Rings HONDA INTEGRA 1994 4.G Owners Manual

Apply power steering fluid to the surface of the spe-
cial tool. Set the new seal rings over the special tool
from the smaller diameter end of the tool, and
expand the seal rings. Do two rings at a time from
each end of the sleeve,
NOTE:
. Do not over-expand the seal ring. Install the resin
seal rings with care so as not to damage them.
After installation, be sure to contract the seal
rings using the specialtool {sizing tool}.
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleeve seal rings as they are not compatible.
Set the special tool in the grooves in the sleeve. and
set each ring in each groove securely.
NOTE: After installation, compress the seal rings
with your fingers temporarily.
BALL JOINT BOOT CLIP GUIDEo?MAG - SL001d)
14. Apply power steering fluid to the seal rings on the
sleeve and to the entire inside surface of the special
tool.
15. Insert the sleeve into the specialtool slowly.
16. Move the sl€eve each direction several times to
make the seal rings snugly fit in the sleeve.
NOTE: Be sure that the seal rings are not turned up.
SLEEVE SEAL RINGSIZING TOOL
13.
07974 - 5450200
Cutout,
't7.Apply power steering fluid to the surface ol the pin-
ion shaft, then assemble the sleeve over the pinion
shaft, aligning the locating pin on the inside of the
sleeve with the cutout in the shaft,
NOTE: Be careful not to damage the valve seal ring
when inserting the sleeve.
Install the circlip securely in the pinion shaft groove.
NOTE: Install rh€ circlip with its tapered side facing
OUI.
19. Apply power steering fluid to the seal ring lip of the
valve oil seal. Then install the seal in the valve
housing using a hydraulic press and special tools as
shown.
18.
ATTACHMENT,32x35mm077{6 - 0010100
{cont'd)
VALVE OIL SEAL
17-55
ir

Steering Gearbox
Reassembly (cont'd)
SI,-EEVE SEAL RINGSBe sure that thesear ings are notturned up, theninstall.
Press the new roller bearing into the valve housing
using a hydraulic press and special tool as shown.
NOTE: Place ths roller bearing on the valve hous-
ing with its letter stamped facing up towards the
valve side.
Pr.33,
I
PINION
E
20.
ATTACHMENT,32x35mm077/aO - (x)1010O
ROLLER BEARINGLetter stamped face
21.Apply vinyl tape to the pinion shaft, then coat thevinyl tape with power steering fluid.
Insert the pinion shaft into the valve housing.
CAUTION: Be carotul not to damage tho valvs soalrings.
23. Remove the vinyltape from the pinion shaft.
Soaling lip frc..
VALVE OIL SEAL
VALVC HOUSING
17-56
24. Press the pinion shaft/sleeve using a hydraulic
Dress as shown.
CAUTION: Before irserting the pinion 3haft, bosuro that the backup ring is csntored with the pin.
ion shaft bearing,
BACKUP BING

25.
26.
Coat the piston seal ring guide with power steering
fluid, and slide it onto the rack, big end first.
Position the new O-ring and new piston seal ring on
the special tool, then slide them down towards big
end of the tool.
NOTE:
. Do not over expand resin seal rings. Install the
resin seal ring with care so as not to damage
them. After installation, be sure to contract the
seal ring using the special tool (sizing tool).
. Replace piston's O-ring and seal ring as a set.
Pull the O-ring off into the piston groove, then pull
the piston seal ring off into the piston groove on top
of the O-ring.
PISTON SEAL RING
GUIDE07GAG - SD,OI00
28.
30.
O.RING
PISTON SEAL RING
Coat the piston seal ring and inside of the special
toolwith power steering fluid.
Carefully slide the tool onto the rack and over the
piston seal ring.
Move the special tool back and forth several times
to make the piston seal ring fit snugly in the piston.
PISTON
E
PISTON
31.
32.
Coat the sliding surface of the special tool and new
cylinder end seal with power steering fluid.
Place the seal on the special tool with its grooved
side facing opposite the special tool.
Grooved side.
CYLINDER ENDSEAL SLIDER0797a - 6890801
Apply a thin coat of grease to the inside of the spe-
cial tool, and install it on the steering rack.
CAUTION: Make sure the rack teeth do not tace
the slot in the special tool.
SEAL SLIDER0t974 - 6890801(cont'd)
CYLINDER END SEAL
CYLINOER END SEAL
17-57

