HONDA INTEGRA 1994 4.G Workshop Manual

Power Steering Hoses, Pipes
Replacement
NOTE:
. Connect each hosg to the corresponding pipe securg-
ly until it stops at the stopp€r on the pipe.
Install the clamp or ad,ustable clamp at the specified
distancs from the hose end as shown in the drawing.
. Add the power steering fluid to the specilied level on
the reservoir and check fo. leaks (see page 17-23).

Put ov6r the pipe untilthe hose stops at the$opper.
CAUTION: Chock all clampsfor doterioration 8nd dstor-
mation, and rsplacG with new onss if n6co33!ry,

Put over the pipe untilthehose stops at the stopper.
2.5 - 5.5 mm
{0.01 - 0.22 inl2.0 - 4.0 mm10.08 - 0.16 inl
2.5 - 5.5 mm10.01 - 0.22 in)
OUYI.fT HOSE11 N.m{1.1 kgl.m, 8 lbl.ftl
INI."ET HOSE
ABLE CLAMP
RETURN HOSE
coot"ER
CLAMPS
17 -34
CLAMPS

OUTI.TT HOSE
Power Steering Pump
Removal
NOTE: Before disconnecting the hoses from the pump,
place a suitable containsr under the car.
1. Drain the power steering fluid from the rsservoir.
2. Remove the belt by loosening the pump adjusting
bolt and mounting bolts.
3. Disconnect the inlet and outlet hoses from the
pump and plug the hoses.
NOTE; Take care not to spill ths tluid on the body
or parts. Wipe off spillod fluid at once.
4. Remove the pump mounting bolt, then remove th€
pump
NOTE: Do not turn the steering whesl with the
pump removeo
5. Wrap the opening of th€ pump with a piece of taps
to provent any foreign mat€rial. Se6 pags 17-44 for
oumD instsllstion,
tNt.€T HOSE
Disassembly
Pulley Removal
1. Drain the fluid from the pump.
2, Hold the stee.ing pump in a vise with soft iaws, and
hold the pulley with the specialtool and remove the
pulley nut and pulley.
CAUTION: Bo clrstul not to damage the pump
ho$ing with thr iaw3 of ths vise.
NOTE: Pullev nut has left-hand threads.
PULLEY NUT {Left-hand thread)
(cont'dl
17-35

Power Steering Pump
Disassembly (cont'dl
Flow Gontrol Valve Removal/lnspoction
l. Rsmove the control valve cov€r by romoving thethree flange bolts.
2. Remove the spring, flow control valve and O-rings.
FLOWCONTROL VALVE
Check the flow control valvg for wgar, burrs, andother damage to the edges of th€ groovos in tho
FLOWOONTROL VALVE
Ch6ck fordamags to €dgos.
17-36
il. Inspect the bore for the flow control valvs for scrat-ches or wear.
5. Slip the valve back in the pump and chock that itmoves in and out smoothly.
- lf OK, go on step 6, if not replace th6 valve androchsck the valve movsment.
NOTE: The original valve was selected for a precise
fit in the pump housing bore, so make sure ths n€w
on6 has the same identification mark.
Outsid€ Oiam€ter
- lf the valve movement still incorr€ct, replaco thepump as an assembly.
6. Attach a hose to the end of the valve as shown.
HOSE
MarkPart NameOutside Diameter
mm (in)
AFLOW CONTROL
VALVE A
17.991 - 17.996(0.7083 - 0.7085)
FLOW CONTROL
VALVE B
17.996 - 18.001
{0.7085 - 0.7087}
FLOW CONTROL VALVE

