate (A) on the cam ring, and aligning the roll pin set hole (B) with the roll pin end (C).

    Fig. 29: Aligning Roll Pin Set Hole With Roll Pin
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

33. Coat the new O-ring (D) with power steering fluid, then position it into the groove on the side plate.
34. Install the pump housing (A) over the pump cover assembly (B).

    Fig. 30: Installing Pump Housing Over Pump Cover Assembly
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

35. Align the bolt holes in the pump cover (A) with the threaded holes in the pump housing. Install the flange bolts loosely first, then torque the flange bolts in a criss-cross pattern in two or more steps.

    Fig. 31: Aligning Bolt Holes In Pump Cover with Threaded Holes With Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

36. Push in the cam ring (A) from the pump housing cap hole (B) with a flat blade screwdriver, to make sure the cam ring is fully seated against the outer case.

    Fig. 32: Pushing In Cam Ring From Pump Housing Cap Hole
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

37. Install the pump preload spring (A) in the pump housing.

    Fig. 33: Identifying Pump Preload Spring W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

38. Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C).
39. Install the pump housing cap on the pump housing, and tighten it to the specified torque.
40. Install the pressure control valve spring (A) in the pump housing.

    Fig. 34: Identifying Pressure Control Valve Spring W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

41. Coat the pressure control valve (B) with power steering fluid, and install it on the pump housing.
42. Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the pressure control valve cap (D).
43. Install the pressure control valve cap on the pump housing, and tighten it to the specified torque.
44. Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B).

    Fig. 35: Coating O-Ring With Power Steering Fluid W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

45. Install the inlet joint on the pump housing.
46. Install the pulley (A), then loosely install the pulley nut (B). Hold the steering pump in a vise with soft jaws (C). Be careful not to damage the pump housing with the jaws of the vise.

    Fig. 36: Identifying Pulley Nut W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

47. Hold the pulley with the pulley holder, and tighten the pulley nut to the specified torque.
48. Check that the pump turns smoothly by turning the pulley. If it turns hard, loosen the four flange bolts on the pump cover, then retighten them in the same manner as in step 35. Retest. If the pump is still hard to turn, replace the pump.
49. Reinstall the power steering pump (see PUMP REPLACEMENT ).

Steering Wheel Removal

SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ) and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before doing repairs or service.

1. Make sure you have the anti-theft codes for the audio system or the navigation system (if equipped), then write down the audio presets.
2. Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
3. Align the front wheels straight ahead, then remove the driver's airbag from the steering wheel (see DRIVER'S AIRBAG REPLACEMENT ).
4. Disconnect the cable reel subcord connector (A).

   Fig. 37: Identifying Cable Reel Subcord Connector And Steering Wheel Bolt
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Loosen the steering wheel bolt (B).
6. Install a commercially available steering wheel puller (A) on the steering wheel (B). Free the steering wheel from the steering column shaft by turning the pressure bolt (C) of the puller.

   Note these items when removing the steering wheel:

   • Do not tap on the steering wheel or the steering column shaft when removing the steering wheel.
   • If you thread the puller bolts (D) into the wheel hub more than five threads, the bolts will hit the cable reel and damage it. To prevent this, install a pair of jam nuts five threads up on each puller bolt.

     Fig. 38: Identifying Commercially Available Steering Wheel Puller On Steering Wheel
     Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the steering wheel puller, then remove the steering wheel bolt and steering wheel from the steering column.

   Fig. 39: Identifying Steering Wheel With Bolt
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

Steering Wheel Disassembly/Reassembly

Fig. 40: Disassembly/Reassembly Of Steering Wheel
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Steering Wheel Installation

1. Before installing the steering wheel, make sure the front wheels are aligned straight ahead, then center the cable reel (A). Do this by first rotating the cable reel clockwise until it stops. Then rotate it counterclockwise about three full turns. The arrow mark (B) on the cable reel label point should point straight up.

   Fig. 41: Identifying Cable Reel
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

2. Position the two tabs (A) of the turn signal cancelling sleeve (B) as shown. Install the steering wheel on to the steering column shaft, making sure the steering wheel hub (C) engages the pins (D) of the cable reel and tabs of the turn signal cancelling sleeve. Do not tap on the steering wheel or steering column shaft when installing the steering wheel.

   Fig. 42: Identifying Cancelling Sleeve Tabs
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Install the steering wheel bolt (A) and tighten it to the specified torque. Connect the cable reel subcord connector (B). Make sure the wire harness is routed and fastened properly.

   Fig. 43: Identifying Steering Wheel Bolt W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Install the driver's airbag, and confirm that the system is operating properly (see DRIVER'S AIRBAG REPLACEMENT ).
5. Reconnect the negative battery cable to the battery, and do these tasks:
   • Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
   • Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the client's audio presets.
   • Set the clock (on vehicles without navigation).
   • Make sure the horn and turn signal switches work properly.
   • Make sure the steering wheel switches work properly.
6. After installation, do these checks.
   • Check the steering wheel spoke angle. If the steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations.
   • Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe inspection (see WHEEL ALIGNMENT ).

