ACURA RL KA9 1996 Service Repair Manual

9. Instal l th e backu p rin g ('9 6 - 9 8 models ) o r wav e
washe r ('9 9 - 0 1 models) .
10 . Coa t th e insid e surfac e o f th e ne w valv e oi l sea l
with powe r steerin g fluid .
11. Slid e th e valv e oi l sea l ove r th e pinio n shaft , bein g
carefu l no t t o damag e th e sealin g lip .
CAUTION : Instal l th e valv e oi l sea l wit h it s groove d
sid e facin g opposit e th e bearing . 16
. Appl y powe r steerin g flui d t o th e insid e o f th e spe -
cia l tool . Se t th e large r diamete r en d o f th e specia l
too l ove r th e valv e sea l ring .
17 . Mov e th e specia l too l u p an d dow n severa l time s t o
mak e th e valv e sea l rin g fi t i n th e pinio n shaft .
18 . Remov e th e specia l tool .
19 . Tur n th e specia l too l over , an d se t th e smalle r diame -
te r en d o f th e specia l too l ove r th e valv e sea l ring .
Mov e th e specia l too l u p an d dow n severa l time s t o
mak e th e valv e sea l rin g fi t snugl y in th e pinio n shaft .
13
. Fi t th e ne w O-rin g i n th e groov e o f th e pinio n shaft .
The n slid e th e ne w valv e sea l rin g ove r th e shaf t
an d th e groov e in o n th e pinio n shaft .
14 . Remov e th e viny l tap e fro m th e pinio n shaft .
15 . Appl y powe r steerin g flui d t o th e surfac e o f th e
valv e sea l rin g tha t wa s installe d o n th e pinio n shaft .
PISTO N SEA L RIN G
SIZIN G TOO L
07NA G - SR3090 0 o r
07NAG-SR3090 A
8. Appl y viny l tap e t o th e steppe d portio n o f th e pin -
io n shaft , an d coa t th e surfac e o f th e viny l tap e wit h
the powe r steerin g fluid .
Reassembl y (cont'd )
7. Pres s th e ne w rolle r bearin g int o th e valv e housin g
usin g a hydrauli c pres s an d th e specia l tool s a s shown .
NOTE : Plac e th e rolle r bearin g o n th e valv e hous -
in g wit h th e stampe d lette r facin g u p toward s th e
valv e side .
DRIVE R07749-001000 0ATTACHMENT ,32 x 35 m m07746-001010 0
12. Appl y viny l tap e t o th e spline s an d steppe d portio n
o f th e shaft , an d coa t th e surfac e o f th e viny l tap e
with th e powe r steerin g fluid .
Powe r Steerin g Gearbo x
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SLEEVE SEA L RIN G GUID E07SAG - SW5010 0 o r07SA G - SW5010 A27. Inser t th e pinio n shaf t int o th e valv e housing .
CAUTION : B e carefu l no t t o damag e th e valv e sea l
rings .
28. Remov e th e viny l tap e fro m th e pinio n shaft .
(cont'd )
20. Appl y powe r steerin g flui d t o th e surfac e o f th e pin -
io n shaft . Assembl e th e sleev e ove r th e pinio n shaf t
b y alignin g th e locatin g pi n o n th e insid e of the
sleev e wit h th e cutou t i n th e shaft . The n instal l th e
ne w sna p rin g securel y in th e pinio n shaf t groove .
NOTE:
• B e carefu l no t t o damag e th e valv e sea l rin g
whe n insertin g th e sleeve .
• Instal l th e sna p rin g wit h it s radiuse d sid e facin g
in.
23 . Appl y powe r steerin g flui d t o th e sea l ring s o n th e
sleeve , an d t o th e entir e insid e surfac e o f th e spe -
cia l tool .
PISTO N SEA L RIN GSIZIN G TOO L07GA G - SD4020 0
o r 07GA G - SD4020 A
24. Inser t th e sleev e int o th e specia l too l slowly .
25 . Mov e th e sleev e eac h directio n severa l time s t o
mak e th e sea l ring s snugl y fi t i n th e sleeve .
NOTE : B e sur e tha t th e sea l ring s ar e no t turne d up .
26 . Appl y viny l tap e t o th e pinio n shaft , the n coa t th e
viny l tap e wit h powe r steerin g fluid .
21 . Appl y powe r steerin g flui d to th e surfac e o f th e spe -
cia l tool . Se t th e ne w sea l ring s ove r th e specia l too l
fro m th e smalle r diamete r en d o f th e tool , an d
expan d th e sea l rings .
NOTE :
• D o no t over-expan d th e sea l ring . Instal l th e resi n
sea l ring s wit h car e s o a s no t t o damag e them .
Afte r installation , b e sur e t o contrac t th e sea l
ring s usin g th e specia l too l (sizin g tool) .
• Ther e ar e tw o type s o f sleev e sea l rings : blac k
an d brown . D o no t mi x th e differen t type s of
sleev e sea l ring s a s the y ar e no t compatible .
22 . Se t th e specia l too l i n th e groove s in th e sleeve , an d
se t eac h rin g in eac h groov e securely .
NOTE : Afte r installation , compres s th e sea l ring s
wit h you r finger s temporarily .
