cv joint HONDA INTEGRA 1994 4.G Service 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 lcont'd)
-4. Determine the requifed thickness of the 32 mm
shims by subtracting the clearance obtained in thestep -3 from the total thickness of the four shims.(Total thickness of the 4 shims) - (Clearance) =
Required thickness of the shims
NOTE: Select the shims so that th6 total thicknessis close to, but less than the required thickness.
Exampls:
Measu.ement is 0.28 mm (0.011 in):
0.70 - 0.28 = 0.42 mm (0.028 - 0.011 = 0.0't7 in)
The selected shims should be 0.25 mm (O.O1O in) and0.15 mm (0.005 in) in thickness.
lf the required shim thickness is 0.lO mm or less, no
shims are necessary.
i[9. Set the selected 32 mm shims on the bearing sur-face of the g€arbox housing.
50, Coat the new O-ring with gresse and install it in thegroove in the gearbox housing.
Apply grease to the needle bearing in the gearbox
housing.
Install the valve body unit on the gearbox housing
by engaging the gears.
NOTE: Note the valve body unit installation posi-
tion (direction of pipe connection).
Tighten the flange bolts to the specified torque.
FLANGE BOLT20 N.m (2.0 kgt m, 14lbf.ft)
VALVE BODY UNIT
ct.
O-RING
-ffiti
NEEOLE BEARING
_#{
17-60
BACK GUIDE SCREW
54. Installthe cylind6r pipes A and B.
NOTE:
. Clean the joints ofthe cylinder pipe A and B tho.-oughly. The joints must be free of foreign mat€.i-
at,
o Install the cylinder pipe A and B by tighting theflare nuts by hand first, then tighten the flarenuts to the specified torque starting with thecylinder side nuts.
CYLINDER PIPE B
Grease the sliding surface of the rack guide andinstall it onto the gear housing.
Apply a thin coat of grease to the n€w O-ring andinstall it on the rack guide screw.
Install the spring, rack guide screw and locknut onthe gear housing.
Adjust the rack guide screw (see page l7-21).
NOTE: After adjusting, check that the rack movessmoothly by sliding to rack right and left.
LOCKNUT
-6t
26 N.m (2.7 kg{.m,20lbtft)

lnstallation
CAUTION; BG Glrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1. Before installing the gearbox, slide the rack all the
way to right.
2. Pass the right side of the steering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack all the
wav to the left.
4. Raise the left side of the steering gearbox above
and through the left side of the rear beam.
5. Install the pinion shaft grommet and insert the pin-
ion shaft up through the bulkhead.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodv.
6. Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
hose connactions for interference with adjacent
pans.
58 N.m 15.9 kg[.m, $ lbl.ftl
TAA
38 N m 13.9 kgl.m, 28 lbt.ftl
17-63
YELLOW GEAR TOOTH
7.Center the steering rack within its stroke.
Make sure that the cable reel of the SRS is centered
as follows:
. Turn the steering wheel left approx. 150 degrees,
to check the cable reel position with indicator.
. lfthe cable reel is centered. the yellow gear tooth
lines up with the alignment mark on the cover.
. Return the steering wheel right approx. 150
degrees to position the steering wheel in the
straight ahead position.
ALIGNMEi'IT MARK
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 tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.
. Be sure that the lower steering ioint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
. lf the steering wheel and rack are not centeted,
reposition the serralions at lower end of the
steering joint.
(cont'dl
22 N.m 12.2 kgi.m, 16lbf.ftlLOWER BOLT

Steering Gearbox
Installation (cont'd)
10. Install the steering joint cover with the clamps andcliDs.
STEERING JOINT COVER
11. Connect the fluid lines to the valve bodv unit.
CLIP
RETURN HOSE
17-64
38 N.m 13.9 kg{.m, 28 lbf.ft)
12. Install the rear beam brace rod and return pipe
clamp on the rear beam.
NOTE: Install the rear beam brace toward thereturn pipe clamp.
13. Install the three way catalytic converter with thenew gaskets and new self-locking nuts, and connectthe heated oxygen sensor (H02S) connector,
HEATED OXYGEN SENSOR CONNECTOF
SELF.LOCKING NUT33 N.m 13.4
SELF.LOCKING NUT22 N.m (2.2 kgt m, 16 lbt.ftl
14. Connect the shift linkage (M/T model: see section
13, A/T model: see section 14).

15.Thread the right and lefi tie-rod ends onto the rack
an eoual number of turns.
TIE-ROO ENDTIE.ROD LOCKNUT
R€connect the tie-rod ends to the steering knuckles,
tighten the castle nut to the specified torque, and
install new cotter pins.
CAUTION: Iorquo tho castle nut to tho lower tor-
que lpocification, thsn tighton it only far cnough to
align thc slot with tho pin hole. Do not align tho
nut by loosoning.
CASILE NUT39 - 47 N.m14.0 - a.8 kgf.m. 29 - 35 lbf ftl
17. lnstallthe front wheels.
18. Fill the system with pgwer steering fluid and bleed
air from the system (see page 17-21).
19. After installation. perform the following checks.
. Check the gearbox Jor leaks (see page 17-231
. Adjust the front toe (see section 18).
o Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
Ball Joint Boot Replacement
Remove the boot set ring and the boot.
CAUTION: Do not contaminate ihe boot in3talls-
tion section with gr€aso.
Pack the interior of the boot and lip with grease.
Wipe the grease off the sliding surface of the ball
pin, then pack the lower area with fresh grease.
CAUTION:
. Ke€p g;eass off the boot in3tallation section and
tho laperad section of the ball pin.
. Do not altow dust, di.t, or other toreign mat6ti-
als to enter tho boot,
LIPBALL PIN TAPEREDSECTIONWipe off the grease.
BOOT INSTALLATIONSECTIONwiDe off the grease.
BOOT INSTALLATIONSECTIONWipe off the grease.
COTTER PINOn reassembly, bendthe cotter pin as shown.
Install the boot in the groove ot the boot installation
section securely, then bleed air.
SALL JOINT BOOTCLIP GUIDE07MAG - SL(x)l00Adiust the depth byturning the tool.
SET RING
Insert the special tool into the threads in the ball pin
and align the end of the tool with the groove in the
boot.
Slide the clip over the tool and into position
CAUTION: After installing the boot, check th. b.ll
pin taperod section tor grease contamiration and
wipe it if nocossary.
NE.ROD END
Turn the right and left tie-rods equally.
17-65