Steering Column Removal and Installation

SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ) and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before doing repairs or service.

Removal

1. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
2. Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
3. Remove the steering wheel (see STEERING WHEEL REMOVAL ).
4. Remove the driver's dashboard undercover (see DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION ).
5. Remove the driver's dashboard lower cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ).
6. Remove the column covers.
7. Remove the steering joint cover A.

   Fig. 44: Identifying Steering Joint Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Release the lock lever, and adjust the steering column to the full tilt up position, and to the full telescopic in position.
9. Tighten the lock lever.
10. Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and joint yoke (D) of the upper shaft to prevent the slider shaft from pulling out.

    Fig. 45: Holding Lower Slide Shaft On Column With Piece Of Wire
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Release the lock lever, and adjust the steering column to the full telescopic out position, then tighten the lock lever.
12. Disconnect the wire harness connectors from the combination switch assembly and cable reel (A).

    Fig. 46: Identifying Combination Switch Assembly And Cable Reel Components W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Remove the combination switch assembly from the steering column shaft by removing the screws (B).
14. Disconnect the connectors from the ignition switch, and release the wire harness clips from the steering column.
15. Remove the steering joint bolt (C), then disconnect the steering joint (D) from the pinion shaft.
16. Remove the steering column (E) by removing the attaching nuts and bolts. If the lower slide shaft (F) is removed, slip it into the upper shaft (G) by aligning the paint or stamped marks (H).
17. Remove the center guide (I) (if equipped) from the top of the pinion shaft, and discard it. The center guide is for factory assembly use only.

Installation

1. Install the steering column in the reverse order of removal, and note these items:
   • Make sure the wires are not caught or pinched by any parts.
   • Take care not to let the sliding capsules fall out of position during column installation.
2. Center the steering rack within its stroke in steering joint connection.
3. Position the steering column joint (A) so the bolt (B) opposite to the notch (C) is within the range shown.

   Fig. 47: Identifying Steering Column Joint Position
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. With the rack in the straight ahead driving position, cut the wire (D) and slip the lower end of the steering joint onto the pinion shaft (E).
5. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure that the steering joint is fully seated. Tighten the steering joint bolt to the specified torque.

   Fig. 48: Identifying Joint Bolt W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Install the steering joint cover (A).

   Fig. 49: Identifying Steering Joint Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Install the steering wheel (see STEERING WHEEL INSTALLATION ).
8. Install the column covers.
9. Install the driver's dashboard lower cover (see DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION ).
10. Install the driver's dashboard undercover (see DRIVER'S DASHBOARD UNDERCOVER REMOVAL/INSTALLATION ).
11. Reconnect the negative cable to the battery, and do these tasks:
    • Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
    • Enter the anti-theft code for the audio and the navigation system (if equipped), then enter the client's audio presets.
    • Make sure the horn and turn signal switches work properly.
    • Make sure the steering wheel switches work properly.
    • Set the clock (on vehicles without navigation).
12. After installation, do these checks.
    • Check the steering wheel spoke angle. If the steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations.
    • Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe inspection (see FRONT TOE INSPECTION/ADJUSTMENT ).

Steering Column Inspection

• Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly.
• Check the lower slide shaft (C) for smooth movement in and out. If the lower slide shaft is removed, slip it into the upper shaft by aligning the paint or stamped marks (D). If it sticks or binds, replace the steering column as an assembly.
• Check the sliding capsules (E) for distortion or breakage. If there is distortion or breakage, replace the steering column as an assembly.
• Check the tilt mechanism and telescopic mechanism for movement and damage.

  Fig. 50: Inspecting Steering Column
  Courtesy of AMERICAN HONDA MOTOR CO., INC.

Steering Lock Replacement

1. Remove the steering column (see STEERING COLUMN REMOVAL AND INSTALLATION ).
2. Center-punch each of the two shear bolts, and drill their heads off with a 5 mm (3/16 in.) drill bit. Be careful not to damage the switch body and steering column when removing the shear bolts.

   Fig. 51: Drilling Shear Bolts
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the shear bolts from the switch body.
4. Install the switch body without the key inserted.
5. Loosely tighten the new shear bolts.
6. Insert the ignition key, and check for proper operation of the steering wheel lock and that the ignition key turns freely.
7. Tighten the shear bolts (A) until the hex heads (B) twist off.

   Fig. 52: Identifying Shear Bolts And Hex Heads
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Register the immobilizer control unit-receiver (see IMMOBILIZER KEY REGISTRATION ), and make sure the immobilizer system works properly.