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33. Positio n th e ne w O-rin g an d ne w pisto n sea l rin g o n
th e specia l tool , the n slid e the m dow n towar d th e
bi g en d o f th e tool .
NOTE :
• D o no t ove r expan d th e resi n sea l rings . Instal l
th e resi n sea l ring s wit h car e s o a s no t t o dam -
ag e them . Afte r installation , b e sur e t o contrac t
th e sea l rin g usin g th e specia l too l (sizin g tool) .
• Replac e piston' s O-rin g an d sea l rin g a s a set .
34 . Pul l th e O-rin g of f int o th e pisto n groove , the n pul l
th e pisto n sea l rin g of f int o th e pisto n groov e o n to p
of th e O-ring .
PISTON SEA L RIN GGUID E07LAG - SM4010 0 o r
07LA G - SM4010 A
32. Coa t th e pisto n sea l rin g guid e wit h powe r steerin g
fluid , an d slid e it ont o th e rack , bi g en d first .
30 . Appl y steerin g greas e o n th e valv e oi l seal , an d
instal l th e pinio n dus t cove r o n th e valv e bod y unit .
Steerin g Rac k Installatio n
31. I f th e rubbe r sto p wa s removed , positio n th e ne w
rubbe r sto p in th e gearbo x housing , the n pres s it i n
usin g a hydrauli c pres s an d th e specia l tool s a s
shown .
NOTE: Mak e sur e tha t th e specia l too l presse s
agains t th e meta l portio n o f th e rubbe r stop .
Powe r Steerin g Gearbo x
Reassembl y (cont'd )
29. Pres s th e pinio n shaft/sleev e int o th e valv e housin g
usin g a hydrauli c pres s a s shown .
DRIVER07749-001000 0
ATTACHMENT ,32 x 35 m m07746-001010 0
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40. Instal l th e cylinde r en d sea l ont o th e steerin g rac k
wit h it s groove d sid e towar d th e piston .
CAUTION : Whe n installin g th e cylinde r en d seal ,
b e carefu l no t t o damag e th e sealin g li p fac e o f th e
sea l wit h th e edge s o r teet h o f th e steerin g rack .
41 . Remov e th e viny l tap e fro m th e steerin g rack .
Remov e an y residu e o f tap e adhesive .
42 . Instal l th e ne w backu p rin g o n th e steerin g rack ,
the n plac e th e cylinde r en d sea l t o piston .
36
. Carefull y slid e th e too l ont o th e rac k an d ove r th e
pisto n sea l ring .
37 . Mov e th e specia l too l bac k an d fort h severa l time s
t o mak e th e pisto n sea l rin g fi t snugl y i n th e piston .
38 . Wra p viny l tap e aroun d th e rac k teet h an d rac k en d
edges , the n coa t th e surfac e of the tap e wit h th e
powe r steerin g fluid .
NOTE : Mak e sur e tha t th e viny l tap e i s wrappe d
carefull y s o tha t ther e is n o steppe d portion .
PISTON SEA L RIN GSIZIN G TOO L07LAG-SM4020 0 o r07LA G-SM4020 A
39. Coa t th e insid e surfac e o f th e ne w cylinde r en d sea l
with powe r steerin g fluid .
35. Coa t th e pisto n sea l rin g an d th e insid e o f th e specia l
tool wit h powe r steerin g fluid .
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44. Inser t 6 " lon g 3/8 " driv e extensio n an d th e specia l
too l int o th e steerin g rac k a s shown .
45. Instal l th e cylinde r en d sea l int o th e botto m o f th e
cylinde r b y pressin g o n th e too l wit h a pres s a s
shown .
CAUTION : D o no t pus h o n th e too l wit h excessiv e
forc e a s it ma y damag e th e cylinde r en d seal . 47
. Coa t th e insid e surfac e o f th e ne w cylinde r en d sea l
with powe r steerin g fluid .
48. Instal l th e cylinde r en d sea l ont o th e steerin g rac k
wit h it s groove d sid e towar d th e piston .
CAUTION : Whe n installin g th e cylinde r en d seal ,
b e carefu l no t t o damag e th e sealin g li p fac e o f th e
sea l wit h th e edge s o f th e steerin g rack .
49 . Remov e th e vinyl tape fro m th e steerin g rack , the n
pus h i n th e cylinde r en d sea l wit h you r finger .
NOTE:
• Remov e an y residu e o f tap e adhesive .
• Tak e car e no t t o damag e th e cylinde r en d sea l
wit h th e thread s an d burr s a t th e stake d positio n
o f th e gearbo x housing .
50 . Instal l th e specia l too l t o th e gearbo x housing , the n
clam p th e too l i n a vis e wit h sof t jaw s a s shown .
CAUTION : D o no t clam p th e cylinder .
CYLINDE R EN D SEA LREMOVE R ATTACHMEN T07NAD-SR3020 A
Power Steerin g Gearbo x
Reassembl y (cont'd )
43. Greas e th e steerin g rac k teeth , the n inser t th e steer -
in g rac k int o th e gearbo x housing .
CAUTION : B e carefu l no t t o damag e t o inne r sur -
