body HONDA INTEGRA 1994 4.G Manual Online

Fluid Leakage Inspection
BOOTCheck lor leaks.
GEARBOX rnd VALVE BODY UNITCheck for leaks at the mating surfaceand rlare nut connections.
PUMP ASSEMBLYCh€ck for leaks at the pumpseal, inlet and outlet fiftings.
Inspect hoses for d6mage, leaks,interference or tlvisting,Inspect fluid lines for damage,rusting or leakage.Inspect for leaks at hose andline ioints or connections,
17-23

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
lnstallation
1.Connect the inlet and outlet hoses. Tighten the
pump fiftings securely.
Loosely install the pump in the pump bracket with
mounting bolts.
11N.m11.r kgf.m, 8lbf.ftlOUTIIT HOUSE
INI.TT HOSEO-RINGReplaco.
ADJUSTINGBOLT
PUMP MOUNTING BOLTS2,r N.m {2.4 kgl.m. 17 lbf'ft}
Install the DumD belt.
CAUTION:
. Make surs that thg powor gtooring bslt i!
securgly on the grooyos of ths pulloy!.
. Do not get powor stggring fluid o. groaso in thg
power steering bclt or pulley trc6. Cloan oft 8ny
tluid or groa36 belore installation.
POWER STEERING BELT
PULI..EY
5.
Adjust the pump belt (see page 17-201.
Fill the reservoir to the uoDer level line.
NOTE; Take care not to spill the fluid on the body
and parts. Wipe off the spilled fluid at once.
GAUTION: Uro only Ganuino Honda Powor Stsor.
ing Fluid-V. Using othor tlui& 3uch a3 ATF or oiher
manutacturor's powor steering tluid will drm89e
the rystgm.
SYSTEM CAPACITY:
1.06litor (1.12 US.qt, 0.93 lmp.qt)
RESERVOIR CAPACIW:
0.79 litor (0.1|:| US.qt, 0.?0 lmp.qtl
UP?ER I.fVEL LINE
IEVEI LINE
- Start the engine, let it run at idle, then turn the
steering wheel lock-to-lock severaltimes to bleed
air from the system.
- Recheck the fluid level and add some if neces-
s8ry.
CAUTIONT Do not fill tha .63ervoir boyond th6
upp€r lcvol lino.
17 -44

Steering Gearbox
Removal
NOTE: Using solvent and a brush, wash any oil and dirt
off the valve body unit, its lines, and the end if the gear-
box. Blow dry with compressed air.
1. Drain the power steering fluid as described on page
17 -21.
2. Rsise the front of car, and support on safety stands
in the propsr locations (see section 1).
3. Remove the front wheels.
il. Removs the st€ering joint cove.,
SIEERING JOIi{T COVEB
Remove the steering joint lower bolt, and move thejoint toward the column.
NOTE: Lock the steering shaft with the ignition key
to retain the steering shaft position.
Remove the cotter pin trom the castle nut and
removo the nut.
Installthe 10 mm hex nut on the balljoint.
Be sure that ths 10 mm hex nut is flush with the ball
ioint pin end, or the threaded section of the ball
ioint pin might be damaged by the ball iointremover.
NOTE: Remove the ball joint using the Ball Joint
Remover, 28 mm {07MAC - 5100200}. Refer to page
l8-11 fot how to use the ball joint rcmover,
Separat€ the tie-rod ball joint and knuckle using the
soscialtool.
CAUTION: Avold d.maging th. blllloint boot.
BALL JOlt{T REMOVER. 28 mm07MAC - SLqt2|X)
Disconnect the shift linkage {MfI model: see section
13, A/[ model see section 14).
Disconnect the heated oxygen sensor (H02S) con-
ngctor, and separate the three way catalytic conver-
ter by removing the s€lf-locking nuts.
NOTE: Always replace the gaskets with new ones.
OXycEt{S€NSOnOONNECTOR SELF.LOCKINGNUT
{cont'd)IHREE WAYCA?ALYTIC CONVERTEN
8.
10.
HEATED
Replacs.
17-45