Rack Guide Adjustment

Special Tools Required

Locknut wrench, 40 mm 07MAA-SL00100 or 07916-SA50001

1. Set the wheels in the straight ahead position.
2. Loosen the rack guide screw locknut (A) with the locknut wrench, then remove the rack guide screw (B).

   Fig. 53: Identifying Rack Guide Screw
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Remove the old sealant from the rack guide screw, and apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads. Loosely install the rack guide screw on the steering gearbox.

   NOTE:

   If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.

   Fig. 54: Identifying Rack Guide Screw
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Tighten the rack guide screw (A) to 25 N.m (2.5 kgf.m, 18 lbf.ft), then loosen it.

   Fig. 55: Tightening Rack Guide Screw W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Retighten the rack guide screw to 3.9 N.m (0.4 kgf.m, 4 lbf.ft), then back it off to the specified angle.

   Specified return angle: 15 ± 5°

6. Hold the rack guide screw stationary with a wrench, and tighten the locknut by hand until it's fully seated.
7. Install the locknut wrench on the locknut (B), and hold the rack guide screw stationary with a wrench. Tighten the locknut an additional 30° with the locknut wrench.
8. Check for unusual steering effort through the complete turning range.
9. Check the steering wheel rotation play (see STEERING WHEEL ROTATIONAL PLAY CHECK ) and the power assist (see STEERING WHEEL ROTATIONAL PLAY CHECK ).

Steering Gearbox Removal

Special Tools Required

• Ball joint remover, 28 mm 07MAC-SL0A202
• Engine hanger adapter VSB02C000015 *
• Engine support hanger, A and Reds AAR-T-12566 *
• Front subframe adapter VSB02C000016 *

  * Available through American Acura Tool and Equipment Program 1-888-424-6857

Note these items during removal:

• Using solvent and a brush, wash any oil and dirt off the valve body unit, it's lines, and the end of the gearbox. Blow dry with compressed air.
• Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.

1. Drain the power steering fluid (see FLUID REPLACEMENT ).
2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped), then write down the audio presets.
3. Make sure the ignition switch is OFF, then disconnect the negative cable from the battery.
4. Raise the vehicle, and support it with safety stands in the proper locations (see LIFT AND SUPPORT POINTS ).
5. Remove the front wheels.
6. Remove the steering wheel (see STEERING WHEEL REMOVAL ).
7. Remove the steering joint cover A.

   Fig. 56: Identifying Steering Joint Cover
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Release the lock lever, and adjust the steering column to the full tilt up position, and to the full telescopic in position.
9. Tighten the lock lever.
10. Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and joint yoke (D) of the upper shaft to prevent the slider shaft from pulling out.

    Fig. 57: Holding Lower Slide Shaft On Column With Piece Of Wire
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Release the lock lever, and adjust the steering column to the full telescopic out position, then tighten the lock lever.
12. Remove the steering joint bolt (A), and disconnect the steering joint by moving the steering joint (B) toward the column.

    Fig. 58: Identifying Steering Joint Bolt
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Remove the center guide (A) (if equipped), and discard it. The center guide is for factory assembly use only.

    Fig. 59: Identifying Center Guide, Steering Joint Cover And Cover Seal
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Remove the steering joint cover B. Be careful not to damage the mating surface on the joint cover B and pinion shaft grommet. Replace the cover seal (C) if necessary.
15. Remove the harness clamp (A) and hose (B), and remove the bolts (C) securing the hose clamps. Remove the mounting nuts (D) and strut brace (E).

    Fig. 60: Identifying Harness Clamp And Hose
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

16. To attach the engine hanger adapter (VSB02C000015), remove the clamp bracket.

    Fig. 61: Identifying Clamp Bracket
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Attach the engine hanger adapter (VSB02C000015) to the threaded hole in the cylinder head.

    Fig. 62: Identifying Engine Hanger Adapter (VSB02C000015) To Threaded Hole In Cylinder Head
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Install the engine support hanger (AAR-T-12566) to the vehicle, and attach the hook (A) to the engine hanger adapter (B). Tighten the wing nut (C) by hand, and lift and support the engine/transmission.

    Fig. 63: Identifying Engine Support Hanger (AAR-T-12566) To Vehicle
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

19. Remove and discard the cotter pin (A) from the tie-rod ball joint nut (B), then loosen the nut.

    Fig. 64: Identifying Tie-Rod Ball Joint Nut Cotter Pin
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Separate the tie-rod ball joints and knuckles using the ball joint remover (see BALL JOINT REMOVAL ).
21. Remove the P/S heat shield (A).

    Fig. 65: Identifying P/S Heat Shield
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Remove the splash shield (A) (see SPLASH SHIELD REPLACEMENT ).

    Fig. 66: Identifying Splash Shield And Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

23. Attach the front subframe adapter to the front suspension subframe (A) hang the hook of the front subframe adapter over the front of the subframe, then tighten the front subframe adapter screw.

