oil HONDA INTEGRA 1998 4.G Workshop Manual

Pump noiseGrating noisefrom pump
Pump noise
I
aou""*,nn
Rattle or chattering
Check the flu id level.lf low, fill the reservoir to theproper level, and check for leaks.Tighten or replace as necessary.
Cavitation caused by air bubblesin the fluid.
Check for a crushed inlet hose ora loose hose clamp allowing airinto the suction side of the sys-tem.Tighten or replace as oecessary.
Check the oumo shaft oil seal.
Check the reservoir for cracks.
NOTE: Pump noise up to 2 - 3minutes alter starting in coldweather is normal.Compare pump noise at operat-ing tomperature to another simi-lar vehicle.
lf pump noise is abnormally loud,remove and inspect the pump forwear and damage (see page 17-36).
Tighten or replace the pulley.lf shaft is loose, replace thepump.
17-15

Troubleshooting
Fluid Leaks
Check the gearbox assembly for oil leaks carefully, Oil can leak out of various points, depending on location of the
faulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
Stoo.ing GearboxReplace the valv€ oil seal fromthe valvo houging.Leaking from the oil seal on thetop of the valve housing.
Roplace the valve oil seal fromthe pinion shaft.Leaking trom cylinder 6nd intol€ft ti6-rod boot,
B€place tho cylindgr ond seal onthe gear housing side.
Replaco th€ cylindor end seal onths cylinder end side.Leaking from cylinder end intoright tie-rod boot.
Leaking from the thaft upper endsection or pin ongagement sgc-tion ofth6 Dinion shaftRoDlace tho valve bodv unit.I
I
Tighten connector. lf it€ still leak-ing. replace th€ lin€, cylinder orvalve housing.
Leaking lrom cylind6r line A or Bconn6ction {Et flare nut).
Leaking caused by a damagedcylinder line A or B.Replace cylinder line A or B.
Tightgn tho connector. ll its stillleaking, r€place the hos€, joint
fitting or valv€ housing.
Leaking from outlet line andreturn line joint fitting on thevalv6 body unit (at flare nut).
17-16

Rack Guide AdjustmentFluid Replacement
Check the reservoir at regular intervals, and add fluid as
neceSsary.
CAUTION: Use only Genuine Honda Powel Ste€ring
Fluid-V. Using other fluids such as ATF or othor manu-
laclurer's power ste€ring fluid will damag€ the systom.
SYSTEM CAPACIW:
B18Gl ongine:
1.06lit€r (1.12 US. qt,0.93 lmp.qt)
Excopt 8l8Cl ongino:
1.0 lher (r.06 US. qt.0.88 imp.qtl
at disa$ombly
RESERVOIR CAPACITY:
0.,0 liter {0.42 US. qt, 0.35 lmp.qt}
LEVEL LINE
LEVEL LINE
Raise the reservoir and disconnect the return hose
that goes to the oil cooler.
Connect a hose of suitable diameter to the discon-
nected return hose and put the hose end in a suit-
able container.
CAUTION: Take care not to spill thq fluid on lhe
body and parts. Wipe off any spilled fluid al onc€.
Start the engine. let it run at idle, and turn the steer-
ing wheel from lock-to-lock several times. When
fluid stops running out of the hose, shut off the
engine. Discard the fluid.
2.
RETURN HOSE{From the oilcooler)
4. Reinstallthe return hose on the reservoir.
5. Fill the reservoir to the uDDer level line.
6. Start the engine and run it at fast idle, then turn the
steering from lock-to-lock several times to bleed air
from the system,
7. Recheck the fluid level and add some it necessary.
CAUTION: Do not lill the reservoir boyond thc
upper level line.
J.
4.
NOTE: Perform rack guide adjustment with the wheels
in the straight ahead position.
1. Loosen the rack guide screw locknut with the spe-
cialtool, then loosen the rack guide screw.
Tighten the rack guide screw until it compresses the
spring and seats against the rack guide, then loosen
it.
Retighten ihe rack guide screw to 3.9 N.m (0.4
kgf.m, 2.9 lbi.ft), then back it ofl to specified angle.
Speciliad Roturn Anglo: 20' Max
Tighten th€ locknut while holding the rack guide
screw.
RACK GUIDE SCREW
25Nm{2.5 kgf.m, 18 lbf ft)
LOCKNUT WRENCH. ilo mm079't 6 - SA50001
E
6.
Check for tight or loose steering through the com-
plete turning travel.
Perform following inspections:
. Steering operation (see page 17-18).
a Power assist with car parked.
I