Description
Outline
The air conditioner system delivers cooled air into the passenger compartment by circulating refrigerant through the sys-
tem as shown below.
CONDENSOR
This car uses HFC-134a {R-134a) refrigerant which does not contain chlorofluorocarbons Pay attention to the following
service items:
. Do not mix refrigerants CFC-I2 (R-l21 and HFC-134a (R-134a) They are not compatible'
. Use onty the recommended potyatkytenegtycol {PAG) refrigerant oil (ND-OIL 8: P/N 38899-PR7-A01) designed for the R-
134a compressor. Intermixing the recommended (PAG) refrigerant oil with any other refrigerant oil will result in com-
pressor tailure.
.A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve.
o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts.
. Use a halogen gas leak detector designed for refrigerant R-134a'
. R-.12 and C-l34a refrigerant servicing equipment are not interchangeable. Only use a Recovery/Recyclins/Charging
System that is U.L.-listed and is certifLd to meet the requirements of sAE J2210 to service R-134a air conditioning sys-
rems.
. Always recover the refrigerant R-134a with an approved Recover/Recycling/Charging System before disconnecting any
A,/C fitting.
coMpRESsoR -coNDENSER - RECEIVER/DRYER
High temperature/
high pressure gas
Suction and comPression
Less moisturized
low pressure vaPor
High temperature/ Traps debris High temperature/
hilh pressure liquid and removes high pressure liquid
Radiation of heat molsture
More liquidified
low Pressure vaPor
Absorption of heat
EVAPORATOR <-'----------.- EXPANSION VALVE
EVAFORATOR
22-6

Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnesses are coverod with
yollow in3ulation.
. B€tore disconnocting 8ny part of tho SRS wire har-
nsss, conngqt th€ 3hort connestor{sl.
. Roplaca ths entire aftected SRS harness a$embly if
it has an op€n circuit or damaged wiring.
lcove.ed with yellow insulation)
Recover the refrigerant with a Recovery/Recycling/
Charging System lsee page 22-22]-.
Femove the bolts, and disconnect the receiver line
and the suction line from the evaporator.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the svstem.
2.
L
6x1.0mm9.8 N.m {1.019f.m,1.2 tbl.ttl
SUCTION LINE
RECEIVEB LINE
3.Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.
Disconnect the connector from the Ay'C thermostat,
and remove the wire harness clips from the evapo-
rator.
Remove the four self-tapping screws, mounting bolt
and the mounting nut.
Disconnect the drain hose, and remove the evapo-
rator.
1.
6x1.0mmAPORATOR9.8Nm{1.0kg{.m,7.2 tbtft)
a
a
8. Install in the reverse order of removal. and:
it you're installing a new evaporator, add refrig-
erant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-2'll.
replace the O-rings with new ones at each fitting.
and apply a thin coat of refrigerant oil (ND-OlL 8:
P/N 38899 - PR7 - A01l before installing them.
NOTE: Be sure to use the right o-rings for HFC-
134a {R-134a} to avoid leakage.
apply sealant to the grommets.
make sure that there is no air leakage.
charge the system (see page 22-39) and test its
performance (see page 22-241.
22-26

Overhaul
L Pull out the Ay'C thermostat sensor from the evapo-rator fins.
2. Remove the self-tapping screws and clamps fromthe housing.
3. Carefully separate the housings and remove theevaporator.
4. lf necessary, remove the expansion valve.
NOTE: When loosening the expansion valve nuts.use a second wrench to hold the expansion valve orevaporator pipe. Otherwise, they can be damaged.
Assemble in the reverse order of disassembly, and:
. feplace the O-rings with new ones at each fitting,and apply a thin coat of refrigerant oil (ND-OIL 8:P/N 38899 - PR7 - A01) before installing them.NOTE: Be sure to use the right O-rings for HFC-134a {R-134a) to avoid leakage.. install the expansion valve capillary tube withthe capillary tube in contact with the suction linedi.ectly, and wrap it with tape.. reinstall the Ay'C thermostat sensor to its originallocation.
A/C THERMOSTATTest. page 22-19
8 N.m (0.8 kgf'm, 6 lbf.ftl
CAPILLARY TUBE
5.
EVAPOAATORblow dirt out of finswith compressed air.
16 N,m 11.6 kgl.m,12 tbt.ttl
24 N.m (2.i1 kg{.m,17 rbt.ftl
EXPANSION VALVE
TAPEReplace.Make sure there is no foreign matter stuck betweenthe capillary tube and outlet line.
6 th fin trom inlet 3id6
12015 mm14.72 ! 0.2 inl
LOWER HOUSING
22-27

