tie rod HONDA INTEGRA 1994 4.G Workshop Manual

.:-\.-----ll@l--l t l- The Malfunction Indicator Lamp (MtL) indicatee Diagnostic Trouble Cod€ (DTC) 7: A problcm inrhe Thronle Position (TPl Sonsor circuit.The TP Sensor is a potsntiometer, lt is connected to the throttle valve shaft. A8 the throttlo position chan96, the throttlopositaon sensor varies the voltage signal to the ECM.
BBUSHHOLDER
PGM-FI System
Throttle Position (TPl Sensor
OUTPUT VOLTAGE IV)
BNUSH
RESISTOF
IXNOTTII
TERMIIIAL;0rr- of€ no
THNOTTIE
YEL/aLU l+l TP SEITSOR
I
a
t
t
Io.|o
RED/BLK {-I
cnn/BLu I - l
)ran1 )ril-Y- -?..
- Th. MIL h.. baln rlport d on.- With th. SCS thort conn.ciolconn.c-ted (rco pngc 11-341.codo 7 i. indlc.t d.
Do the ECM Reset hocedure (se€page l 'l-35).
l. ..mrtt nt fClur., lyrt m la OX.t thb dm. ll.at drlv. rn.y brncoaataryl.Chack lor poo? connactlo|ra otloora wlr.r !t C223 lloc.t d !tdgtn drod( tow..t, Cl15 ITP ...t-rorl, C419 (TCMI .nd ECM.
ls the MIL on and do€s itindicats codo 7?
Turn th€ ignition switch OFF.
Disconnect tho 3P connector lromth€ TP sensor.
Turn the ignition switch ON.
Meosu.o voltage betwoon YEL/BLU (i ) terminal and GRN/BLUI -, torminal.
Measurs voltagG betw66n YEUBLU (+l terminal and bodygiound.ls there approx. 5 V?
(To page 1 1-611
11-60
(To page 1 1-6'l )
,,,----

Component Location
lndex
Powar Siooring:
NOTE:
a
a
It an intact airbag ass€mbly has been r€moved from a scrapped car or has been found defective or damaged during
transit. storage or service, it should be doploy€d (see section 23).
Before removing tho gearbox, remove ths ignition key to keep the steering shaft Jrom turning.
After installing the gearbox, check ths whe€l alignment and adiust if necessary.
CAUTION:
. All SRS aloctricll wiring h!m!|$a rrc covcred with
yrllow in3uhtion.
. 8€for€ disconnocling lny ptrt ol thc SRS wiro h!r'
ne*r, connect thc lhort conncctor{3l.
. Rcplsce lhc ontira ttfact d SRS harnccc a$embly il
it hs3 !n oprn circuh 01 dtm!9.d wiring.
SIEERING COLUiINRemoval, page 17-28Inspection, pago 17-30Installation, p6ge 17-31rcNMON SwlTCHSee s6ction 23
STEERII{G GEARBOXRack Guide Adjustment, pag.11-21
Removal, pags 17-45Diossombly, page 17-{8Bea65€mbly, page 17-53Installation, page 17-63
POWEN STEERING PUMPPump Beft Inspoction. page 17-2OPump Eeft Adjustm6nl, pago 17-2OPump Pressurg Ch€ck, page 17-22Removai, p6go 17-35Disassembly, p3gs 17-35Reassombly, psge l7-40lnstallation, page 17-44
STEERING WHEELRemoval. page 17-24Oisassembly/Reassembly, pageInstallation, page 17-2617-25
TIE'ROD END BALL JOINTBall Joint Eoot Replacement, page 17-63
17-3

Troubleshooting
Noise and Vibration
NOTE: Pump noise in first 2 - 3 minutes after starting in cold weather (-20.C, -4"F or colder) is normal.
Humming
Rattle or chattering
Right cylinder end soal squeak
Pump noise. though not loud,lrom the vslvo bodv unit can be heard when turn-ing the steering wheel right or left. This is normsl.
Humming due to pulsation ol fluid is no.mal, paniculady when wheel is turnedwith ca. stopped.
lf equipped with automatic trans-mission, the hum could b€ tor-que convener or pump notse.
Confirm by temporarily removingpump b€lt.
High pressure line touching theframe,Reposhion tho line.
Loose steering shaft connector.tie-rod, or balljoint.Check and tighten, or replacepa s as necessary.
Column shaft wobbling.Replace column assembly.
Check the rack guide for properadjustment (16o page 17-21).Adjust, if n€ca€ssry.
Rattling sound and feeling when turning the steoring wheel right and lett with thoengine OFF is a sound when th6 valve unit contacts tho stopper. This is normal.
Striking sound wh6n turning the ste€ring whoglfully right o. left is a sound whenthe r6ck end contacts th6 stopper. This is normal.
17-14