    Fig. 67: Lifting Front Suspension Subframe
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

24. Raise the jack (B) and line up the slots in the arms with the bolt holes on the corner of the jack base, then attach them with bolts securely.
25. Remove the inlet line holder mounting bolt (A) on the front suspension subframe.

    Fig. 68: Identifying Inlet Line Holder Mounting Bolt
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

26. Remove the inlet line holder mounting bolt (B) and return hose (C) from the gearbox mounting bracket (D).
27. Place several shop towels under the line connections, and cover the gearbox mounting part to protect it from the power steering fluid. Loosen the flare nut (A), and disconnect the inlet line (B).

    Fig. 69: Identifying Flare Nut And Inlet Line
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

28. Loosen the flare nut (C), and disconnect the return line (D).
29. After disconnecting the lines, plug or seal them with a piece of tape or equivalent to prevent foreign materials from entering.

    NOTE:

    Do not loosen the cylinder line A and B between the valve body unit and the cylinder.

30. Remove the front suspension subframe right mid mount bolts (A).

    Fig. 70: Identifying Front Suspension Subframe Right Mid Mount Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

31. Remove the front suspension subframe left mid mount (A).

    Fig. 71: Identifying Front Suspension Subframe Left Mid Mount
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

32. Remove the steering gearbox mounting bolts on the left gearbox mount, and remove the steering stiffener plate (A).

    Fig. 72: Identifying Steering Stiffener Plate
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

33. Remove the front suspension subframe front bracket (A) from the body and the subframe.

    Fig. 73: Identifying Front Suspension Subframe Front Bracket
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

34. Remove the front suspension subframe rear bracket (A) mounting bolt (B).

    Fig. 74: Identifying Front Suspension Subframe Rear Bracket And Mounting Bolt
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

35. Loosen the two front suspension subframe mounting bolts (C) on the right and left, and slowly lower the jack supporting subframe (D) with the front subframe adapter until the subframe has dropped 30 mm (1 3/16 in.) total.
36. Remove the two flange bolts from the right side of the gearbox, then remove the gearbox mounting bracket (A) and cushion (B).

    Fig. 75: Identifying Gearbox Mounting Bracket And Cushion
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

37. Move the steering gearbox toward the front, and remove the pinion shaft grommet (A) from the top of the valve body unit.

    Fig. 76: Identifying Pinion Shaft Grommet
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

38. Apply vinyl tape (B) to the splines on the pinion shaft.
39. Apply vinyl tape or equivalent material (A) to the brake lines (B) to protect them from the pinion shaft.

    Fig. 77: Applying Vinyl Tape Or Equivalent Material To Brake Lines
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

40. Move the steering gearbox to the driver's side, and rotate it so the pinion shaft points toward the front of the vehicle.
41. Carefully move the steering gearbox as an assembly toward the driver's side of the vehicle until the pinion shaft clears the wheel well opening. Be careful not to damage the brake lines with the pinion shaft.

    Fig. 78: Identifying Steering Gearbox Assembly
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

42. Remove the steering gearbox through the wheel well opening on the driver's side.

    Fig. 79: Removing Steering Gearbox
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

43. After removing the steering gearbox, make sure that no power steering fluid gets on the gearbox mount cushions, gearbox housing, surface of the subframe and stiffener. Wipe off any spilled fluid at once.

Steering Gearbox Overhaul

Exploded View

Fig. 80: Exploded View Of Steering Gearbox W/Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Special Tools Required

• Cylinder end seal remover attachment 07NAD-SR3020A
• Pilot collar 07GAF-PH70100
• Valve seal ring sizing tool 07NAG-SR3090A
• Sleeve seal ring guide 07YAG-S2X0100
• Sleeve seal ring sizing tool, 36 mm 07ZAG-S5A0100
• Attachment, 32 x 35 mm 07746-0010100
• Driver 07749-0010000
• Piston seal ring guide 07HAG-SF10100
• Piston seal ring sizing tool 07HAG-SF1020A or 07HAG-SF10200
• Cylinder end seal slider 07ZAG-S5A0300
• Pincers Oetiker 1098 or equivalent, commercially available

NOTE:

Refer to the EXPLODED VIEW as needed during this procedure.

Removal

1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL ).

   Disassembly

2. Remove the boot bands (A) and tie-rod clips (B). Pull the boot away from the ends of the steering gearbox.

   Fig. 81: Identifying Boot Bands And Tie-Rod Clips
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Unbend the lock washers (A).

   Fig. 82: Identifying Lock Washers
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

4. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench.

   Fig. 83: Holding Flat Surface Sections Of Steering Rack With Wrench
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Remove the lock washer (D) and rubber stop (E).
6. Loosen the locknut (A), then remove the rack guide screw (B).