Steering Column
Inspection
Check the steering column ball bearing and the steer-
ing joint bearings for play and proper movement. ll
there is noise or if there is excessive plav, replace the
ioint or column assembly.
Check the retaining collar tor damage. lf ir is dam'
aged, replace the retaining coilar.
Check the absorbing plates, absorbing plate guides
and sliding capsules for distonion and breakage.
Replace them as an assembly if they are distorted or
DroKen.
ABSORBING PLATE
COLUMN SALL BEANING
IGNITION SWITCHsee section 23.
Move the tilt lever from the loose position to lock
position 3 to 5 times; then measure the tilt lever
preload 10 mm (0.4 in) from the end of the tilt lever.
Preload: 70-90 N {7 -9 kgl, 15-20 lbll
lf the measurement is out of the specification,
adjust the preload using the following procedures.
a. Loosen the tilt lever, and set the steering column
in the neutral position,
b. Remove the 6 mm lock bolt and remove the stop.
c. Adjust the preload by turning the tilt lock bolt left
or right.
d. Pull up the tilt lever to the uppermost position
and install the stop. Check the preload again. lf
the measurement is still out of specification,
repeat the above procedures (a) through (c) to
adjust.
CAUTION: Be carelul not to loosen the lilt lsvel
when installing the stop or tightening the 6 mm
lock bolt.
RETAINING COLLAR
AESORBING PLATE
JOINTBEARINGS
PLASTICINJECTIONS
This pan is attachedto the column bracketwith the plastic iniectaons.
t
SPRING SCALE
TILT LOCK BOLT
17-30
9.8 N.m (1.0 kst.m, 7.2 lblft)
t
{
I

Power 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.
l. Drain the power steering fluid as described on page
11-21.
2. Raise the front of vehicle, and support on safety
stands in the proper locations (see section 1).
3. Remove the front wheels.
4. When the vehicle is equipped with the SBS airbag
system, remove the steering wheel (see page 17-
24t.
5. Remove the steering
6. Remove the steering joint lower bolt, and move the
ioint toward the column.
STEERING JOINTLOWER SOI-T
(cont'd)
19. Install the pulley as shown below, then loosely
install the pulley nut. Hold the steering pump in a
vise with soft jaws.
CAUTION: Be carelul not to damlge tho pump
hou3ino with ths ilws of th6 vies.
Hold the pulley with the special tool, and tighten thepu ey nut.
ioint
Va
20.
PULI.IY NUT6,1 N.m {6.5 kgt m,47 lbf,ftl
'(
Check that the pump turns smoothly by turning thepulley by hand.
.-l
21.
PULLEY
UNIVERSAL HOLDER
CLIP
17-41

Power Steering Gearbox
Disassembly (cont'd)
25. Using a cutter or an equivalent tool, cut and remove
the four seal rings from the sleeve.
CAUTION: 86 caroful not to damage the edgos of
the 3leeve grooves whon removing the scal rings
and O-ring.
Using I cutter or an equivalent tool, cut the valve
seal ring and O-ring at the groove the pinion shaft.
Remove the valve seal ring and O-ring.
CAUTION: 86 careful not to d.mago the sdges ol
lhe pinion shaft groove whgn removing the valvo
seal ring and O-ring.
SLEEVE
Cutting slot position.
17 -48
t"fRemove the valve oil seal and wave washer ring
from the pinion shaft.
NOTE:
. Inspect the ball besring by rotating the outer
race slowly. lf there is excessive play, replace the
pinion shaft and sleeve as an assembly.
. The pinion shaft and sleeve are a precise fit; do
not intermix old and new pinion shafts and
steeves.
VALVE OII- SEALReplace.
Press the valve oil seal and bushing out of the valve
housing using a hydraulic press and special tool
shown below.
ATTACHMENT, 23 x 25 mm
07NAD - SB3020A
VALVE OIL SEALReplace.
28.
BALL EEARING
BUSHING

ra
NOTE:
. Clean the disassembled parts with a solvent and dry them with compressed air. Do not dip the rubber parts in a sol-
venr,
. Always replace the O-rings and rubber seals with new ones before assembly,
. Apply recommended power steering fluid to the parts indicated in the assembly procedures.
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.
. Use the appropriate specialtools where necessary.
FLANGE BOLT20 N.m 12.0 kgf.m, 14 lbl.ftl
VALVE HOUSING
CYLINDER LINE B26 N.m 12.7 kgf.m, 20
VALVE OIL SEALReplace.
SLEEVE SEAL RINGSReplace.st"cEvE
VALVE SEALReplace.
WAVE WASHER
VALVC SEAL RINGReplace.
O-RINGReplace.
PINION SHAFT
RACK GUIDE SCREW
LOCKNUT \
cEARBoxHousrNc \b
SPRING
f,ACK GUIDE
BACKUP RING
Replace.
GEAR HOUSINGCYLINDER ENDReplace.
CYLINDER END SEALReplace.O.RINGReplace.
I
o0'
STEERING RACK
PISTON SEAL RINGReplace.
CYLINDER END69 N.m {7.0 kgtm,51 lbtftl
{cont'd}

