gearbox HONDA INTEGRA 1994 4.G User Guide

Unovon or rcugh 8te6ring.
3
Adjust rack guide (se€ poge 17-21).
ll the probl6m is not corrected bYadjusting lhe rack guide. replacothe gearbox.
Adiud bolt t€nsion. Roplace b€lt, ifn€c€ssary {s€e page 17-20).
lf the ongin€ stalls when wheel isturned whil€ car is stoDPed ormoving at low spoed, adjust idlesp€€d (soe section 1 1 ).
ldl6 soosd low or orrrtic.
Chock power sieering Iluid levol. Itlgv6l ie excessivoly low, ch€ck forleaks in the system. Add fluid totho spocifiod level.
Air in rssorvoir. or ch€ck pow6a
steoring fluid l6v6l.
lf fluid lev6l is OK, check o-ringsand seals on both €nds of ihopump inlet hose, and th€ oilpump housing mating surfacosfor suction leaks. Reolace oarts65 n€CeSSAry.
Adjust belt tonsion (see page 17-m) or r€Dlaco beh.Pump b6lt slipping on pull6y(pump stops momontarily).
Check if pump prossure is withinthe ranoe 6.400 - 7,100 kPa (65 - 75kgr/cm,, 924 - 1,067 psil and th6gsuge needls travol is 1500 kPa {15kgflctn2, t71 p6i) or less. Check theflow control valve if the needletr.vel €xcoods 1500 kPa {15kg?cm,, i71 psi). lf rhe flow controlvalvo is normal, replace th€ pump
as an assomblv.
Sel the power itooring p.oasuregaug6. Cl066 th€ shut-off v6lv6fully and m€a5uro tho pumppr6ssur6 (6s€ pagg 17-221,
7-1

Troubleshooting
Fluid Leaks
Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points. depending on location of thefaulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
Steering GearboxLeaking from the oil seal on thetop of the valve housing.Roplace the valve oil seal fromthe valve housing.
Leaking from cylinder end intoleft tie'rod boot.Replace the valve oil seal lromthe pinion shaft.
Reolace the cvlinder end seal.
Leaking from cylinder end intoright tie rod boot.
Tighten attaching bolts or replacethe valve body unit or gear hous-Ing.
Leaking from the vslve bodyuniVhousing mounting soction.
Tighten connector. It still leaking.replace the pipe, cylinder orvalve housing unil.
Leaking from cylind6r pipe A or Bconnection (at tlare nut).
Leaking caused by damaged cy-linder pipe A or B.Replace the cylinder pipe A or B.
Leaking from feed pip6 andreturn pipe of the valve body unit(at flare nut).
Tighten connector. lI still leaking,replace the pipe or valve housIn9,
17-16

Place the front wheels in the straight ahesd position and
measure the distSnce the steering wheel can be turned
without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm l0 - o.:Xl inl
lf the plsy excseds the service limit, psrform rack guide
adjustment (see page 17-211.
lf the play is still excessive after rack guide adjustment,
inspect the stsering linksgo and gearbox as described
on the next page.
ROTANONAL PLAY
Inspection and Adjustment
Steering OperationPower Assist Gheck with
817-1
Gar Parked
1. Check the power steering fluid level (see page 17-
21) and pump belt tension lsee page l7-20).
2.Start the engine, allow it to idle, and turn the steer-
ing wheel from lock-to-lock sev€ral times to warm
uo the fluid.
Attach a spring scale to the steering wheel. With the
engine idling and the car on a clean, dry floor, pull
the scale as shown and read it as soon 8s the tires
begin to turn,
il. The scal6 should read no more than 33 N (3.4 kgf,
7.5 lbf). lf it reads more or less, ch€ck the gearbox
and pump.

Steering Linkage and Gearbox
STEERING COLUMNlnsoect tor loose columnmounting bolts and nuts.
BOOTInspect f6r damage and deterior6tion.
STEERING JOINTSCheck tor loose joint bolts.
PINION SHAFT GROMMETInspect lor damage and deterioration.
STEERING
TIE.ROD LOCKNUTCheck for loose locknut.
Inspect lor loose mounting bolts.GEARBOX MOUNTING CUSHIONSInspect for deterioration.
BALL JOINT BOOTInspect tor damage and deterioration.See psge 17-63 for replacement.
17-19

lnspection and Adjustment
Pump Pressure Check
Check the fluid pressure as follows to determine
whether the trouble is in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belt tension,
CAUnON: Dilconn€st the high pros3uro ho3s with cale
!o e3 not to spill tho powor stooring fluid on th6 lramo
lnd olhor parG.
1. Disconnect the outlet hose from the oumo outlet fit-
ting, 8nd install the pump joint adapter on the
pump outlet.
2, Connect the hose joint sdapter to the power steer-
ing pressure gauge, then connect the outlet hose to
the adaotor.
3. Instsll the power steering pressure gauge to the
pump joint adaptor as shown.
OUTLET HOSE FlTnNG
HOSE ATTACHING BOLT1l Nm11.1 kg{ m 8lbf.ftl
6 x 1.0 m.n BOLT{P!rt of tooll11 N.m11.1 kgtm,8lbf.ftl
P/S JOINT ADAPTOR IPUMPIo?NAK - SmolrA
PUMP OUTI.TTFITIING
Open the shut-off valve fully.
Open the pressure control valve fully.
17 -22
1.
Start the engine and let it idle.
Turn the stee.ing wheel from lock-to-lock several
times to warm the fluid to operating temperature.
Measure steady-state fluid pressure while idling
with the shut-off valve fully open. lf the pump is in
good condition, the gauge should read less than
1500 kpa (15 kgf/cm,,213 psi).
lf it reads high, check the feed line or valve body
unit (see General Troubleshooting l7-10).
Close the shut-off valve. then close the pressure
control valve gradually until the pressure gauge
needle is stabl6, Read the pressure.
lmmediately open the shut-off valve fully.
CAUTION: Do not keep the shut-ott valvs closod
moro thgn 5 soconds or th9 pump could b6 dam"
agod by over-h6ating,
lf the pump is in good condition, the gauge should
read at least 6.400 - 7,400 kpa (65 - 75 kgIlcm,,924- 1,067 psi). A low reading means pump output is
too low for full assist. Repair or replace the pump.
10.
P/S PRESSURE GAUGE

