Cylinder HONDA INTEGRA 1998 4.G Repair Manual

From page 17-10
Normal
Check lorce required to turn thewhool (see page 17-'18).Start the engine and measu16the force required to turn thewheel to the right and left.Difference of the force requiredto twn the wheel to the right andto the left should be 5 N (0.5 kgf,1 lbl) or below.
Deformed
I
iFaulty cylinder lines
Not bent
Adjustment OK
Faulty valve body unit
Abnormal --> Faulty gearbox
Ch€ck th6 pans other than the gearbox-related parts lorDrooer rolaton.
. . lmproper rotation ofthe steering column-related pan{s}----------------- . tau[y $eenng lornt. Faulty rack endtio-rod ond balljoints. Intgrferonce in the steering system
Normal -----> lmproperly adjusted rack guide
Check lor bent rack shaft.
Check pump fluid pressure (seepage 17-22).Turn the steoring wheel fully tothe right and l€ft while idlingwilh the pressure control valveIully open, and measure the Iluidpressure. lt should be 6,400 -
7,400 kPa (65 - 75 kgflcmr, 924 -
1,067 psi).
Normal
Ch€ck the gearbox.Remove the gearbox and mea-sure the pinion torque.The lorque should be;. 0.7 - '1.2 N.m (7 - 12 kgf.cm, 6 -
10 lbf.in) wjth the steering rackin the straight driving position.
Abnormal
Adjust the rack guide {see page17-211, and recheck the pinion
torque.
17-11

Troubleshooting
General Troubleshooting (cont'dl
Assist (excessively light steering) athigh speod.
Shock or vibration when wheel isturned to full lock.
Steering wheel will not return
smoothly.
a-, aa GrI r- tz
ll the problom is not correcled byadiusting the rack guide, adjustthe front wh66l alignment (see
s6ction 18).
Ch6ck th6 rack guide propgr ad-justment (see pago 17-21).
Check the rack guido lor proper
adjustment (see page 17-21).
Rack guid€ is adjusted properly.
lf the problem is not corrected byadjusting the rack guide, replscothe gearbox.Check the belt for slippage andadjust as nec€ssary {s6e page 17-20).
A and B cylinder lines are nor-mal, chgck wheol alignment (se€
section 18).
Whe6l alignment is abnormal,adjust as needod.
It should be 0.7 - 1.2 N.m {7 - 12kgl.cm.6 - 10 lbf.in) or belowwith the steering rack in thestraight ahoad driving position.
wh€el alignment is normal.R€mov€ the gearbox from thofram6 snd measure the pinion
torque on the gearbox.
lf the measurements are out ofsp€cifications. adjust the rackgurd9.
It the problom is not corrected byadiusting the rack guido. r€placethe goarbox.
{
I

I
Troubleshooting
17-14
Noise and Vibration
NOTEr Pump noise in first 2 - 3 minutes after starting in cold weather is normal.
Humming
Rattle or chattering
Humming due to pulsation oI lluid is normal, particularly when the wheel isturned with the vehicle stoooed.
Outlet hose (High-pressure hose)touching the frame.
Right cylinder end seal squeak.
Pump noise, though not loud, from tho valv6 body unit can be heard when turn-ing the steering wheel to full lock in either direction. This is normal. Do not hold
the steering wh6el at tull lock tor more that live seconds wh€n inspecting.
Loose steering shaft connector,tie-rod, or ball ioint.
Check and tighten, or replacepans as necessary,
Column shaft wobbling.Reolace the column assemblv.
Check ihe rack guide tor proper
adjustment (see page 17-21).Adiust, if nec€ssary.
Rattling sound and feeling when turning the steering wheel right and left with the
engine OFF is normal.