Power Steering Gearbox
Reassembly (cont'dl
i
valv6 Body Reasrombly
1. Apply vinyl tape to the stepped portion of the pin-
ion shaft, and coat the surface of the vinyl tspe with
the power steering fluid.
Vinyl tlp€lst.ppcd ponionl
Groov€ side.
Install the wave washer,
Coat the inside surface of the new valve oil seal
with power steering fluid.
Slide the valve oil sesl over the pinion shaft, being
careful not to damage the sealing lip.
CAUTIONT ln3tall the v8lve oil 3eal whh itr groovod
side facing oppositc thc braring.
Fit the new O-ring in the groovo of the pinion shaft.
Then slide the new valve sesl 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 seal ring.
Sr.lino
E
lip
VALVE SEAL RINGReplace.Do not over-expand.
17-50
7. Apply power steering fluid to the surJace of the
valve seal ring that was installed on the pinion
shaft,
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.
Move the sDecial tool uo and down several times to
make the valve seal ring fit in the pinion shaft.
11.
(w(ffi \
Use the wider diameter Make th6 valve seal ringend of the special snugly fit in the pinion
tool first to make shaft using the other endthe valve seal ring (smaller diameter end) ofIit in the pinion the special tool.shalt.
Remove the special tool,
Turn the special tool over and set the smaller diam-
eter end of the special tool over the valve seal ring,
Move the special tool up and down several times to
make the vslve seal ring snugly fit in the pinion
shaft.

12.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. Oo not mix the different types of
sleeve seal rings as they are not compstible.
Align the special toolwith each groove in the sleeve.
and slide a sleeve seal ring into each groove.
NOTE: After installation, compress the seal rings
with your fingers temporarily.
BALL JOINT B(X)? CUP GUIDE07MAG - SLdrlrx,
Apply power steering fluid to the seal rings on the
sleeve and to the entire inside surface of the soecial
tool.
SLEEVE SEAL NINGSIZING TOOL0r9?a - sat02n0
Insert the sleeve into the special tool slowly.
Move the sleeve each direction several times to
make the seal rings snugly fit in the sleeve.
NOTE: Be sure that the seal ringsare notturned up.
13.
14.
to.
17-51
Cutout.
17.Apply power steering fluid to the surface of the pin-
ion shaft, assemble the sleeve over the pinion shaft
by aligning the locating pin on the inside of the
sleeve with the cutout in the shaft. Then install the
new circlip securely in the pinion shaft groove.
NOTE:
. Be careful not to damage the valve seal ring
when inserting the sleeve.
. Install the circlip with its radiused side facing in,
18. Installthe circlip securely in the pinion shaft groove.
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
snown.
CAUnON: Instsll tho valvo oil s€.| with its groovcs
side facing th. tool.
19.
ATTACHMET{T,32x35mm077i15 - (xll01lX,
VALVE OIL SEALReplace.Make sure thespring in theoilseal.
(cont'd)

Power Steering Gearbox
Reassembly (cont'dl
20. Press the bushing into the valve housing using a
hydraulic press and speciai tool as shown.
DRIVER07749 - U)l 0000
ATTACHMENT,32x35mmPress
I07746 - fi)l01(x)
sUSHING
21.Apply vinyl tape to the pinion shaft, then coat the
vinyl tape with power steering fluid.
I
i
I
VALVE OIL SEALReplace.
VALVE HOUSING
Vinyltape
PINION
E
SITEVE SEAL RINGSReplace.8e sure that theseal rings are notturned up, theninstall.
Insert the pinion shaft into the valve housing.
CAUTION: Be careful not to damage the valve seal
rings.
Remove the vinyl tape from the pinion shaft.
Seding lip lrce.
17-52
24. Press the pi.ion shafvsleeve into the valve housing
using a hydraulic press as shown.
NOTE: Check that the pinion shaft/sleeve turns
smoothly by turning the pinion shaft with your
hand.