ACURA TL 1995 Service Repair Manual

Valve Bod y Uni t Reassembl y
Assis t contro l valv e unit :
1 . Coa t th e housin g sea l wit h powe r steerin g fluid , an d
instal l i t i n th e groov e o f th e valv e housing .
The n instal l th e valv e body .
VALV E HOUSIN G
HOUSIN G SEA L
VALV E BOD Y
9 N- m (0. 9 kgf-m , 6. 5 Ibf-ft )
2. Instal l th e valv e springs .
3 . Coa t th e pressur e contro l valv e an d assis t contro l
valv e wit h powe r steerin g fluid , the n instal l the m
int o th e valv e body .
ASSIS T CONTRO L VALV E
PRESSUR E CONTRO L VALV E
4. Coa t th e ca p sea l wit h powe r steerin g fluid , an d
instal l th e it i n th e groov e o f th e cap .
5 . Instal l th e ca p o n th e valv e body .
9 N- m (0. 9 kgf-m , 6. 5 Ibf-ft )
CAP SEA LReplace .
Valve bod y unit :
6 . Appl y powe r steerin g flui d t o th e sea l rin g li p o f th e
valv e oi l seal , the n instal l th e sea l i n th e valv e hous -
in g usin g a hydrauli c press and th e specia l tool s a s
shown .
CAUTION : Instal l th e valv e oi l sea l wit h it s groove d
sid e facin g th e tool .
ATTACHMENT ,32 x 35 m m07746-001010 0
Press.
DRIVE R07749-001000 0
VALVE OI L SEA LReplace .Make sur e th esprin g in th eoil seal .
CAP
SPRIN G
SPRIN G
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Steering Gearbo x
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 -
ing wit h th e stampe d lette r facin g u p toward s th e
valv e side .Press .
DRIVE R07749-001000 0
ATTACHMENT .32 x 35 m m07746-001010 0
ROLLER BEARIN GLetter stampe d fac eupward .
8.Appl y viny l tap e t o th e steppe d portio n o f th e pin -
ion 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 .
Vinyl tap e
(Steppe d portion ) Mak
e sur e th e sprin g i s
seate d in th e oi l seal .
Sprin gside.
PINIO N SHAF T
BACKU P RIN G
VALV E OI L SEA L
Replace .
9. Instal l th e backu p rin g wit h it s tapere d sid e a s
show n below .
10 . Coa t th e insid e surfac e of the 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 th e sprin g
sid e facin g opposit e th e bearing . 12
. Appl y viny l tap e t o th e spine 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 .
O-RIN GReplace .Do no t twist .
VALV E SEA L RIN G
Replace .
D o no t over-expand .
Viny l tap e
PINIO N SHAF T
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 vinyl tape fro m th e pinio n shaft .
15 . Appl y powe r steerin g flui d t o th e surfac e of the
valv e sea l rin g tha t wa s installe d o n th e pinio n shaft .
16 . Appl y powe r steerin g flui d t o th e insid e o f th e spe -
cial tool . Se t th e large r diamete r en d o f th e specia l
tool 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 .
Make th e valv e sea l rin g
fi t snugl y i n th e pinio n
shaf t usin g th e othe r en d
(smalle r diamete r end ) o f
th e specia l tool .
Us
e th e large r diamete r
en d o f th e specia l
too l firs t t o mak e
th e valv e sea l rin g
fit i n th e pinio nshaft.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 .
Tapere d position .
Sealing li p VALV
E SEA L RIN G
Replace .
PISTON SEA L RIN G
SIZIN G TOO L
07NA G-SR3090 0 o r
07NA G-SR3090 A
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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 circli p securel y i n 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 circli p wit h it s radiuse d sid e facin g out .
21 . Appl y powe r steerin g flui d t o 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 as no t t o damag e them .
Afte r installation , b e sur e t o contrac t th e sea l
rings 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 .