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

Power Steering Hoses, Lines
Replacement
NOTE:
. Connect each hose to the corresponding line securely
until it contacts the stop on the line. Install the clamp
or adjustable clamp at the specified distance from the
hose end as shown.
. Add the recommended power steering fluid to the
specified level on the reservoir and check for leaks.
ADJUSTABLE HOSE CLAMP: (al
. Position the adjustable hose clamps at the points
indicated by (a) in the drawing below.
. Slide the hose over the line until it contacts the stop.
CAUTION: Ch€ck all clamps for deterioration or defor-
mation; replace the clamps with new ones it necessary'
HOSE CLAMP: (b)
. Position the hose clamps at the points indicated by
(b) in the drawing below.
. Slide the hose over the line until itcontactsthe stop.
2.5 - 5.5 mm(0.01 - 0.22 in)
RETURN LINE JOINT28 N m 12.9 kg{'m,2'l lbf'ft|
PUMP OUTLET HOSE(High'pressure)
37 N.m (3.8 kgtm,27 lbf.ft)
2.5-5.5 mm
10.01 - 0.22 in)2.0 - {.0 mm
10.08 - 0.16 inl
CYLINDER LINES17 N.m (1.7 kgt m, 12 lbf'ft)
PUMPOUTI.IT HOSE(High-pressure)
11 N.m11.1 kgl.m,8lbJftl
PUMPINLET HOSE(Low-pressurel
RETURN HOSE
Exc.pt Bl8Cl engino
17-34

15. Disconnect the two lines from the valve bodv unit
on the steering gearbox.
CAUTION: After disconnscting the hose and line,plug or seal the hose and lino whh I pi6ce ot tape
o. oquivalent to prevont foreign matarials from
6rioring the vslve body unit,
NOTE:
. Place the line disconnected in the previous steD
at the rear side of the gearbox so that they do
not hinder in the gearbox removal.
. Do not loosen the cylinder lines A and B between
the valve body unit 8nd cvlinoer.
ADJUSTABLE HOSE CLAMP
Remove the steering gearbox mounting bolts.16.
\
RETURN HOSE
GEARBOX MOUNTING BOTTS
17-43
't7.
19.
Pull the steering gearbox all the way down to clear
the pinion shaft from the bulkhead, and remove thepinion shaft grommet.
Move the steering gearbox to the right so th€ left
rack end clears the rear beam.
Mov€ the steering gearbox to the loft, and tilt theleft side down to remove it from the vehicle.
PINION SHAFT GBOMMET
STEERING GEARBOX

8.Remove the cylinder line A and B from the gearbox.
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 17-47 for
valve body unit disassembly.)
FLANGE BOLT
10.
CYLINDER LINE B
VAI.VE BODY UNIT
11.Orill 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: Oo not allow metal shavings to enter the
cylinder housing.
12. Install a puller yoke to the steering gearbox. Clamp
the puller yoke in a vise with soft jaws as shown,
then loosen and remove the cvlinder end,
CYLINDER END
STAKED POINT
\\
i D.pth:2.5 - 3.0 mm {0.10 - 0.'12 inl
re
17-45l

Power Steering Gearbox
Disassembly (cont'dl
VINYL TAPE
12 mmFLANGE NUT
13. Set the gearbox in a press so the gearbox housing
pornts upward.
14. Install the flange bolt into the end of the steering
rack until it bottoms in the hole, then back the
flange bolt out 1/4 turn. Hold the flange bolt and
tighten the flange nut against the rack by hand.
15. Press the cylinder end seal and steering rack out of
the gearbox.
NOTE: Hold the steering rack to keep it from falling
when pressed clear.
T-
I
I170 mm
CYLINDEREND SEAL
Remove the flange bolt and cylinder end seal from
the steering rack.
Press
t
18.
17.
Ple3s
I
ATTACHMENT, 23 x 25 mm
07NAD - SR3020A
CYLINDER ENDSEAL
19. Carefully pry the piston seal ring and O-ring off the
oiston of the rack.
CAUTION: Be carelul not to damage the inside of
seal ring groove when remoying the seal ring.
lnsert a 24" long, 3/8" drive extensjon, and the spe-
cial tool into the cylinder from the gearbox side.
CAUTION: Be careful not to damage the inside sur-
lace of the housing with the lools.
Set the gearbox in a press, then press out the cylin-
der end seal and backup ring from the gearbox.
CAUTION:
. Keep the tool straight to avoid damaging the
cylinder wall, Chcck thc tool angle, and correct il
necessary, when removing the cylinder end s€al.
. Use a press to remove the cylinder end seal. Do
not try to remove the seal by striking the tool. lt
will brcak the backup ring and the cylinder end
seal will remain in the gesrbox.
Replace
17-46

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}

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