fac e o f th e cylinde r wal l wit h th e rac k edges . 46
. Wra p viny l tap e aroun d th e rac k en d edges , an d
coa t th e surfac e o f th e tap e wit h th e powe r steerin g
fluid.
NOTE : Mak e sur e tha t th e viny l tap e is wrappe d care -
full y s o tha t ther e i s n o steppe d portion .
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51. Coa t th e insid e surfac e o f th e cylinde r en d wit h
powe r steerin g fluid , the n instal l th e cylinde r en d b y
screwin g it int o th e gearbo x housing .
52 . Remov e th e too l fro m th e gearbo x housing .
53 . Afte r tightenin g th e cylinde r end , stak e th e poin t o f
th e cylinde r show n below . Fo r '9 9 - 0 1 model s g o t o
ste p 56 .
NOTE : Stak e th e cylinde r i n th e positio n opposit e
fro m wher e th e stak e wa s remove d durin g disas -
sembly . 54
. Selec t th e 4 4 m m shim(s ) ('9 6 - 9 8 model s only) .
NOTE : Onl y reinstal l th e origina l 4 4 m m shim(s ) whe n
th e steerin g gearbo x i s reassemble d withou t replacin g
th e pinio n shaft , valv e housing , an d gearbo x housin g
wit h ne w ones .
I f th e pinio n shaft , valv e housing , an d gearbo x housin g
ar e replaced , selec t th e ne w shim(s ) a s follows .
Shi m selection :
a . Se t th e fou r 4 4 m m shim s o n th e bearin g surfac e o f
th e gearbo x housing . Tota l thicknes s o f th e fou r
shim s shoul d equa l n o mor e tha n 0.7 0 mm .
Shi m set : fou r 4 4 m m shim s (Thickness : 0.1 0 mm ,
0.1 5 mm , 0.2 0 mm , 0.2 5 m m respectively )
CAUTION : Th e fou r 4 4 m m shim s d o no t hav e
thicknes s identificatio n marks . Measur e th e thick -
nes s o f eac h shi m usin g a micrometer , an d mar k
th e shi m fo r identification .
b . Instal l th e valv e bod y uni t o n th e gearbo x housing ,
an d tighte n th e flang e bolt s t o th e specifie d torque .
c . Measur e th e clearanc e betwee n th e gearbo x housin g
an d valv e bod y uni t usin g a feele r gaug e a s shown .
NOTE : Measur e th e clearanc e a t th e poin t midwa y
betwee n th e tw o mountin g bolts .
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Reassembly (cont'd )
d. Determin e th e require d thicknes s o f th e 4 4 m m
shim s b y subtractin g th e clearanc e obtaine d i n th e
ste p - "C " fro m th e tota l thicknes s o f th e fou r shims .
(Tota l thicknes s o f th e fou r shims ) - (Clearance ) =
Require d thicknes s o f th e shim s
NOTE : Selec t th e shim s s o tha t th e tota l thicknes s
i s clos e to , bu t les s tha n th e require d thickness .
Example:
Measuremen t i s 0.2 8 m m (0.01 1 in) :
0.0 7 - 0.2 8 = 0.4 2 m m (0.02 8 - 0.01 1 = 0.01 7 in )
Th e selecte d shim s shoul d b e 0.2 5 m m (0.01 0 in ) an d
0.1 5 m m (0.00 6 in ) i n thickness .
I f th e require d shi m thicknes s i s 0.1 0 m m o r less , n o
shim s ar e necessary .
55 . Se t th e selecte d 4 4 m m shim s o n th e bearin g surfac e
o f th e gearbo x housing . 60
. Instal l cylinde r line s A an d B .
NOTE :
• Clea n th e joint s o f cylinde r line s A an d B
thoroughly . Th e joint s mus t b e fre e o f foreig n
material .
• Instal l cylinde r line s A an d B by lightin g th e flar e
nut s b y han d first , the n tighte n th e flar e nut s t o
th e specifie d torque .
Power Steerin g Gearbo x
61. Greas e th e slidin g surfac e of the rac k guide , an d
instal l i t ont o th e gearbo x housing .
62 . Fo r '9 6 - 9 8 models : Appl y a thi n coa t o f greas e t o
th e ne w 0-ring , an d instal l i t o n th e rac k guid e screw .
Fo r '9 9 - 0 1 models : Appl y sealan t t o th e al l aroun d
thread s o n th e rac k guid e screw .
63 . Instal l th e spring , rac k guid e scre w an d locknu t o n
th e gearbo x housing .
64 . Adjus t th e rac k guid e scre w (se e pag e 17-16 ).
NOTE : Afte r adjusting , chec k tha t th e rac k move s
smoothl y b y slidin g th e rac k righ t an d left .
56
. Coa t th e ne w O-rin g wit h grease , an d carefull y fi t i t
o n th e valv e housing .
57 . Appl y greas e t o th e needl e bearin g i n th e gearbo x
housing .
58 . Instal l th e valv e bod y uni t o n th e gearbo x housin g
b y engagin g th e gears.
NOTE : Not e th e valv e bod y uni t installatio n positio n
(directio n o f lin e connection) .
59 . Tighte n th e flang e bolt s t o th e specifie d torque .
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65. Install the new lock washer in the groove in the