1. Carefully pry out the mirror holder with a tlat tip
screwdriver as shown.
CAUTION: To p.ev€nt damage to tha mirlor, wrap
ths end ot a tlat tip screwdriv€r with a shop towel.
MIRROR HOLDER
2. Installation is the reverse of the removal orocedure.
NOTE: Apply grease to the locations indicated by
the arrows.
Hatchback
JOINT PIN
Sedan
JOINT PIN
Mirrors
Mirror Holder ReplacementMirror Visor and Mirror Covel -
Replacement
Hatchback
1. Remove the mirror holder.
2. Turn the actuator forward. then remove the screws.
< : Scraw location3, 4
3. Detach the hooks, then remove the mirror visor.
MIRROR VISOR
20-50
I

Rear Window Molding
Replacement (cont'd)
8.
7. With a brush. apply a light coat of glass primer
around the edge of the glass.
NOTE: Scrape otl excess glass primer with a putty
knife after installing new molding.
6mm1O.23 Inl
SUBFACE
INSIDE SURFACE6mm(0.23 inl
Degrease the inner surfaces ol new molding
thoroughly, then apply a light coat ot glass primer
to the surtaces.
NOTE:
a Apply glass primer around the entire groove of the
new molding,
a Do not apply glass primer to the outer surface.
L Run a bead oJ adhesive in the groove of the molding'
20-66
MOLDING
^--
JOINT
1 O. Place the rear window outside-up. then align the joint
ot the molding with the "T" mark at the top ot the
glass as shown.
MOLOING
11.
wtNDOW
Press the molding into position around the entire
edge of the rear window.
NOTE: Check that the molding is not wrinkled or lift-
ed awav at corners.
MOLDING

Headliner
9, Lower the headliner as shown.
NOTE: Take care not to bend and scratch the
headliner.
Replacement {cont'd)
LEFT OUARTER PILLAR
TRIM PANEL
11.
RIGHT OURTER PILLARTRIM PANEL
1O. Bemove the headliner through the hatch opening'
Installation is the reverse of the removal procedure.
NOTE:
a When inserting the headliner through the hatch
opening, be careful not to fold or bend it. Also,
be careful not to scratch the bodY.
a Check that both sides of the headliner are secure-
ly attached to the trim and Panels.
a When installing the roof trim, install the Joint
toward the rear.
20-100
HEADLINER
HEADLINER
Sodan
'1.Remove:
a Center Dillar lower trim (see page 20-94)
a Front and rear door trim lsee page 20-94)
a Front pillar trim (see page 2O-9 .
a Center pillar trim (see page 20-94)
a Rear pillar trim panel (see page 20 95)
a Rearview mirror (see Page 20-521
Remove the sunvisor and holder from each side


: Screw locationS, 6
2.
^l
s,1
LOCK WASHER
loutsidel
HOLDER
/
$-.unu,"o"
/' BRACKET
NOTE:
a lf necessary, remove the sunvisor bracket as
shown.
a When installing the sunvisor bracket, apply grease
and make sure it's installed properly.
,@
suNvrsoR

Headliner
Replacement {cont'd)
5. Remove the .ool trim (moonroof modell.
6. Detach the clips by sliding the headliner forward.
A : Clip locations, 3
HEADLINER
Remove the headliner through the passenger's door
opening.
lnstallation is the reverse ot the removal procedure
NOTE:
a When inserting the headliner through the door
opening. be careful not to fold or bend it. Also,
be careful not to scratch the body
a Check that both sides ot the headliner are secure-
ly attached to the trim and Panels.
a When installing the roof trim, install the joint
toward the rear.
)
HEADLINER
20-102

8. Separate the seat cushion and seat tracks.
NOTE:
a Before separating, slide the seat cushionbackward.
a Take care not to bend the joint rod.
< : Bolt locations, 4
JOINT BOD
Disconnect the rear seat access cable (hatchback
passenger'sl.
REAR SEATACCESS CABLE
RECLINEAOJUSTER
9. Separate the seat track and recline adiuste..


: Bolt, nut locations
A

: Bolt, IBY : Nut, 2
j
A;iil;iiry-,'- j @i+ilJ
_o()_ _/ _ _].'*",
RECLINEADJUSTER
Installation is the reverse of the removal procedure.
NOTE:
a To prevent wrinkles when installing a seat-backcover, make sure the material is stretched even,ly over the pad before securing all the hooks.a Apply grease to the moving surtaces.
10.
20-105