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Electrical Power Steering System (Eps): Removal & Installation Honda S2000 AP1

Electronic Steering 40 illustrations ~1863 words

Steering Gearbox Removal and Installation

Special Tools Required

  1. Ball joint thread protector, 12 mm 07AAF-SDAA100
  2. Ball joint remover, 28 mm 07MAC-SL0A202

Removal

Note these items during removal

  1. Using solvent and a brush, wash any oil and dirt off the gearbox. Blow dry with compressed air.
  2. Be sure to remove the steering wheel before disconnecting the steering joint. Damage to the cable reel can occur.

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  1. Do the battery terminal disconnection procedure {see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
  2. Raise the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-221314-S10900723812006022400000) ).
  3. Remove the front wheels.
  4. Remove the driver's airbag: '00-05 models (see «DRIVER'S AIRBAG REPLACEMENT»(ref-351949-S23129439232009122900000) ) '06-09 models (see «DRIVER'S AIRBAG REPLACEMENT»(ref-351949-S23129439232009122900000) )
  5. Remove the steering wheel (see «STEERING GEARBOX OVERHAUL»(ref-351951-S19441781852009122900000) ).
  6. '00-07 models; place a mark (A) on the steering joint (B) and the pinion shaft (C) to identify the position of the joint on the pinion shaft.
  7. Remove the lower joint bolt (D) from the steering joint.
  8. Loosen the upper joint bolt (E) on the steering joint, and pull the steering joint fully to the steering shaft (F) side.
  9. Under the dashboard; loosen the joint bolt (A) on the column, and pull the steering shaft (B) fully to the column side.
  10. In the engine compartment; disconnect the steering joint (A) and pinion shaft (B) by moving the steering joint toward the steering shaft (C).
  11. Remove and discard the cotter pin (A) from the 12 mm nut (B), then remove the nut.
  12. Separate the tie-rod ball joint and knuckle using the ball joint remover (see «BALL JOINT REMOVAL»(ref-221354-S20922790902006022400000) ).
  13. Remove the seven clips (A) and the two flange bolts (B), then remove the splash shield (C).
  14. Remove the stabilizer bar holder brackets (A) from the frame, and lower the stabilizer bar (B).
  15. Disconnect the ground cable (A) and motor 2P connector (B). Loosen the harness band (C), and release the wire harness (D) from the gearbox. After disconnecting the connector, put a piece of tape over the steering gearbox connector to protect it from dust, dirt, and foreign materials.
  16. Disconnect the torque sensor 3P connector (A). After disconnecting the connector, put a piece of tape over the steering gearbox connector to protect it from dust, dirt, and foreign materials.
  17. Except CR model: Remove the gearbox mounting bolts. Right side: Left side
  18. CR model: Remove the gearbox mounting bolts, steering gearbox front stiffener (A), and steering gearbox rear stiffener (B). Front side: Rear side
  19. Pull the steering gearbox toward the front. Move the steering gearbox to the passenger's side and remove it.

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Scheme 70: Installation
Scheme 70: Installation

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  1. Before installing the gearbox, center the steering rack within its stroke.
  2. Pass the driver's side of the steering gearbox through the right wheel housing. Place the steering gearbox on the front subframe, and move it into the original position.
  3. Except CR model: Install the gearbox mounting bolts. Right side: Left side
  4. CR model: Install the gearbox mounting bolts, steering gearbox front stiffener (A), and steering gearbox rear stiffener (B). Front side: Rear side
  5. Connect the torque sensor 3P connector (A).
  6. Connect the motor 2P connector (A) and ground cable (B). Secure the wire harness (C) with the harness band (D).
  7. Raise the stabilizer bar (A) to the original position, and install the stabilizer bar holder brackets (B).
  8. Install the splash shield (A) with the seven clips (B) and two flange bolts (C).
  9. Wipe off any grease contamination from the tapered section and threads of the ball joint. Then reconnect the tie-rod ends (A) to the steering knuckles (B), and tighten the 12 mm nut (C) to the specified torque.
  10. Install the new cotter pins (D), and bend them as shown.
  11. From the engine compartment, slip the lower end (A) of the steering joint (B) by aligning the marks (C) on the pinion shaft (D) and joint.
  12. From the under the dashboard, push the steering shaft (A) fully to engine compartment side, but do not push excessively on the steering shaft. Then tighten the joint bolt (B) to the specified torque. '00 model U.S.A. models VIN JHMAP 114-YT000001 thru VIN JHMAP 114-YT008411 Canada models VIN JHMAP 114-YT800001 thru VIN JHMAP 114-YT800750 Torque: 22 N.m (2.2 kgf.m, 16 lbf.ft) Other models: Torque: 29 N.m (3.0 kgf.m, 22 lbf.ft)
  13. Line up the bolt hole (A) with the groove around (B) the pinion shaft, and install the lower joint bolt (C) and the upper joint bolt (D) to the specified torque. '00 model U.S.A models VIN JHMAP114-YT000001 thru VIN JHMAP 114-YT008411 Canada models VIN JHMAP 114-YT800001 thru VIN JHMAP 114-YT800750 Torque: 22 N.m (2.2 kgf.m, 16 lbf.ft) Other models: Torque: 29 N.m (3.0 kgf.m, 22 lbf.ft)
  14. Install the steering wheel (see «STEERING WHEEL INSTALLATION»(ref-221352-S03813849852006022400000) ).
  15. Install the driver's airbag: '00-05 models (see «INSTALLATION ('00-05 MODELS)»(ref-351949-S11637309442009122900000) ) '06-09 models (see «INSTALLATION ('06-09 MODELS)»(ref-351949-S13373170412009122900000) )
  16. Install the front wheels, and adjust the front wheel alignment (see «FRONT AND REAR SUSPENSION (WHEEL ALIGNMENT)»(ref-221354) ).
  17. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ). Turn the ignition switch to ON (II), and check that the SRS indicator comes on for about 6 seconds and then goes off. Make sure the horn and turn signal switches work properly. Make sure the steering wheel switches work properly.
  18. After Installation, do the following checks: Check the steering wheel spoke angle. If 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 splines. Set the steering column to the center tilt position, and to the center telescopic position, do the front toe inspection (see «FRONT TOE INSPECTION/ADJUSTMENT»(ref-221354-S28530634182006022400000) ). Make sure the steering wheel spokes are centered. Do the memorizing the torque sensor neutral position (see «MEMORIZING THE TORQUE SENSOR NEUTRAL POSITION»(ref-351951-S39897370852009122900000) ). Start the engine, and let it idle. Turn the steering wheel from lock-to-lock several times. Check that the EPS indicator does not come on.