SLEEVE
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 .
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
vinyl tape wit h powe r steerin g fluid .
27 . 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 .
Sealin g li p face .
VALVE OI L SEA L
Replace .
VALVE HOUSIN G
PINIO N SHAF T
SLEEV E SEA L RING SReplace .Be sur e tha t th e
sea l ring s ar e no t
turne d up , whe ninstalled .
28. Remov e th e viny l tap e fro m th e pinio n shaft .
SLEEV E SEA L RIN GReplace .SLEEVE SEA L GUID E07SAG-SW5010 0or07SAG-SW5010 A PISTO
N SEA L RIN G
SIZIN G TOO L
07GA G-S04020 0
or07GA G-SD4020 A
Cutout
.
LOCATION PI NCIRCLI PReplace .
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Steering Gearbo x
Reassembl y (cont'd )
29. Pres s th e pinio n shaft/sleev e usin g a hydrauli c
pres s a s shown .
CAUTION : Befor e insertin g th e pinio n shaft , b e
sur e tha t th e backu p rin g is centere d wit h th e pin -
ion shaf t bearing .
NOTE: Chec k tha t th e pinio n shaft/sleev e turn s
smoothl y b y turnin g th e pinio n shaft .
BACKU P RING .
Press .
Pinion center .
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 .
PINIO N DUS T COVE R
VALVE OI L SEA LReplace .
Steering Rac k Reassembl y
31. 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 .
PISTO N
PISTON SEA L RIN GGUID E07HAG-SF1010 0or07HA G-SF1010 A
O-RINGReplace .
PISTON SEA L RIN GReplace .
32. Positio n th e ne w O-rin g an d ne w pisto n sea l rin g o n
the specia l tool , the n slid e the m dow n towar d th e
big 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 .
33 . Pul l th e O-rin g of f int o th e pisto n groove , the n pul l
the 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 .
34 . Coa t th e pisto n sea l rin g an d th e insid e o f th e spe -
cia l too l wit h powe r steerin g fluid .
35 . 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 .
PISTO N SEA L RIN GReplace .
PISTON SEA L RIN GSIZIN G TOO L07HAG-SF1020 0or07HAG-SF1020 A
36. 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 in th e piston .
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37. Coa t th e slidin g surfac e o f th e specia l too l an d ne w
cylinde r en d sea l wit h powe r steerin g fluid .
38 . Plac e th e sea l o n th e specia l too l wit h it s groove d
sid e facin g opposit e th e specia l tool .
Groove d side .
CYLINDE R EN D SEA L
Replace . CYLINDE
R EN D
SEA L SLIDE R07974-689080 1or07974-689080 A
39. Appl y a thi n coa t o f greas e t o th e insid e o f th e spe -
cia l tool , an d instal l i t o n th e steerin g rack .
CAUTION : Mak e sur e th e rac k teet h d o no t fac e th e
slo t i n th e specia l tool .
CYLINDE R EN D SEA L
Replace .
CYLINDE R EN D
SEA L SLIDE R
07974-689080 1or07974-689080 A
Make sur e th esprin g in th e cylinde rend seal .
40. Separat e th e cylinde r en d sea l fro m th e specia l tool ,
the n remov e th e too l fro m th e steerin g rack .
CYLINDE R EN D SEA LReplace .
CYLINDE R EN D SEA L
SLIDE R
07974-689080 1or07974-689080 A
41. 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 .
BACKU P RIN G
CYLINDE R EN D SEA L
Replace .
42. Greas e th e steerin g rac k teeth , the n inser t th e steer -
in g rac k int o th e cylinde r 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 housin g wit h th e rac k edges .
CYLINDE R HOUSIN G
STEERIN G RAC K
Groove d side .
STEERIN G RAC K
PISTO N
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Steering Gearbo x
Reassembl y (cont'd )
43. Inser t 6 " lon g 3/8 " driv e extensio n int o th e specia l
too l an d pu t the m on th e rac k a s shown .
