Rings HONDA INTEGRA 1994 4.G Manual Online

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

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

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.

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

Steering Gearbox
Disassembly
Stssring Rack Disassembly
NOTE:
. Before disassembling the gearbox, wash it off with
solvent and a brush.
. Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox (see page 17-45).
2. Remove the air hose and clips.
3. Remove the tie-rod end and locknut.
4. Remove the boot bands and tube clamps. Pull the
boots away from the ends of the gearbox.
CLIP
BOOT
5. Hold the steering rack with a wrench and unscrew
the rack end with a wrench.
Loosen th6 locknut and remove tha rack guide
screw.
Ramove the spring and rack guide from the gear
housing.
7.
LOCKNUTRACK GUIDE
17-48,
TUBE CLAMP

20.Apply vinyl tape to the pinion shaft.
Separate the valve housing from the pinion shafv
valve using a press.
VALVE HOUSING
Vinyl t.p.
Check the inner wall of the valve housing where the
seal ring slides with your finger. lf there is a step in
the wall, the valve housing is worn. Replace the
valve housing.
NOTE:
There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valve housing only the wall is stepped.
When the valve housing is replaced, install new
32 mm shim(s) on the bearing surface of the
housing to adjust the thickness.
21.
22.
23. Check fo. wear. burrs and other damage to the
edges of the grooves in the sleeve.
NOTE: The pinion shaft and sleeve are a precision
matched set. It either the pinion shaft or sleeve
must be replaced, replace the both parts as a set.
SLEEVE SEAL RINGSCh6ck for oeel off oroamag0,
24. Remove the circlip and pinion shaft sleeve from the
oinion shaft.
(cont'd)
17-51

Steering Gearbox
Disassembly (cont'dl
25. Using a cutter or an equivalent tool, cut and remove
the four seal rings from the sl6eve.
CAUTION: Bc clroful not to drmrg. ths .dgc. otthc alcava g1oov6 whan rcmoving the 3cd rings
lnd O.ring.
Using a cutter or an gquivalent tool, cut the valve
seal ring and O-ring Et the groove the pinion shaft.Remove the valv€ saal ring 8nd O-ring,
CAUTION: Br crrltul not to drm.gr thc cdgct ofthc plnion rhdt grooya whcn rcmoving the vllvc
!.!l ring rnd O-ring.
26.
SI-EEVE
Cutting slot position.
17.52
Remova the valve oil seal 8nd backup ring from thepinion shaft.
NOTE:
. Inspect the ball bearing by rotating the outer
race slowly. lf thsre is excessive play, replace thepinion shaft and sleeve as an assembly.. The pinion shaft and sleeve are a precise fiu donot intermix old and new pinion shafts and
steev8s,
28, Press th6 valve oil s€al and roller besring out ofthe
valve housing using a hydraulic press and specialtool shown below.
PILOT COLLARO?GAF - PHTO1OO

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

Steering Gearbox
Reassembly lcont'd)
Vllvc Body Rea3sombly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl tape with
the power steering tluid,
2. Install the backup ring with its tapered side as
shown below.
3. Coat the inside surface of the new valve oil seal
with power steering fluid.
4. Slide the valve oil seal over the pinion shaft. being
careful not to damage the sealing lip.
CAUTION: ln3tall the valve oil ssal with hs groovad
3ide tacing opposits the besring.
Vinyl trpolst.ppcd ponion,Tapered position.
Groove side.
VALVE OIL SEAL
Fit the new O-ring in the groove of the pinion shaft.
Then slide the new valve seal ring over the shaft
and groove in on the pinion shaft.
Remove the vinyl tape from the pinion shaft.
NOTE: Do not over - expand the valve saal ring.
S€aling
E
lip
PINION SHAFT
VALVE SEAL RING
17-54
7. Apply power steering fluid to the surface of the
valve seal ring that was installed on the pinion
shaft.
8. Apply power steering fluid to the inside of the spe-
cial tool. Set the larger diameter end of the special
tool over the valve seal ring.
9. Move the special tool up and down several times to
make the valve seal ring Jit in the pinion shaft.
10. Remove the special tool.
.11. Turn the special tool over and setthe smallerdiam-
eter end of the special tool over the valve seal ring.
Move the sDecial tool uD and down severai times to
make the valve seal ring snugly fit in the pinion
shaft.
VALVE SEAL RING
(H(ffi
Use the wider diameterend ot the specialtool first to makethe valve seal ringfit in the pinionshaft.
Make the valve seal ringsnugly fit in the.pinionshaft using the other end(smaller diameter end) ofthe specialtool.