7.Submerge the valve in a container of power steer-
ing fluid or solvent, and blow in the hose. lf air bub-
bles leak through the valve at less than 100 kPa
11.0 kgf/cm,, 14.2 psi), replace or repair it as follows.
AIR PRESSURE
i- POWER STEEBINGFLUID or SOLVENT
8, Hold the bottom end of th€ valve with a oDen end
wrencn.
9. Unscrew the seat in the top end of the valve, and
remove any shims, the relief check ball, relief valve
and relief valve spring,
REUEF VALVERELIEF CHECK BALL
sHrM(sllf us€d.SEAT13 N.m11.3 ks[.m, I lbf.tt]
Clampthis end ina vise with sott iaws.
FLOW CONTROL VALVE REUEFvALvESPBING
10. Clean all the parts in solvent, dry them off, then
reassemble and retest the valve. Sge page 17-43 for
f low control valve installation.
NOTE: lf necessary, relief pressure is adiusted at
the facto.y by adding shims under the check ball
seat. lf you found shims in your valve, be sure you
reinstall as many as you took out,
')4.
nlll
Pump Rotor Removal
CAUTION: Tho pump components are made ot alu-
minum. B€ car6ful not to damage them when servicing.
1. Remove the inlet joint and O-rjng.
13 x 1.9 mmO.RINGReplac€.
2. Remove the pump cover and O-ring.
PUMP COVER
58.5 x 1.5 mmO.RINGFeplace.
(cont'd)
17-37

Power Steering Pump
Disassembly {cont'd}
3. Remove the pump cam ring from the pump hous-
Ing.
NOTE: Replace the pump as an assembly. if the
cam ring must be replaced.
PUMP CAM RINGCheck for damage or wear.
Remove the pump rotor and vanes.
NOTE: Replace the pump as an assembly, if the
pump rotor or vanes must be replaced.
PUMP ROTORCheck lor damage or wear.
1734
Remove the two rollers from the side plate.
Remove the side piate and preload spring.
NOTE: Replace the pump as an assembly, if the
side plate must be replaced.
5 x 26.8 mm
7. Remove the O-rings from the side plate.
SIDE PLATECheck for damage or wear.
ROLLER4,5 x 119.8 mm
16.8 x 1.9 mmO.RINGReplace.
54 x 1.9 mmO-RINGReplace.
ROLI..ER

Remov€ the circlip, then remove the drive shaft
assembly from the pump housing using a plastic
namm€r.
Remove the seal spacer and oil seal.
Inspect the pump housing for damage on the seal-
ing surfaces.
/-clRcLlP
Q'/
ra -,"
DRIVE SHAFTfor bend,damage or wear,
PUMP HOUSING
11. lnspect the bearing by rotating the outar race slow-
ly. lf any play or roughness is felt, replace the bear-
ing.
Remove and discard the bearing using the
tool and a gress.
Pra3s
+
special
13.Install the new bearing
press.
I{UB DIS/ASSEMBLY BASE07GAF - SD40700
using the special tool and a
Press
+
Installwith thered shielded sidelacing down.
07GAF - SDis)700NOTE: Support the inner racewith the tool securely.
17-39

Power Steering Pump
Reassembly
CAUTION: The power steering componsnts are mado of sluminum. Avoid dsmaging th€ componcnts during assombly,
NOTE:
. Clean the disassembled pans with a solvent and dry them with compressed air. Do not dip the rubber parts in a sofvent.
. Always replace the O-rings and rubber seals with new ones before assembly.. Apply recommended power steering fluid or steering grease (Honda P/N: 08733 - B070E) to the parts indicated in theassemblv procedures.
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.. Replacethe pump asan assembly ifthe parts indicated with asterisk (*) are worn or damaged.
ROLLER5 x 26.8 mm
PUMP covEn /
."'MP cAM RING
, / .",or r*r,
^ / -e^urrae vrues / / sirx1.smm
\Al {ro pratesl I / o_nrNc
dA-h1//EZil*l///'^ee'ace
o-ntNGReplace.
16.8 x 1.9 mm O-RING
\A I {ro Platesl
,h$;@:",n1
i'"otr
/-V#mtt.m,1a|tt.fti// / / \E
RoLLER / |a.5 x ag.a mm / |68.5 x 1.9 mm Io-RING / INLET
Reptace.
I
.PUMP HOUSING
xf:.i'/pp@6{fr;ryDRIVE SHAFTPUMP SEALSPACERROLLER /1.5 x 49.8 mm /68.5 x 1.9 mmO-R|NG / INLET JO-INT
Replace.
I'PUMP ROTOR>ei
iiij:f:,ll-T;-,",,,, ll;il'- g--lblY""."*";
Replace. :
$+--- srntnc
E -5.8x1.9mm
22.r x r.9 mm o-RfNG ------t@-<'t o^::t:\-GReplace.Replace.
FLANGE BOLT'11 N.m 11.1 kg-m,8lb-ftI
17-40
CONTROL VALVE COVEN