Troubleshooting
Fluid Leaks
Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points. depending on location of thefaulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
Steering GearboxLeaking from the oil seal on thetop of the valve housing.Roplace the valve oil seal fromthe valve housing.
Leaking from cylinder end intoleft tie'rod boot.Replace the valve oil seal lromthe pinion shaft.
Reolace the cvlinder end seal.
Leaking from cylinder end intoright tie rod boot.
Tighten attaching bolts or replacethe valve body unit or gear hous-Ing.
Leaking from the vslve bodyuniVhousing mounting soction.
Tighten connector. It still leaking.replace the pipe, cylinder orvalve housing unil.
Leaking from cylind6r pipe A or Bconnection (at tlare nut).
Leaking caused by damaged cy-linder pipe A or B.Replace the cylinder pipe A or B.
Leaking from feed pip6 andreturn pipe of the valve body unit(at flare nut).
Tighten connector. lI still leaking,replace the pipe or valve housIn9,
17-16

Steering Linkage and Gearbox
STEERING COLUMNlnsoect tor loose columnmounting bolts and nuts.
BOOTInspect f6r damage and deterior6tion.
STEERING JOINTSCheck tor loose joint bolts.
PINION SHAFT GROMMETInspect lor damage and deterioration.
STEERING
TIE.ROD LOCKNUTCheck for loose locknut.
Inspect lor loose mounting bolts.GEARBOX MOUNTING CUSHIONSInspect for deterioration.
BALL JOINT BOOTInspect tor damage and deterioration.See psge 17-63 for replacement.
17-19

Steering Wheel
Installation
Airbag installation
CAUTION:
. B€fore inrtalling the stooring wheel, align tho front
who6l3 etraight ahead.
. Bo sure to install the harness wires so that thGy are
not pinched or intorfsring with othor car parts.
. Do not roplace thc original stsoring wheel with any
othor design. since it will maks it impo$ibla to prop-
erly install the airbag. {Only use genuine HONDA
replscomont parts)
. After rols3embly. confirm thai the whoels are still
straight ahoad 8nd that steoring wheel spoke anglo
is correct. lf minor spoke anglo adiustment is noc€s-
srry, do so qnly by adlustment ol th€ tie-rods, not byromoving and repositioning the steering wh€€|.
@ contirm ihat the airbag assombly is
socurely attachsd to the stooring wheel; oth€rwise,
scvoro porsonal iniury could r€sult during airbag
doploym6nt.
1. Before installing the steering wheel, center the
cable reel.
Do this by tirst rotating the cable reel clockwise
until it stoos.
Then rotate it counterclockwise (approximately two
turnsl until:- The yellow gear tooth lines up with the mark on
the cover.- The arrow on the cable reel label points straight
UD.
YELI-OW GEAR
ALIGNMENT MARK
17-26
2. Install the steering wheel.
NOTE: Be sure the steering wheel shaft engages
the cable reel and canceling sleeve.
a9 N.m (5.0 ksf'm,36 lbf.ftl
Attach the cruise control sevresume switch€s con-nector to the steering wheel clip.
Connect ihe horn connector.
CRUISE CONTROLSET/NESUME SWITCHESCONNECTOR

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

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

Steering Gearbox
Reassembly (cont'dl
65. Adjust the air hose fitting position of the boots by
turning it as shown below.
Front
AIR HOSE FITTING
Connect the air hose between the right and left
boot. then install the clips on the cylinder pipe B assnown.
Install the right clipin this position.
CLIP
17-62
67.Install new boot bands on the boot and bend both
sets of locking tabs.
Lightly tap on the doubled-over portions to reduce
their height.
GAUTION: Stake tho band locking tabs firmly.
Slide the rack right and left to be certain that the
boots are not detormed or twisted.
Install the right and left tie-rod ends on the rack
ends.
70.