power steering HONDA INTEGRA 1998 4.G Owner's Guide

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.

Strsring Rack Roarssmbly
25. Coat the special tool with power steering fluid, and
slide it onto the rack, big end first.
26. Position the new O-ring and new piston seal ring on
the special tool, then slide them down towards big
end of the tool.
NOTE:
. Do not over expand resin seal rings. Install the
resin seal ring with care so as not to damage
them. After installation. be sure to contract the
seal ring using the specialtool (sizing tool).
. Replace piston's O-ring and sesl ring as a set.
27. Pull the O-ring off into the piston groove, then pull
the piston seal ring off into the piston groove on top
of the O-ring as shown.
Coat the piston seal ring and inside of the special
tool with power steering fluid.
Carefullv slide the tool onto the rack and over the
piston seal ring.
30. Move the special tool back and forth several times
to make the piston seal ring fit snugly in the piston.
28.
29.
PISTON
Replace.
31.Coat the sliding surface of the special tool and new
cylinder end seal with power steering fluid,
Place the seal on the special tool with its grooved
side facing opposite the special tool.
Grooved side.
CYLINOER END SEALReplace. 0797,t - 68D8OA
Apply a thin coat of grease to the inside of the spe-
cial tool, and install it on the steering rack.
CAUTION: Make sure the rack tecth do not lace
the 3lot in the special tool.
CYLINDER END SEALReplace.
CYLINDERSEAL SLIDER07974 - 6890800ot(cont'd)07974 - 6A1080A
17-53

Power Steering Gearbox
Reassembly {cont'd}
34. Separate the cylinder end seal from the special tool,
then remove the tool from the steerino rack.
CYLINDER END SEALReplace.
lnstall the backup ring on the steering rack. then
place the cylinder end seal to piston.
Grease the steering rack teeth, then insert the steer-
ing rack into the gearbox housing.
CAUTION: Be carelul not to damage to inner sur-
tace of the gearbox housing with the rack edges.
BACKUP BING
CYLINDER END SEAL
17-54
37.
38.
Set the gearbox in a press with the cylinder housing
facing upward.
Install the flange bolt into the end of the steering
rack until it bottoms in the hole. then back the
tlange bolt out 1/4 turn. Hold the flange bolt and
tighten the flange nut against the rack by hand.
Install the cylinder end seal into the bottom of the
cylinder by pressing on the bolt with a press as
shown.
CAUTION: Do not push on th€ boh with excossive
lorce; as it may damage thecylinder end seal.
Press
I
12 x 170 mm FLANGE BOLT
12 mm FLANGE NUT
Wrap vinyl tape around the rack end edges, and
coat the surface of the tape with the power steering
flu id.
NOTE: Make sure that the vinyl tape is wrapped care-
fully so that there is no stepped ponion.
Coat the inside surface of the new cvlinder end seal
with power steering fluid.
Install the cylinder end seal onto the steering rack
with its grooved side toward the piston.
CAUTION: When installing the cylinder end seal,
be careful not to damage the sealing lip face of the
seal with the edges of the steering rack,
Stak6d oosition.
39.
41.
Make sure the springis in the cylinder end

Power Steering Gearbox
Reassembly (cont'dl
Installthe cylinder lines A and B.
NOTE:
. Clean the joints of the cylinder line A and B thor-
oughly. The joints must be free ol foreign materi-
at.
. Install the cylinder line A and B by tightening the
flar€ nuts by hand first, then tighten the flare
nuts to the specified torque staning with the
cylinder side nuts.
CYLINDER I-INE B26 N.m {2.7 kgf.m, m lbl.ftl
50.
5t.Grease the sliding surface of the rack guide
install it onto the gearbox housing,
and
52.
53.
LOCKNUT
q
SPRING
RACK GUIDE SCREW
Install the spring, rack guide screw and locknut on
the gearbox housing.
Adjust the rack guide screw (see page 17-2'll,
NOTE: After adiusting, check that the rack moves
smoothly by sliding to rack right and left.
17-56
STEERING RACK
WOODEN BLOCK
54.Install the new lock washer in the groove in the
steering rack.
Screw each rack end into the rack.
Hold the left end of the steering rack with I wrench
and tighten to th€ rack ends with another.
56.
After tightening the rack end, stake the four sections
of lock washer with a commerciallv available rollpin drift and a mallet.
RACK END5{ l{.m
{5.5 kgl.m, aO lbt.ftl
ROLL PIN DRIFTlcomm.rci.lly .v.ihbl.l(Sn.pon f{o, PPR8 or .quiv.lc.n}
LOCK WASHERReplace.
NOTE: This dritt has ato prevent puncturingot metal washer.