   Fig. 84: Identifying Rack Guide Screw And Locknut
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Remove the spring (C) and the rack guide (D) from the gearbox housing.
8. Remove the cylinder lines from the gearbox.

   Fig. 85: Removing Cylinder Lines From Gearbox
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
10. Remove the two flange bolts, then remove the valve body unit (A) from the gearbox housing (B). Remove the O-ring (C).

    Fig. 86: Identifying Valve Body Unit From Gearbox Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Drill a 3 mm (0.12 in.) diameter hole about 2.5-3.0 mm (0.10-0.12 in.) in depth in the staked point (A) on the cylinder. Do not allow metal shavings to enter the cylinder side on the gearbox housing. After removing the cylinder end (B), remove any burrs at the staked point.

    Fig. 87: Identifying Drill Hole
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

12. Hold the gearbox housing using a C-clamp (commercially available) (A) and the wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in the vise. Then remove the cylinder end (C).

    Fig. 88: Holding Gearbox Housing Using C-Clamp
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

13. Install a commercially available bearing separator (A) on the gearbox housing as shown.

    Fig. 89: Identifying Commercially Available Bearing Separator On Gearbox Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Place an appropriate size deep socket wrench (B) on the steering rack (C).
15. Set the steering gearbox in a press so the gearbox housing side points upward, then press the cylinder end seal (D) and steering rack out of the gearbox. Hold the steering rack to keep it from failing when pressed clear. Be careful not to damage the inner surface of the cylinder side on the gearbox housing with the tool.
16. Install the cylinder end seal remover attachment so it will fit through the rack guide hole of the gearbox housing. Insert a 24" long, 3/8" drive extension (A), and install it on the attachment. Make sure the attachment is securely positioned on the backup ring edges. Be careful not to damage the inner surface of the cylinder with the attachment.

    Fig. 90: Identifying Cylinder Seal
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

17. Place the steering gearbox in a press, then remove the cylinder end seal (A) and backup ring (B) from the gearbox housing by pressing on the 24" long, 3/8" drive extension.

    Note these items when pressing the cylinder end seal:

    • Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal.
    • Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool would break the backup ring, and the cylinder end seal would remain in the gearbox housing.

      Fig. 91: Identifying Cylinder Seal And Backup Ring
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.

    Fig. 92: Identifying Piston Seal Ring And O-Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

19. Before removing the valve housing (A), apply vinyl tape (B) to the splines on the pinion shaft.

    Fig. 93: Applying Vinyl Tape To Splines Of Pinion Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Separate the valve housing from the pinion shaft/ valve using a press.
21. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn. Replace it.

    NOTE:

    There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped.

    Fig. 94: Checking Inner Wall Of Valve Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Check for wear, burrs, and other damage to the edges of the grooves in the sleeve.

    NOTE:

    The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.

    Fig. 95: Checking Sleeve Grooves For Wear, Burrs And Other Damages
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

23. Remove the snap ring (A) and sleeve (B) from the pinion shaft.

    Fig. 96: Identifying Snap Ring And Sleeve From Pinion Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

24. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve. Be careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.

    Fig. 97: Identifying Seal Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

25. Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the cutting groove position (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring.

    Fig. 98: Identifying Valve Seal Ring And O-Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

26. Remove the valve oil seal (A) and wave washer (B) from the pinion shaft.

    Note these items during disassembly:

    • Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play or wear, replace the pinion shaft and sleeve as an assembly.
    • The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.

      Fig. 99: Identifying Valve Oil Seal And Wave Washer
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

27. Remove the valve oil seal (A) and roller bearing (B) out of the valve housing using a hydraulic press and pilot collar.

    Fig. 100: Removing Valve Oil Seal And Roller Bearing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

28. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in the solvent.

    Reassembly

29. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with power steering fluid.

    Fig. 101: Applying Vinyl Tape To Stepped Portion Of Pinion Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

30. Install the wave washer (B).
31. Coat the inside surface of the new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D).
32. Apply vinyl tape (A) to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with power steering fluid.

    Fig. 102: Applying Vinyl Tape To Splines And Stepped Portion Of Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

33. Fit the new O-ring (B) in the groove of the pinion shaft. Then slide the new valve seal ring (C) over the shaft and in the groove on the pinion shaft.
34. Remove the tape, and apply power steering fluid to the surface of the valve seal ring (A).

    Fig. 103: Applying Power Steering Fluid To Surface Of Valve Seal Ring
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

35. Apply power steering fluid to the inside of the valve seal ring sizing tool. Set the larger diameter end of the sizing tool over the valve seal ring, and move the sizing tool up and down several times to make the valve seal ring fit in the pinion shaft groove.
36. Remove the sizing tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fit snugly in the pinion shaft groove.
37. Apply power steering fluid to the surface of the sleeve seal ring guide. Slip two new seal rings (A) over the ring guide from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B).