Pump Rotor Installation
L Coat the lip of the new oil seal with steering grease
(Honda P/N 08733 - 8070E).
Install the new oil seal in the pump housing by
hand, then install the pump seal spacer.
NOTE: Insert the oil seal with its grooved side fac-
ing in.
Install the pump drive shaft assembly with the spe-
cialtool.
Install the 38 mm circlip with its tapered side facing
out,
3.
4.
DRIVER ATTACHMENT07947 - 6:1io50038 mmcrncuP
- DRIVE
fu'/'i,Ert\=zl4
I"J PUMP SEALIf /sprcen
x,tY -ot seal
-Gll
ATTACHMENT, 37 x ,r0
07t,16 - dt102d,
5. Coat the side plate grooves with the recommended
power steering fluid, then position the 16.8 x
1.9 mm and 54 x 1,9 mm O-rings on the side plate.
16.8 x 1.9 mmO.RING
5a x 1,9O.RING
l
SIDE PLATE
17-41
6. Install the preload spring in the pump housing.
7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in
the pump housing.
8. Set the side plate over the roller and install it on the
pump housrng.
9. Set the 5 x 26.8 mm roller in the 5 mm hole in the
side plate.
5 x 26.8 mmROLLER
5 mm HOLE
SIDE PLATE
PRELOADSPRING
,1.5 mm
10.Assemble pump rotor to the drive shaft with the "o"
mark on the rotor facing upward.
Set the 10 vanes in the grooves in the rotor.
NOTE: 8e sure that the round ends of the vanes are
in contact with the sliding surface of the cam ring.
PUMP ROTOR
(cont'd)
11.

Power Steering Pump
Reassembly (cont'dl
Set the pump cam ring over the two rollers with the"8" mark on the cam ring upward.
Apply clean power steering fluid to the vanes and
cam ring.
Install the 68.5 x 1,9 mm O-ring on the pump cover.
Align the roller set holes in the pump cover with the
rollers.
'16. Align the projection on the pump housing and theprojection on the pump cover, and tighten the four
bolts.
20 N.m{2.0 kg .m, lil lbf.ftl
PUMP COVER
PROJECTIONS
13.
PUMP CAM RING
14.
15.
17 -42
17.
18.
13 x 1.9O.RING
E
Set the 13 x 1.9 mm O-ring on the inlet joint.
Install the inlet joint on the pump housing.
11.1 kgt.m. t lbf.ftl
INLET JOINT
T9

Flow Gontrol Valve Installation
1. Apply steering grease (Honda P/N 08733 - B070E) to
new O-rings.
2. Coat the flow control valve with clean power steer-
ing fluid.
3. Install the flow control valve, spring and control
valve cover on the pump housing.
4. Tighten the three control cover bolts.
FLOW CONTROLVALVE
SPRING
E;W
11 N.m {1.1 kgl.m,8lbtftl
2
Pulley Installation
1. Hold the steering pump in a vise with soft jaws.
CAUTION: Be careful not to damago the pump
hou3ing with the laws ol th€ vise.
2. Install the pump pulley as shown. Then install the
pulley nut.
Hold the pulley with the special tool and tighten the
pulley nut.
PULLEY NUT6ir N.m (6.5 kgt.m,47 lbt tt)
Check that the pump turns smoothly by turning the
pulrey.
PULLEY NUT
PULLEY
17-43