Power Steering Gearbox
Reassembly (cont'dl
63. 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.
CAUTION: Stake ihe bsnd locking tabs tirmly.
Slide the rack right and ieft to be certain that the
boots are not deformed or twisted.
Install the right and left tie-rod ends on the rack
enos.
64.
lnstallation
CAUTION: Bo caretul not to bond or damrge the powcr
steering lines when in3t8lling the grlrbox.
1. Before installing the gearbox, slide the rack all the
way to right.
2, Pass the right side of the stsering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack 8ll the
way to the right.
4. Rsise the left side of the steering gearbox above
and through the left side of the rear beam.
5. Install the pinion shaft grommet and insert the pin-
ion shaft up through the bulkhesd.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodY.
oo.
tAa
17-58

Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
tube connections for interference with adjacent
parts.
58 N.m 15.9 kgl.m, 43 lbf.ftl
Connect the power steering fluid lines to the valve
body unit.
7.
38 N.m {3.9 kgt m, 28 lbf.ftl
RETURN HOSE
PUMP OUTI.TY HOSE(High-pressure)
37 N.m (3.8 kgf.m, 27 lbt.ftl
Center the steering rack within its stroke.
Before connecting the steering joint, perform the
lollowing operation.
. Center the cable reel by first rotating it clockwise(approximately two turns) until the arrow mark
on the label points straight up,
Slip the lower end of the steering ioint onto the pin-
ion shaft {line up the bolt hole with the groove
around the shaft), and tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.
. Be sure that the lower steering joint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
o lf the steering wheel and rack are not centered,
reoosition the serrations at lower end of the
steering joint.
(cont'd)
LOWER BOLT22 N.m {2.2 kgf.m, 16 lbf.ft,
17-59

Power Steering Gearbox
Installation (cont'dl
11. Install the steering joint cover with the clamps and
clips.
lnstall the rear beam brace rod and return line
clamp on the rear beam.
NOTE: lnstall the rear beam brace toward the
return line clamp.
12.
CLIP
38 N.m 13.9 kgl'm,28 lbf tl)
17-60
13. Install the three way catalytic converter with the
new gaskets and new self-locking nuts, and connect
the secondary heated oxygen sensor (HO2S) con-
nector.
SECONOARYHEATED OXYGEN SENSOR CONNECTOR
22 N.m {2.2 kgf.m, 16lbIft)
Connect the shift linkage (M/T model: see section
13, A,,/T model; see section 14).
Thread the right and left tie-rod ends onto the rack
an equal number of turns.
14.

)
)
16.Reconnect the tie-rod ends to the steering knuckles,
tighten the nut to the specified torque, and install
new cotter Dins.
COT?ER PINReplace.On reassembly, bendthe cotter pin as shown.
lnstall the front wheels.
Fill the system with power steering fluid and bleed
air from the system (see page 17-21).
After installation, perform the tollowing checks.
. Check the gearbox for leaks (see page l7-23).
. Adjust the front toe (see section 18).
. Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods equally, it nec-
essary.
Ball Joint Boot Replacement
CAUTION: Do not contaminste th! boot in3tllhtion sec-
tion with grca3o.
1. Remove the boot from the tie-rod end, and wiDe the
old grease off the bsll pin.
2. Pack the lower area of the ball pin with fresh grease.
3. Pack the interior of the new boot and liD with Jresh
grease.
CAUTION:
r Keep grease off tho boot inst.llrtion section 8nd
ths tapered 3cction if tho ball pin.
. Do not lllow du3t. dirt. or other foreign matcrials
to entar lh6 boot.
17.
18.
Lfp -A-1
L:I
ru
Install the new boot using the special tool as shown
Derow.
NOTE: The boot must not be a gap at the boot instal-
lation sections.
CAUTION: Aftor installing tho boot, chock tho ball
pin tapgrgd 3oction tor grorsg conttmination, and
wipe it if nccossary.
BALL PIN TAPEREDsEcnoNWipe offthe grease.BOOT INSTALLATIONsEcnoNWipe off the groaso.
19.
FROI{T HUBDIS/ASSEMBLY TOOL07965 - SA5o5o0
17-61