    Note these items when installing the seal ring:

    • Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal rings using the sizing tool.
    • There are two types of sleeve seal rings; black and brown. Do not mix the different types of seal rings as they are not compatible.

      Fig. 104: Applying Power Steering Fluid To Surface Of Sleeve Seal Ring Guide
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

38. Align the ring guide with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.
39. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the sleeve seal ring sizing tool, then slowly insert the sleeve into the sizing tool.

    Fig. 105: Applying Power Steering Fluid To Seal Rings On Sleeve
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

40. Move the sleeve back and forth several times to make the seal rings fit snugly in the sleeve. Make sure the seal rings are not twisted.
41. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve.

    Fig. 106: Applying Power Steering Fluid To Surface Of Pinion Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

42. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press, driver, and the attachment. Install the seal with its grooved side facing the tool.

    Fig. 107: Applying Power Steering Fluid To Seal Ring Lip Of Valve Oil Seal
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

43. Press the roller bearing (C) into the valve housing with a hydraulic press, driver, and the attachment.
44. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid.

    Fig. 108: Applying Vinyl Tape To Pinion Shaft
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

45. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C) and valve oil seal sealing lip (D).
46. Remove the vinyl tape from the pinion shaft, then remove any residue of the tape adhesive.
47. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/ sleeve turns smoothly by hand after installing it.

    Fig. 109: Pressing Pinion Shaft/Sleeve Into Valve Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

48. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.
49. Position the new O-ring (A) and new piston seal ring (B) on the piston seal ring guide, then slide them down toward the big end of the tool.

    Note these items during reassembly:

    • Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the sizing tool.
    • Replace piston's O-ring and seal ring as a set.

      Fig. 110: Positioning O-Ring And Piston Seal Ring On Piston Seal Ring Guide
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

50. Pull the 0-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.
51. Coat the piston seal ring (A) and the inside of the piston seal ring sizing tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.

    Fig. 111: Coating Piston Seal Ring And Inside Of Piston Seal Ring Sizing Tool With Power Steering Fluid
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

52. Move the piston seal ring sizing tool back and forth several times to make the piston seal ring fit snugly in the piston.
53. Coat the sliding surface of the cylinder end seal slider (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.

    Fig. 112: Placing Seal On Cylinder Seal Slider With Its Grooved Side
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

54. Coat the surface of the steering rack (A) with power steering fluid.

    Fig. 113: Coating Surface Of Steering Rack With Power Steering Fluid
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

55. Install the cylinder end seal (B) onto the steering rack with its grooved side (C) toward the piston (D).
56. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.
57. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C).

    Fig. 114: Identifying Backup Ring On Steering Rack
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

58. Apply multipurpose grease to the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage the inner surface of the cylinder wall with the rack edges.

    Fig. 115: Applying Multipurpose Grease To Steering Rack Teeth
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

59. Insert an appropriate size deep socket wrench (A) onto the steering rack as shown.

    Fig. 116: Inserting Appropriate Size Deep Socket Wrench Onto Steering Rack
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

60. Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal.
61. Remove the tool, and center the steering rack.
62. Coat the sliding surface of the cylinder end seal slider (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.

    Fig. 117: Placing Seal On Cylinder Seal Slider With Grooved Side
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

63. Coat the inside surface of the cylinder end seal slider and steering rack with power steering fluid, then install the cylinder end seal (A) onto the steering rack with its grooved side toward the cylinder.

    Fig. 118: Coating Inside Surface Of Cylinder Seal Slider And Steering Rack With Power Steering Fluid
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

64. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.
65. Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.
66. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B). Do not clamp the cylinder part of the gearbox housing in the vise.

    Fig. 119: Holding Gearbox Housing Using C-Clamp
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

67. Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B). Tighten the cylinder end to the specified torque.

    Fig. 120: Tightening Cylinder Locknut W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

68. Stake the point of the cylinder shown (opposite from where the stake was removed during disassembly).
69. Coat the new O-ring (A) with multipurpose grease, and carefully fit it on the valve housing.

    Fig. 121: Coating O-Ring With Multipurpose Grease On Valve Housing W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

70. Apply multipurpose grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections).
71. Tighten the flange bolts (D) to the specified torque.
72. Install the cylinder lines.

    Note these items during reassembly:

    • Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material.
    • Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.

      Fig. 122: Tightening Flange Bolts W/Torque Specifications
      Courtesy of AMERICAN HONDA MOTOR CO., INC.

73. Apply multipurpose grease to the sliding surface and circumference of the rack guide (A), and install it onto the gearbox housing. Wipe the grease off the threaded section of the housing.

    Fig. 123: Identifying Rack Guide Screw W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

74. Remove the old sealant from the rack guide screw (B), then apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads. Install the rack guide, the spring (C), rack guide screw, and locknut (D).
75. Adjust the rack guide screw (see RACK GUIDE ADJUSTMENT ). After adjusting, check that the rack moves smoothly by sliding it right and left.