Steering Gearbox
Removal (cont'dl
Remove the return pipe clamp from the left side of
the rear beam. and move the return piDe above the
steering gearbox.
Remove the rear beam brace.
Remove the left tie-rod end, then slide the rack
the way to the right.
11.
12.
RETURN PIPE CLAMP
13.
I.TFT TIE-ROD END
14. Disconnect the two lines from th€ valve bodv unit
on the steering gea.box.
CAUTION: Aftor dkconnccting tho ho3o and pip.,
plug or r.d thc ho3. rnd pipc whh I pioco of tapo
or .quivll.nt to prcvont torcign m!tori!|3 f.om
ritrdng thc vdv. body unit.
NOTE:
. Place the pipe disconnected in the previous step
at the rear side of the gearbox so that they do
not hinder in the gearbox removal.
. Do not loosen the cylinder pipes A and B be-
tween the valve body unit and cylinder,
RETUR]T HOSE
15. Remove the steering gearbox mounting bolts.
GEARBOX MOU NNG BOLTS
17-46

Remove the cylinder pipe A and B from the gear-
box.
Drain the fluid from the cylinder fittings by moving
the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body unit from the gearbox. {See page 17-51 for
valve body unit disassembly.)
FLANGE BOLT
CYLINDER PIPE B
VALVE BODY UNIT
11.Drill a 3 mm {0.12 in) diameter hole approximately
2.5 - 3.5 mm (0.10 - 0.14 in) in depth in the staked-
point on the cylinder.
NOTE: Do not allow metal shavings to enter the
cylinder housing.
STAKEO POINT
D.prh:2.5 - 3,0 mm 10.10 - 0.12 inl
CYUNDER END
12. Install a puller yoke to the stesring gearbox. Clamp
the puller yoke in a vise with soft iaws as shown,
then loosen and remove the cvlinder end.
PULLER YOKE:Commercirlly AvrilabloSn.p-Ono T/N qrie'-1
oTclo T/N 7372
(cont'd)
17-49

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.

41.
Install a puller yoke to the steering gearbox, then
clamp the puller yoke in a vise with soft jaws as
shown.
PULLER YOXE:Commcrcirlly AvrihbloSn.p-Ono T/N Cr123-lorco T/N 7372or aquivrlani
Grease the inside surface of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der housing.
After tightening the cylinder end, stake the point of
the cylinder housing shown below.
NOTE: Stake in the cylinder in the position opposite
from where the stake was removed during disas-
semblv.
Strke point, D.pth: 1.0 mm (0.04 inl
4.0 mm 10.15 inlCYLINDER HOUSING
CYLINDER END
CYLINOER69 N.m 17.0 kgf.m, 51 lbtft)
,t8. Select the 32 mm shim(s).
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shaft, valve housing, and gear-
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
rows.
Shim r€lection:-'1. Set the four 32 mm shims on the b€aring surface of
the gearbox housing. Total thickness of the four
shims should eoual no more than 0.70 mm.
Shim set: tour 32 mm shims (Thickness: 0.10 mm,
0.15 mm, 0.20, 0.25 mm respectivelyl
CAUTION: The tour 32 mm shimr do not hlva
thlckn$s idcntitication mukt. Mo!3ur. tho thicl-
oa33 of rach 3him using a miclomctrl, and mlrk
tho shim lor id6ntific8tion.
-2. Install the valve body unit on the gearbox, and
tighten the flange bolts to the specitied torque
VALVE BODY UNIT
FLANGE BOLT20 N.m {2.o kgtm, 14lbt'ftl
SHIM SET{foul thim.)
Measure the clearance between the gearbox and
valve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midway
between the two mounting bolts.
(cont'd)
17-59

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)

R6ar Door:
'13. Adjust clearance "H" as follows.
"H" lsos page 20-421
- 1 Loosen the nut securing the stopper plates.
2 Loosen the nut securing the roller guide, and
move the guide up or down to align the glass
with the body at the rear and center pillars.
GLASS
ROLLER GUIDE
-3 Loosen the locknuts securing the center glass
guide, and adjust the glass fore and aft by mov-
ing the center glass guide.
NOTE: Hold the adjusting bolts with a hex
wrench or tlat tip screwdriver when loosening
the locknuts.
I
-4 Repeat steps-2 and -3 until clearance "H" is
within the specified limits. then fasten the center
glass guide and roller guide.
Press the stopper plates against the glass stop-
pers, then fasten the stopper plates.
NOTE: Check that the stopper plates contact
the glass stoppers evenly.
STOPPER PLAYElF ontl
204s