Fluid Leakage Inspection
BOOTCheck lor leaks.
GEARBOX rnd VALVE BODY UNITCheck for leaks at the mating surfaceand rlare nut connections.
PUMP ASSEMBLYCh€ck for leaks at the pumpseal, inlet and outlet fiftings.
Inspect hoses for d6mage, leaks,interference or tlvisting,Inspect fluid lines for damage,rusting or leakage.Inspect for leaks at hose andline ioints or connections,
17-23

Steering Column
Installation (cont'dl
Finaltorque:22 N.m{2.2 kgf.m, 16lbt.ftl
CAUTION:
. All SRS electrical wiring hrrnossos are covgrod wilhyellow insulation,
. When disconn€cting the SRS wire harness, installthe short connector on the airbag. th€n dbconnoct
the wire harness.
. Replaca the entire alfected SRS harness assembly if
there is an open circuit or damage to tho wiring.
1. Slip the upper end of the steering joint onto the col-
umn shaft {line up the bolt hole with the flat on the
shaft), and loosely install the upper steering joint
bolt.
UPPER STEERING JOINT BOLTBolt must line up withflat on shaft.
STEERINGJOINT
Slip the lower end of the steering joint onto the pin-
ion shaft. Line up the bolt hole with the groove
around the shaft) and loosely jnstallthe lower bolt.
NOTE:
. Be sure that the lower steering joint bolt. is
securely in the groove in the steering gearbox
pinion.
. Before tightening the steering joint bolts, pull on
the sleering joint to make sure that the steeringjoint is fully seated.
LOWER STEERING JOINT BOLTFin6ltoroue:22 N.m {2.2 kgt m. 15 lbf.ftl
17 -32
Install the steering column with the flange nuts,then installthe column holder and flange bolts.
Tighten the upper and lower steering joint boltsloosely installed in steD 2,
FLANGE BOLTS22 N.m12.2 ksi.m, 16 tbtftl
Install the steering joint cover with the clamps andclip.
CLIP

Steering Gearbox
Removal
NOTE: Using solvent and a brush, wash any oil and dirt
off the valve body unit, its lines, and the end if the gear-
box. Blow dry with compressed air.
1. Drain the power steering fluid as described on page
17 -21.
2. Rsise the front of car, and support on safety stands
in the propsr locations (see section 1).
3. Remove the front wheels.
il. Removs the st€ering joint cove.,
SIEERING JOIi{T COVEB
Remove the steering joint lower bolt, and move thejoint toward the column.
NOTE: Lock the steering shaft with the ignition key
to retain the steering shaft position.
Remove the cotter pin trom the castle nut and
removo the nut.
Installthe 10 mm hex nut on the balljoint.
Be sure that ths 10 mm hex nut is flush with the ball
ioint pin end, or the threaded section of the ball
ioint pin might be damaged by the ball iointremover.
NOTE: Remove the ball joint using the Ball Joint
Remover, 28 mm {07MAC - 5100200}. Refer to page
l8-11 fot how to use the ball joint rcmover,
Separat€ the tie-rod ball joint and knuckle using the
soscialtool.
CAUTION: Avold d.maging th. blllloint boot.
BALL JOlt{T REMOVER. 28 mm07MAC - SLqt2|X)
Disconnect the shift linkage {MfI model: see section
13, A/[ model see section 14).
Disconnect the heated oxygen sensor (H02S) con-
ngctor, and separate the three way catalytic conver-
ter by removing the s€lf-locking nuts.
NOTE: Always replace the gaskets with new ones.
OXycEt{S€NSOnOONNECTOR SELF.LOCKINGNUT
{cont'd)IHREE WAYCA?ALYTIC CONVERTEN
8.
10.
HEATED
Replacs.
17-45

Steering Gearbox
Removal (cont'dl
Remove the return pipe clamp from the left side of
the rear beam. and move the return piDe above the
steering gearbox.
Remove the rear beam brace.
Remove the left tie-rod end, then slide the rack
the way to the right.
11.
12.
RETURN PIPE CLAMP
13.
I.TFT TIE-ROD END
14. Disconnect the two lines from th€ valve bodv unit
on the steering gea.box.
CAUTION: Aftor dkconnccting tho ho3o and pip.,
plug or r.d thc ho3. rnd pipc whh I pioco of tapo
or .quivll.nt to prcvont torcign m!tori!|3 f.om
ritrdng thc vdv. body unit.
NOTE:
. Place the pipe disconnected in the previous step
at the rear side of the gearbox so that they do
not hinder in the gearbox removal.
. Do not loosen the cylinder pipes A and B be-
tween the valve body unit and cylinder,
RETUR]T HOSE
15. Remove the steering gearbox mounting bolts.
GEARBOX MOU NNG BOLTS
17-46

11.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead, and remove thepinion shaft grommet.
Move the steering gearbox to the right so the left
rack gnd clears the rear beam.
Hold the steering gearbox and slide the rack all the
way to the left, then place the left rack end below
the rear beam.
Move the steering gearbox to the left. and tilr the
left side down to remove it from the car.
18.
19.
PINION SHAFT GROMMET
STEEBING GEARBOX
17-47