Piston ring HONDA INTEGRA 1994 4.G Owner's Guide

lST.HOLD CLUTCH
SNAP RING
CLUTCH END PLATE
CLUTCH DISCSStandard thicknoss:1.94 mm 10.076 inl
DISC SPRING
CLUTCH PISTON
O-RINGSRoplace.
CLUTCH PLATESStandard thickno3si2.00 mm (0.o79 in)
14-143

CAUTION: lf either end ot the comprassol attachm€nt
is sel ovsl an araa ol the spdng retaine. which is unsup-
ported by the retum spring. the letainer may be damag6d,
4. Compress the return spring.
Do not set horo.
RETURN SPRING
5.Remove the snap ring. Then remove the special
tools, spring retainer and return spring.
Wrap a shop towel around the clutch drum and ap-
ply air pressure to the oil passage to remove the
piston. Place a finger tip on the other end while ap-
plying air p.essure.
6.
COMPRESSED AIRHOSE NOZZLEOSHA-approved 30 psirype onry
CLUTCH
S AP RING
PISTON
14-145

Clutch
Reassembly
NOTE:
a Clean all psrts thoroughly in solvent or carburetorcleaner. and dry them with compressed air.a Blow out all passages.
a Lubricate all pans with ATF before .eassembly.
1. Inspect the check valve; if it's loose, replace theprston,
NOTE: Except 1st-hold clutch.
CHECK VAIVE
PISTON
14-146
3, Installthe piston in the clutch drum. Apply pressure
and rotate to ensure proper seating.
NOTE: Lubricate the piston O-ring with ATF beforeinstalling,
CAUTION: Do not pinch rh6 O-ring by installing th€piston with too much lorco.
CLUTCH DRUM
Installthe return spring and spring retainer. and po-
sition the snap ring on the retainer
4.
SNAP RING
SPRING RETAINER
RETURN SPRING
CLUTCH ORUM

I
Rcf. No. I Tool Numb€lDcscriptionO'ty I P!9. Relrrrncc
o
@
@(t
@
@
o
@
@
@
@
@
@
@.r
@-2
@
@
@
@
@
@
@
@
07GAF - PH70100
07GAF - SD40700
07GAG - SD40100
07GAG - SD40200
07GAG - SD40400
07JGG - 0010104
07MAC - 5100200
07MAG - 5100100
07NAD - SR30200
07NAG - SR30900
OTNAK - SR3O11A
OTNAK - SR3O12A
07406 - 0010001
07406 - 0010300
07405 - 0010400
07725 - 0030000
07746 - 0010100
07746 - 0010200
007i$ - 0010000
07916 - SA50001
07947 - 6340500
07974 - 6890801
0797,1 - SA50200
Pilot Collar
Hub DivAssembly Base
Piston Seal Ring Guide
Piston Seal Ring Sizing Tool
Cylinde. End Seal cuide
Belt Tension Gauge
Ball Joint Remover, 28 mm
Ball Joint Boot Clip Guide
Cylinder End Seal Remover Attachment
Valve Ssal Ring Sizing Tool
P/S Joint Adapter (Pump)
P/S Joint Adapter (Hos6)
P/S Pressure Gsuge
Pressure Control Valve
Pressure Gauge
Universal Holder
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm
Driver
Locknut Wrench, i[0 mm
Driver Anachment
Cylinder End Seal Slider
Sleeve Sesl Ring Sizing Tool
1
I
1
1
1
1
1
1
1'I
1
1
1
1
1
1'l
1
I
1
1
1
1
'17 -52
17-39
17 -57
17 -57
17-EO
17 -20't7 -15
17-50
17-5{
17 -22
17 -22't1-22
17 -22
17-35, 53
17-55, 56
17 -1'l
t7-55
17 -2'l
17 -11
17-57,58
17-55
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17-2

Pressure Control
Low assist at higher speeds:
When steering resistance is low. such as when driving at high speeds. or when driving straight ahead, the input shaft is
near or in the neutral position, so there is little or no flow to any of the power cylinder orifices, Most of the feed pressure
trom the pump is bypassed to the reservoir. Because of this, the pressure stays the same in both sides of the power cylin-
der, resulting in low or no assist.
vaz =- S\->/-\7/RETURN PASSAGE(To RESERVOIRI
VALVE UNITINPUT SHAFT
High assist at lower speeds:
When steering resistance is high, such as when driving at low speed, or when turning the wheel with the car stopped, the
difference in angle created between the input shaft and the valve opens the fluid passage on one side, and closes the fluid
passage on the other side, at each pair of orifices. The fluid pressure increases in the side of the power cylinder fed by the
larger fluid passage. This increased pressure pushes on the rack piston, allowing the steering wheel to be turned with light
effon. On the other side of the power cylinder, the return passage opens allowing the steering fluid to return through the
input shaft to the reservoir. The fluid passages to the power cylinder automatically change in size, increasing as the steer-
ing resistance increases. In other words, the passages become larger and power assist increases when the steering effort
would normally be high, (for example. when parking or making low speed turns). and the passages become smaller and
power assist decreases when the steering effort would normally be low, (for example, when driving at high speeds or
straight ah€ad).
FLUIO PASSAGE TOPOWER CYLINDERFrom PUMP
A
/t-:\
v"
=iJ
RETURNPASSAGE
FLUID PASSAGE FROMPOWER CYLINDER
ALVE F.om PUMP
RESERVOIR