and com
it with a
a
a
a
a
4t l\-N
r-

-l/
Compressor
Clutch Overhaul (cont'dl
Remove the screw from the field coil ground terma-
nal. Remove snap ring A with snap rjng pliers, then
remove the field coil.
NOTE:
. Be careful not to damage the field coil
pressor during removal/installation.
. Once snap ring A is removed, replace
new one.
SNAP RING AReplace.
FIELDcorL
5. lnstall in the reverse order of removal, and:
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaces
with non-petroleum solvent.
check the pulley bearings for excessive play.
make sure the snap rings are in the groove prop-
efly.
apply locking agent to the threads of the center
bolt, and tighten it securelY
make sure that the pulley turns smoothly after
it's reassembled.
1. Remove the relief valve and the O-ring.
NOTE:
. Do not let the compressor oil run out.
. Make sure there is no foreign matter in the sys-
tem.
RELIEF VALVE13.2 N.m {1.35 kgtm,9.76lbtftl
2. lnstall and tighten the relief valve.
Clean the mating surfaces.
Replace the O-ring with a new one at the relief
valve, and apply a thin coat of refrigerant oal
(ND-OIL 8: P/N 38899 - PR7 - A01) before install-
ing it.
NOTE:
. To avoid contamination, do not return the oil
to the container once dispensed, and never
mix it with other refrigerant oils.
. lmmediately after using the oil, replace the
cap on the container, and seal it to avoid
moisture absorption.
. Do not spill the refrigerant oil on the car; lt
may damage the painu if the refrigerant oil
contacts the paint, wash it off immediately.
Check for leaks, and insert the cap in the top of
the valve.
22-34

Condenser
Replacement
RAOIATOR UPPENMOUNT BRACKETS
Recover the relrigerant with a Becovery/Recycling/
Charging System (see page 22-221.
Remove the coolant reservoir,
NOTE: Do not disconnect the reservoir hose from
the coolant reservoir and the radiator.
COOLANT RESERVOIR
Remo.ve the bolts and the radiator upper mount
brackets, and remove the bolt from thg suction hose
bracket.
9.8 N.m {1.0 kgf.m.7.2 lbtftl
'1Iffi
22-37
6x1.0mm9.8 N.m (1.0 kgl.m,7.2 lbt.ft)
......-.....
CONOENSER LINE
Remove the bolts. and disconnect the discharge line
and the condenser line from the condenser.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the system.
DISCHARGE LINE
Remove the two mounting bolts, then lift out the
condenser as shown.
NOTE: Do not damage the radiator and condenser
fins when removing the condenser.
6x1.0mm9.8 N.m (1.0 kgf.m, 7.2 lbl.tt)
Install in the reverse order of removal. and:
. if you're installing a new condenser, add refriger-
ant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-21t,.
. replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil {ND-OIL 8:
P/N 38899 - PR7 - A01) before installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage.
a do not damage the radiator and condenser fins
when installing the condenser,
. be sure to install the condenser mount cushions
securely into the holes.
. charge the system (see page 22-39) and test its
performance (see page 22 24!.

Starting
Startel
System
Overhaul
from clutch side.
-s@]
MOLYBDENUMDISULFIDE
CAUTION: Disconnecl th€ battery n€gative cable befole
lomoving the startet.
NOTE: The original radio has a coded theft protection
citcuit. Be sure to get the customer's code number before
- disconnecting the batterY.- removing the No.3 2 (7.5 A) fuse from the under-hood
fuse/relay box.- removing the tadio.
Atter service, reconnect power to the radio and turn at
on. When the word "CODE" is displayed, enter the cus-
tomer's 5-digit code to restore radio operation.
tr./.' BRUSH HOLDERTest, page 23-8'l
ERUSH
COVER
I
6
OVERRUNNING CLUTCH ASSEMBLYInspection, page 23_84
SOLENOIDPLUNGERInspection, page 23-85
BRUSH HOLOER
ARMATURE
STARTERSOLENOIDTest, page 23-78
PINION GEAR IDLER GEAR
Inspection, page 23-11
IDLER GEAR
I
@*
SOLENOID HOUSING
HARNESS BRACKET
STEEL BALL
install steel ball
lnspection and Test,page 23-82
ROLLER BEARINGSand CAGEPrevenl rollers trom being scattered and lost.
MOLYBDENUM DISULFIDE
_R1
MOLYADENUMDISULFIDE
23-80
ENO COVER
ARMATURE
GEAR HOUSING

Alternator Overhaul
CAUTION: Do not r€move th€ pulley unl€Es the t.ontbearing needs r6placsm6nt.
To loosen the pulley locknut, use 10 mm and 22 mmwrenches. It necessary, use an impact wrench.
Test, page 23-107SPAC
REAR BEARING
ER RING
rl
@n
CAUTION: Do not get grease
or oil on the slip rings.
HOLDERTOR
ARUSH HOLOER
FRONT BEARING
PULLEY LOCKI{UT1'll N.m 111.3 kgt.m,82 tbf.trl
STATOR/DRIVE ENDHOUStt{G
BBUSHINSULA
)
(@P "
STATOR THROUGHBOLT
VOLTAGE REGULATOR
DIODE IRECTIFIER) ASSEMBLYTest, page 23-106
6
q
%A
re
TERMINAL INSULATORqt
PULLEY LOCKNUT111 N.m (1 1.3 kgt.m, 82 lbf.ft)
PULLEY
10 mm BOX WRENCH
REAR HOUSING
Inspection, page 23-
fu"- "o*n.r" ".,"- BRACKET
23-105