Rack Guide Removal/Installation

Note. During removal/installation, do not allow dust, dirt, or other foreign materials to enter the gearbox.

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Scheme 83: Rack Guide Removal/Installation
Scheme 83: Rack Guide Removal/Installation
  1. Loosen the locknut (A), then remove the rack guide screw (B), the spring (C), and the rack guide (D).
  2. Apply multipurpose grease to the sliding surface of the rack guide, and install it onto the gearbox housing.
  3. Coat the new O-ring (E) with multipurpose grease, and carefully fit it on the rack guide screw groove.
  4. Install the spring, the rack guide screw, and the locknut.
  5. Adjust the rack guide screw (see «RACK GUIDE ADJUSTMENT»(ref-221352-S06042619742006022400000) ). After adjusting, check that the rack moves smoothly by sliding the rack right and left.

Rack End Removal and Installation

Special Tools Required

  1. Attachment, 32 x 35 mm 07746-0010100
  2. Driver handle 07749-0010000

Note. Do not allow dust, dirt, or other foreign materials to enter the gearbox. Do not disassemble the steering gearbox assembly (motor). If the motor is faulty, replace it as an assembly.

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Scheme 84: Removal
Scheme 84: Removal

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  1. Remove the boot bands (A) and discard them. Remove the tie-rod clips (B), and pull the boots away from the ends of the steering gearbox. NOTE: After removing the boot, check for water, dirt, or other foreign matter on the ball screw surface (C) and interior of the boot. If contaminated, clean the ball screw, gearbox housing, and boot completely.
  2. Unbend the lock washer.
  3. Hold the flat surface sections (A) on the passenger's side steering rack shaft with one wrench, and unscrew both rack ends (B) with another wrench. Be careful not to damage the shaft surface with the wrench. Remove the lock washers (C) and discard them.
  4. Check the rubber stop (A) for damage or deterioration. If the rubber stop is damaged or deteriorated, replace it. Grasp the left rack end, and pull the rack shaft all the way to the left. Carefully remove the rubber stop by prying it out of the gearbox housing (B) with a flat tip screwdriver (C) on the cut-out portion (D) so as not to damage the housing.
  5. If the rubber stop was removed, position a new rubber stop (A) in the gearbox housing, then drive it in using the attachment and the driver as shown. Make sure that the attachment and the driver presses against the metal portion (B) of the rubber stop.

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Scheme 89: Installation
Scheme 89: Installation

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  1. Install the new lock washer (A) on the rack shaft. Align the lock washer tabs (B) with the slots (C) in the rack shaft. Install the rack end (D) while holding the lock washer in place. Repeat this step for the other side of the rack shaft.
  2. Hold the flat surface sections (E) on the steering rack shaft with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the shaft surface with the wrench.
  3. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
  4. Apply multipurpose grease to the circumference (A) of the rack end joint housing.
  5. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends. NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
  6. Center the steering rack within its stroke. Install the boots (A) in the rack end with the tie-rod clips (B). Clean off any grease or contamination from the groove around (C) on the housing.
  7. After installing the boots, wipe the grease off the thread section (D) of the rack end.
  8. Install the new boot band (A) by aligning the tabs (B) with holes (C) of the band.
  9. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincers or equivalent (B).
  10. Slide the rack right and left to be certain that the boots are not deformed or twisted.

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Scheme 94: Gearbox Bracket Removal/Installation
Scheme 94: Gearbox Bracket Removal/Installation

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  1. Remove the bracket clamp bolt (A) from the gearbox bracket (B), then pry open the bracket to remove it from the gearbox.
  2. Install the gearbox bracket on the gearbox with the bracket clamp bolt toward the rear.
  3. Adjust the distance between the bracket mounting bolt hole (A) and the gearbox mounting bolt hole (B) to the dimension shown. Make sure the bracket mounting bolt holes are parallel with gearbox mounting bolt holes.
  4. Install the bracket clamp bolt, and tighten it to 25 N.m (2.5 kgf.m, 18 lbf.ft).

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Scheme 96: EPS Control Unit Removal/Installation
Scheme 96: EPS Control Unit Removal/Installation
  1. Do the battery terminal disconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).
  2. Remove the EPS control unit.
  3. Disconnect the EPS control unit connectors.
  4. Install the EPS control unit in the reverse order of removal. NOTE: If the EPS control unit is replaced, the EPS control unit must memorize the torque sensor neutral position (see «MEMORIZING THE TORQUE SENSOR NEUTRAL POSITION»(ref-351951-S39897370852009122900000) ).
  5. Do the battery terminal reconnection procedure (see «BATTERY TERMINAL DISCONNECTION AND RECONNECTION»(ref-221385-S11486664822009111300000) ).

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