    NOTE:

    If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.

76. Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.

    Fig. 124: Identifying Lock Washer W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

77. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.
78. Bend the lock washer (A) back against the flat spots on the rack end joint housing.

    Fig. 125: Identifying Lock Washer
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

79. Apply multipurpose grease to the circumference of the rack end joint housing (A).

    Fig. 126: Applying Multipurpose Grease To Circumference Of Rack Joint Housing
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

80. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends.
81. Center the steering rack within its stroke.
82. Clean off any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.

    Fig. 127: Identifying Tie-Rod Clips And Boots
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

83. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
84. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.

    Fig. 128: Aligning Tabs With Holes Of Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

85. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincers or equivalent (B).

    Fig. 129: Closing Portion Of Band
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

86. Slide the rack right and left to be certain that the boots are not deformed or twisted.
87. Reinstall the steering gearbox (see STEERING GEARBOX INSTALLATION ).

Steering Gearbox Installation

1. Before installing the steering gearbox, make sure that no power steering fluid is on the mating surface of the gearbox and the front suspension subframe. To prevent the gearbox mounting bolts from loosening after the installation, remove the power steering fluid from the mount cushions and bolt holes.
2. Apply a mild soap and water solution to both sides of the mount cushion mating surfaces (A).

   Fig. 130: Identifying Mount Cushion Mating Surfaces
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Pass the cylinder of the steering gearbox (B) through the wheel well opening on the driver's side.
4. Carefully move the steering gearbox toward the passenger's side until the pinion shaft clears the wheel well opening on the body.
5. Rotate the steering gearbox so the pinion shaft (A) points upward.

   Fig. 131: Identifying Pinion Shaft Points Upward
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

6. Continue moving the gearbox toward the passenger's side until the steering gearbox is in position. Make sure the power steering return line and inlet line are routed above the gearbox.
7. Remove the vinyl tape from the pinion shaft, and install the pinion shaft grommet (A). Align the slot in the pinion shaft grommet with the lug portion (B) on the valve housing.

   Fig. 132: Identifying Pinion Shaft Grommet
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

8. Position the cutout (A) on the mounting cushion (B) as shown, and install it on the cylinder of the gearbox securely.

   Fig. 133: Identifying Mounting Cushion W/Torque Specification
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

9. Install the gearbox mounting bracket (C) over the mounting cushion, and loosely install the two flange bolts.
10. Install the steering stiffener plate (A) and gearbox mounting bolts on the left side of the gearbox, then tighten them to the specified torque.

    Fig. 134: Identifying Steering Stiffener Plate W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

11. Tighten the flange bolts on the right side of the gearbox to the specified torque alternately in two or more steps.
12. Loosely connect the return line and inlet line by hand securely.
13. Install the inlet line holder (A) and return hose (B) on the gearbox mounting bracket (C).

    Fig. 135: Identifying Inlet Line Holder And Return Hose On Gearbox Mounting Bracket W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

14. Install the inlet line holder (D) on the front suspension subframe. Make sure that there is no interference between the inlet and return lines and any other parts.
15. Tighten the return line flare nut (A) to the specified torque.

    Fig. 136: Tightening Return Line Flare Nut W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

16. Tighten the inlet line flare nut (B) to the specified torque.
17. Raise the jack supporting the front suspension subframe (A) (see SUBFRAME REPLACEMENT ).

    Fig. 137: Supporting Front Suspension Subframe W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

18. Install the front suspension subframe rear bracket (B). Tighten the new 12 mm flange bolt (C) and the new 14 mm special bolt (D).
19. Install the front suspension subframe front bracket (A) with the 12 mm flange bolts (B) and a new 14 mm special bolts (C), and tighten them to the specified torque.

    Fig. 138: Identifying Front Suspension Subframe Front Bracket W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

20. Install the new front suspension subframe left mid mount bolts (A) and mount bolts (B).

    Fig. 139: Identifying Front Suspension Subframe Left Mid Mount Bolts W/Torque Specifications
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

21. Install the new front suspension subframe right mid mount bolts (A).

    Fig. 140: Identifying Front Suspension Subframe Right Mid Mount Bolts W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

22. Install the splash shield (A) (see SPLASH SHIELD REPLACEMENT ).

    Fig. 141: Identifying Splash Shield And Bolts
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

23. Install the P/S heat shield (A).

    Fig. 142: Identifying P/S Heat Shield W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

24. Wipe off any grease contamination from the ball joint tapered section and threads. Reconnect the tie-rod ball joints (A) to the knuckles.

    Fig. 143: Identifying Tie-Rod Ball Joints And Knuckles W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

25. Install the tie-rod end ball joint nut, and tighten it to the specified torque. Install the new cotter pin (B), and bend it as shown (C) or (D).
26. Remove the engine hanger adapter, and the engine support hanger.
27. Install the front wheel, then set the wheels in the straight ahead position.