Steering Gearbox
Disassembly lcont'd)
13, Set the gearbox in a press so the gear housing points
upward.
14. Installthe flange bolt into the end ofthe steering rack
until it bottoms in the hole, then back the flange bolt
out 1/4 turn. Hold the tlange bolt and tighten the
flange nut against the rack by hand.
15. Press the cylinder end seal and steering rack out of
the gearbox,
NOTE: Hold the sreering rack to keep it from talling
when pressed clear.
VINYL TAPEPre$
I
12 mmFLANGE NUT
STEERINGGEARBOX
16.Remove the soecial tool and cylinder end seal lrom
the steering rack.
17-50
17.
CYLINDER ENOSEAL
18.
Remove the 12 mm bolt and nut from the steering
rack, then install a 24" long.3/8" drive extension, and
the special tool into the cylinder from the gearbox
side.
CAUTION: Be caretul not to damagc th€ in3idr
surface ot ths housing with tho tool3.
Set the gearbox in a press, then press out the cylinder
end seal and backup ring trom the gearbox.
CAUTION:
Ksep the tool straight to avoid damagingtha cYlind.r
wall. Chsck tis tool angls, and corr€st if nrcolrary,
whsn rsmoving the cylinder end seal.
Use ! prors to r6movo tho cylinder end rgal. Do not
try to remove the soal by 3triking ths tool. h will
break the brckup ring and tho cylind€r end leal will
romain in ths gsarbox.
2it" LONG 3/8" DRIVE EXTENSION:Comm€rcirlly Availobl.
CYLINDER END SEALREMOVER ATTACHME?ST
19. Carefully pry the piston seal ring and O-iing off the
piston of the rack.
CAUTION: Be careful not to damags th€ insidc ot
seal ring groove whgn romoving th€ seal ring.
Replace.

Reassembly
NOTE:
. Clean the disassembled parts with a solvent and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly.
. Apply power steering fluid or steering grease {HONDA P/N: 08733 - 8070E) to the parts indicated in the assembly pro-
cedures.
. Do not allow dust, dirt. or other foreign materials to enter the power steering system.
. Use the appropriate specialtools where necessary.
FLANGC BOLT20 N.m 12.0 kg{.m, lil lbt'ftl
CYLINDER PIPE A26 N'm (2.7 kgf.m, 20 lbf.ftl
VALVE I{OUSING
BOLI..ER BEARINGReplace.
VALVE SEAL RINGReplace.+-cncl|P
RACK GUIDE SCREW
S1IEVE SEAI RINGSReolace.
SITEVE
BACKUP RIM}
VALVE SEAL RINGRaplacs.
O.RINGReplac€.LOCKNUT
CYLINDER HOUSING
O-RINGBACKUP RING Replace.
\
PINION SHAFT
SHIMS
O-RINGReplace.
CYUNDER END SEALReolace.GEAR HOUSING
CYLINDER END SEALReplaco.O.RINGReplace.
I
x nd#$Y
IPISTON SEAL RINGReplace.
STEERING RACK
(cont'd)
17-53

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

Steering Gearbox
Reassembly lcont'dl
34. Separate the cylinder end seal from the spscial tool,then remove the tool from the steering .ack.
lnstall the backup ring on the steering rack, thenplace the cylinder end seal to piston.
Grease the steering rack teeth, then insert the steer-ing rack into the gear housing.
CAUTION: Be clrs{ul not to d.mage to inn9r !ur-ftca of thc goar housing with th€ rsck cdg6.
CYUNDER END SEAL
BACKUP RING
CYLINDER END SCAL
17-58
CYUNDER END SEAL
37.
'to
Set lhe gearbox in a press with the cylindor housing
facing upward.
Install the flange bolt into the end of the steering rack
until it bottoms in the hole, then back the flang€ bolt
out 1/il turn. Hold the flange bolt and tighten the
flange nut against the rack by hand.
Install the cylinder end seal into the bottom of the
cylinder by pressing on the bolt with a press as
shown.
CAUTION: Do not push on ihc bolt with excelcivr
forcc; 83 it may dEmago thr cylindor ond 3o!1.
Pr9!t
I
12 x 170 mm FLANGE BOLT
12 mm FLANGE NUT
STEERING RACK
CYUNDER END SEAL
41.
Remove the flange bolt and center the steering rack.
Install the special tool or vinyl tape onto the end ofthe steering rack, then coat the special tool or vinyltape with power steering fluid.
Coat the inside surface of the new cylinder end sealwith power steering fluid.
Install the cylinder end seal onto the ste€ring rackwith its grooved side toward the piston.
Remove the special tool. Push in the cylinder endseal with finger.
NOTE: Take care not to damage the cylinder endseal with the threads and burrs at the stakod oosi-tion of the gearbox.St k d po3ition.
c.oov.d3id...--#

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