steering rack.

66. Install the steering rack ends into the rack.

67. Hold the steering rack with a wrench ('99 - 01 mod-

els: left end only), and tighten the rack ends with

another wrench.
69. Apply steering grease to the circumference of the

rack end housing.

70. Apply a light coat of silicone grease to the boot

grooves on the rack ends.

71. Install the boots in the rack end with the tube clamps.

NOTE: Install the boots with the rack in the straight

ahead position (right and left tie-rods are equal in

length).
68. After tightening the rack ends, stake the four section

of lock washer with a commercially-available roll

pin drift and mallet.

• Place the wood block, then set the lock washer

section of rack end securely on the wood block.

• Be sure the tool is aligned with the stake point

(four dents) of the steering rack end before stak-

ing.ProCarManuals.com

75. Slid e th e rac k righ t an d lef t t o b e certai n tha t th e
boot s ar e no t deforme d o r twisted . 78
. Loosel y instal l th e tie-ro d locknut s an d tie-ro d end s
o n th e rac k ends .
73
. Ben d bot h set s o f lockin g tabs .
74 . Lightl y ta p o n th e doubled-ove r portion s t o reduc e
thei r height .
CAUTION : Stak e th e ban d lockin g tab s firmly . 76
. Instal l th e thre e line s ( 6 m m retur n line , 1 0 m m
retur n lin e an d senso r inle t line ) t o th e valv e bod y
uni t a s shown .
77 . Instal l th e lin e mountin g cushion s b y alignin g th e
mark s o n th e 1 0 m m retur n lin e (larg e diamete r
line).
Reassembl y (cont'd )
72. Instal l th e ne w boo t band s o n th e boot s a s shown .
Power Steerin g Gearbo x
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5. Reconnect the feed line to upper side of the valve

body unit.
2. Position the line mounting cushions by aligning the

marks on the 10 mm return line (large diameter

line).

3. Install the feed line on the slot of the cushions.

4. Install the two line clamps on the line mounting

cushions as shown below.
Installation

CAUTION: Be careful not to bend or damage cylinder

lines A and B or the four fluid lines when installing the

gearbox.

1. Assemble the mounting bracket over the mount

cushion, then loosely install the gearbox on the rear

beam with two gearbox mounting bolts.

NOTE: Move the feed line over the gearbox so that

it does not interfere with the gearbox during instal-

lation.ProCarManuals.com