44. 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 tool s wit h a pres s a s
shown .
CAUTION : D o no t pus h o n th e tool s wit h excessiv e
force a s i t ma y damag e th e cylinde r en d seal .
Press .
STEERIN G RAC K
CYLINDE R EN D SEA L
Replace .
a
45. Remov e th e tools , an d cente r th e steerin g rack .
46 . Instal l th e specia l too l ont o th e en d o f th e steerin g
rack , the n coa t th e specia l too l wit h powe r steerin g
fluid.
Stake d position .
Mak e sur e th e sprin g
i s i n th e cylinde r en d seal .
Groove d side .
CYLINDER EN D SEA L
Replace .
CYLINDE R EN D SEA L GUID E
07GA G-SD4040 0 o r
07GA G-SD4040 A
47. Coa t th e insid e surfac e o f th e ne w cylinde r en d sea l
wit h powe r steerin g fluid .
48 . Instal l th e cylinde r en d sea l ont o th e steerin g rac k
with it s groove d sid e towar d th e piston .
49. Remov e th e specia l tool , the n pus h i n th e cylinde r
en d sea l wit h you r finger.
NOTE : 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 posi -
tio n o f th e gearbox . 50
. Instal l a pulle r yok e t o th e steerin g gearbox , the n
clam p th e pulle r yok e i n a vis e wit h sof t jaw s a s
shown .
CAUTION : D o no t clam p th e cylinde r housing .
51 . Greas e th e insid e surfac e o f th e cylinde r end , the n
instal l th e cylinde r en d b y screwin g it int o th e cylin -
der housing .
52 . Remov e th e pulle r yok e fro m th e steerin g gearbox .
53 . Afte r tightenin g th e cylinde r end , stak e th e poin t o f
th e cylinde r housin g show n below .
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 . Stak e point . Depth : 1. 0 m m (0.0 4 in )
CYLINDE R HOUSIN G
4.0 m m (0.1 6 in)
CYLINDE R EN D
CYLINDE R EN D
6 9 N- m (7. 0 kgf-m , 5 1 Ibf-ft ) BUSHIN
G
B e carefu l no t t o damag e
the bushin g whe n insertin gthe cylinde r end .
CYLINDE
R EN D SEA L
REMOVE R ATTACHMEN T
07NA D-SR3020 A
6
" LON G 3/8 " DRIV E EXTENSION :
(Commerciall y available ) PULLE
R YOKE :
(Commerciall y available )
Snap-On ® T/ N CJ123- 1
OTC ® T/ N 737 2
or equivalen t
STEERING GEARBO X
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54. Selec t th e 4 4 m m shim(s) .
NOTE : Onl y reinstal l th e origina l 4 4 m m shim(s )
when th e steerin g gearbo x i s reassemble d withou t
replacin g th e pinio n shaft , valv e housing , an d gear -
bo x housin g wit h ne w ones .
If th e pinio n shaft , valv e housing , an d gearbo x
housing ar e replaced , selec t th e ne w shim(s ) a s fol -
lows .
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 thick -
nes s identificatio n marks . Measur e th e thicknes 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 gearbox , an d
tighte n th e flang e bolt s t o th e specifie d torque .
SHIM SET(fou r shims )
c.Measur e th e clearanc e betwee n th e gearbo x 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 .
FEELE R GAUG E
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 - 3 fro m th e tota l thicknes s o f th e fou r shims .
(Tota l thicknes s o f th e 4 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
is 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) :
0.7 0 - 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 sur -
fac e o f th e gearbo x housing .
FLANGE BOL T20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
44 m m SHIM S(Selecte d numbe r o f
shims )
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 posi -
tio n (directio n o f pip e connection) .
59 . Tighte n th e flang e bolt s t o th e specifie d torque .
