Civic Wagon 4WD L4-1590cc 1.6L SOHC (D16A6) MFI (1989)
_mfi/Page-897003.png)
18.
Remove circlip and cylinder cap from seal retainer, then the two 37.5mm O-rings from cylinder cap.
19.
Remove rack bushing B from seal retainer, then cylinder end seal.
20.
Carefully remove piston seal ring using a suitable screwdriver, then the 27.5mm O-ring.
ASSEMBLE
Fig. 5 Rack Installation
1.
Prior to assembly, clean all disassembled parts, replace all O-rings and seals.
2.
Install 27.5mm O-ring in rack groove with narrow edge facing out, then piston seal ring using suitable tool.
3.
Coat piston seal ring and suitable sizing tool with power steering fluid. Slide tool onto rack and over piston seal ring, then rotate tool to break in
piston ring.
4.
Install both 37.5mm O-rings onto cylinder cap, then slide cylinder cap onto seal retainer.
5.
Install ring stopper or circlip and 24.9mm O-ring on seal retainer.
6.
Install rack bushing B with groove facing steering rack piston.
7.
Coat end seal slider tool and cylinder end seal with a suitable grease, then install end seal on slider tool with groove toward tool.
8.
Coat rack and teeth with a suitable grease, then install tool on steering rack. Face rack teeth away from slider tool slot, Fig. 5.
9.
Remove slider tool, then install seal retainer on steering rack.
10.
Push rack bushing B into seal retainer.
11.
Install the 46.5mm O-ring and retainer washer into gear housing.
12.
Place gear housing in a suitable vise and press seal retainer and steering rack into gear housing.
13.
Coat cylinder barrel with power steering fluid and slide barrel over rack into gear housing until it seats.
14.
Place end seal guide tool onto steering rack, then install cylinder spring over rack.
15.
Coat rack bushing A with power steering fluid and install it on cylinder spring.
16.
Coat inside of cylinder with power steering fluid and install cylinder end seal with groove facing out.
17.
Coat end seal guide tool with a suitable grease, then slide cylinder over rack onto gear housing.
18.
Push steering rack into cylinder to prevent damage to steering rack.
19.
Torque cylinder bolts to gear housing to 16 ft. lbs.
20.
Using a suitable press, install bearing on pinion with seal side facing down.
21.
Install 12mm snap ring on pinion, ensure pinion bearing turns smoothly.
22.
Install pinion assembly into pinion holder in gear housing.
23.
Install 28mm snap ring in groove in pinion, with taper side facing out.
24.
Coat 46.5mm O-ring with a suitable grease and install it into groove of housing cap.
25.
Torque housing cap attaching bolts to 8 ft. lbs. Arrow on housing cap must face toward front of car when gear box is installed.
26.
Coat rack guide with a suitable grease, then install rack guide, spring, O-ring and rack guide screw into gear housing.
27.
Install locknut on rack guide screw finger tight.
28.
Tighten guide screw until it seats against guide, then loosen it. Torque guide screw to 3 ft. lbs. and back off 1/10 of a turn.
29.
While holding guide screw, torque locknut to 18 ft. lbs.
30.
Install tie rod, torque to 42 ft. lbs., then bend lock washers against flat on flange.
31.
Install boots and bands.