    NOTE:

    Before installing the wheel, clean the mating surfaces of the brake disc and inside of the wheel.

28. Lower the vehicle.
29. Install the new cover seal (A) all the way around in the steering joint cover B. Make sure there are no wrinkles in the seal, then install the steering joint cover B.

    Fig. 144: Identifying Cover Seal W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

30. Center the steering rack within its stroke.
31. Position the steering column joint (A) so the bolt (B) opposite to the notch (C) is within the range shown.

    Fig. 145: Positioning Steering Column Joint
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

32. With the rack in the straight ahead driving position, cut the wire (D) and slip the lower end of the steering joint onto the pinion shaft (E).
33. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, and loosely install the joint bolt (C). Make sure the joint bolt is securely in the groove in the pinion shaft. Pull on the steering joint to make sure the steering joint is fully seated.

    Fig. 146: Aligning Bolt Hole On Steering Joint With Groove W/Torque Specification
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

34. Tighten the steering joint bolt to the specified torque.
35. Install the steering joint cover A.

    Fig. 147: Identifying Steering Joint Cover
    Courtesy of AMERICAN HONDA MOTOR CO., INC.

36. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about three full turns) until the arrow mark on the label points straight up. Reinstall the steering wheel (see STEERING WHEEL INSTALLATION ).
37. Reconnect the negative battery cable to the battery, and do these tasks:
    • Turn the ignition switch ON (II); the SRS indicator should come on for about 6 seconds and then go off.
    • Enter the anti-theft code for the audio system and the navigation system (if equipped), then enter the client's audio presets.
    • Set the clock (on vehicles without navigation).
    • Make sure the horn and turn signal switches work properly.
    • Make sure the steering wheel switches work properly.
38. Fill the system with power steering fluid, and bleed air from the system (see FLUID REPLACEMENT ).
39. After installation, do these checks:
    • Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks (see FLUID LEAKAGE INSPECTION ).
    • Check the steering wheel spoke angle.

      If steering spoke angles to the right and left are not equal (steeling wheel and rack are not centered), correct the engagement of the joint/ pinion shaft serrations.

    • Set the steering column to the center tilt position, and to the center telescopic position, then do the front toe inspection/adjustment (see WHEEL ALIGNMENT ).

Tie-rod Ball Joint Boot Replacement

Special Tools Required

Front hub disassembly tool 07965-SA50500

1. Disconnect the tie-rod ball joint from the knuckle (see step 19 in STEERING GEARBOX REMOVAL ).
2. Remove the tie-rod end from the rack end.
3. Remove the tie-rod ball joint boot from the tie-rod end, and wipe the old grease off the ball pin.
4. Pack the lower area of the ball pin (A) with fresh multipurpose grease.

   Fig. 148: Identifying Grease Applying Area
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Pack the interior of the new tie-rod ball joint boot (B) and lip (C) with fresh multipurpose grease.

   Note these items when installing new grease:

   • Keep grease off the boot mounting area (D) and the tapered section (E) of the ball pin.
   • Do not allow dust, dirt, or other foreign materials to enter the boot.
6. Install the new tie-rod ball joint boot (A) using the front hub disassembly tool. The boot must not have a gap at the boot installation sections (B). After installing the boot, check the ball pin tapered section for grease contamination, and wipe it if necessary.

   Fig. 149: Identifying Tie-Rod Ball Joint Boot With Front Hub Disassembly Tool
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

7. Install the tie-rod end to the rack end.
8. Connect the tie-rod ball joint from the knuckle (see step 24 ).
9. Check the wheel alignment, and adjustment it if necessary (see WHEEL ALIGNMENT ).

Gearbox Mount Cushion Replacement

1. Remove the steering gearbox (see STEERING GEARBOX REMOVAL ).
2. Position the 34 mm socket wrench (A) on the flange part of the gearbox housing with a washer (B), a 10 x 105 mm flange bolt (C) and a 10 mm nut (D) as shown.

   Fig. 150: Identifying Socket Wrench On Flange
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

3. Hold the flange bolt with a wrench, and tighten the nut With a wrench. Remove the gearbox mount cushion (E).
4. Apply a mild soap and water solution to the new gearbox mount cushion surface (A), then place it on the gearbox mounting cushion hole.

   Fig. 151: Identifying Socket Wrench
   Courtesy of AMERICAN HONDA MOTOR CO., INC.

5. Position the 34 mm socket wrench on the flange part of the gearbox housing with a washer, a flange bolt, and a nut as shown.
6. Install the gearbox mount cushion by tightening the nut until the mount cushion edges (B) contact the gearbox flange surface.
7. Install the steering gearbox (see STEERING GEARBOX INSTALLATION ).

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