VALVE BOD YUNITFLANG E BOL T
2 0 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
NEEDLE BEARIN G
O-RIN
G
Replace .
VALVE BOD Y UNI T
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Steering Gearbo x
Reassembl y (cont'd )
60. Instal l th e cylinde r line s A an d B .
NOTE :
• Clea n th e joint s o f th e 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 th e cylinde r line s A an d B by
tightening the
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 .
CYLINDE R LIN E B
CYLINDE R LIN E A
20 N- m (2. 0 kgf-m , 1 4 Ibf-ft )
2 6 N- m (2. 7 kgf-m , 2 0 Ibf-ft )
61. Greas e th e slidin g surfac e o f th e rac k guide , an d
instal l i t ont o th e gearbo x housing .
RACK GUID E
SCRE W
SPRING
LOCKNU T
62. Appl y a thi n coa t o f greas e t o th e ne w O-ring , an d
instal l i t 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 17-24 ).
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 . 65
. Instal l th e ne w loc k washe r i n th e groov e i n th e
steerin g rack .
STEERIN G RAC K EN DLOC K WASHE R 6 4 N- m
Replace . (6. 5 kgf-m , 4 7 Ibf-ft )
66. Scre w eac h rac k en d int o th e rack .
67. Hol d th e steerin g rac k wit h a wrenc h an d tighte n
th e rac k en d wit h another .
CAUTION : B e carefu l no t t o damag e th e rac k sur -
face wit h th e a wrench .
68 . Afte r tightenin g th e rac k end . Stak e th e fou r sectio n
o f loc k washe r wit h th e too l an d hydrauli c press .
NOTE:
• Plac e th e woo d bloc k o n th e pres s table , the n se t
th e loc k washe r sectio n o f th e rac k en d o n th e
woo d bloc k securely .
• B e sur e th e too l i s aligne d wit h th e fla t section s
o f th e steerin g rac k en d befor e pressing .
• Stak e th e loc k washe r i n th e cente r o f th e fla t
sectio n o f th e steerin g rac k end .
Press .
LOC K WASHE R
Replace .
RAC
K GUID E
O-RINGReplace .
TUB
SLO T
STAK E POIN T
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69. Appl y steerin g greas e t o th e circumferenc e o f th e
rac k en d housing .
STEERIN G GREAS E
RAC K EN D HOUSIN G
RAC K EN D GROOV E
SILICON E GREAS E
70. Appl y a ligh t coa t of silicon e greas e t o th e boo t
groove s o n th e rac k ends .
71 . Instal l th e boot s in th e rac k en d wit h th e tub e clamps .
NOTE : Instal l th e boot s wit h th e rack , i n th e straigh t
ahea d positio n (righ t an d lef t tie-rod s ar e equa l i n
length) .
NOTE: Wip e greas e of fthe threa d section .
SILICON E GREAS E
BOO T
TUBE CLAM P
72. Adjus t th e ai r tub e fittin g positio n o f th e boot s b y
turnin g it a s show n below .
LEFT BOO T RIGH T BOO T
(Viewe d fro m th e (Viewe d fro m th e
lef t side ) righ t side )
Offse t shaf t
center lin e
135°±10 °
BOO T110° ± 10 '
BOO T
AI R TUB E FITTIN G
AIR TUB E FITTIN G
73. Instal l th e tw o pip e clamp s a s show n below .
74 . Connec t th e ai r tub e betwee n th e righ t an d lef t
boot , an d instal l i t i n th e clip s o f th e pip e clamps .
Offset shaf t cente r line .
AIR TUB E
AI R TUB E PIP
E CLAMP S
Front
. Front
.
Front .
RACK EN D
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Steering Gearbo x
Reassembl y (cont'd )
75. Instal l th e ne w boo t band s o n th e boot , an d ben d
bot h set s o f lockin g tabs .
76 . 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 .
LOCKIN G TAB S
BOO T BAN D
Replace .
77. 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 .
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