1994 HONDA INTEGRA oil

Unovon or rcugh 8te6ring.
3
Adjust rack guide (se€ poge 17-21).
ll the probl6m is not corrected bYadjusting lhe rack guide. replacothe gearbox.
Adiud bolt t€nsion. Roplace b€lt, ifn€c€ssary {s€e page 17-20).
lf the ongin€ stalls when wheel isturned whil€ car is stoDPed ormoving at low spoed, adjust idlesp€€d (soe section 1 1 ).
ldl6 soosd low or orrrtic.
Chock power sieering Iluid levol. Itlgv6l ie excessivoly low, ch€ck forleaks in the system. Add fluid totho spocifiod level.
Air in rssorvoir. or ch€ck pow6a
steoring fluid l6v6l.
lf fluid lev6l is OK, check o-ringsand seals on both €nds of ihopump inlet hose, and th€ oilpump housing mating surfacosfor suction leaks. Reolace oarts65 n€CeSSAry.
Adjust belt tonsion (see page 17-m) or r€Dlaco beh.Pump b6lt slipping on pull6y(pump stops momontarily).
Check if pump prossure is withinthe ranoe 6.400 - 7,100 kPa (65 - 75kgr/cm,, 924 - 1,067 psil and th6gsuge needls travol is 1500 kPa {15kgflctn2, t71 p6i) or less. Check theflow control valve if the needletr.vel €xcoods 1500 kPa {15kg?cm,, i71 psi). lf rhe flow controlvalvo is normal, replace th€ pump
as an assomblv.
Sel the power itooring p.oasuregaug6. Cl066 th€ shut-off v6lv6fully and m€a5uro tho pumppr6ssur6 (6s€ pagg 17-221,
7-1

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

NOTE: Perform rack guide adjustment with the wheels
in the straight ahead position.
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 .ack guide, then loosen
it.
Retighten the rack guide screw to 3.9 N.m {0.4
kgf'm, 2.9 lbf.ft), then back it off to specified angle.
Specified R6turn Angle: 20 t 5"
Tighten the locknut while holding the rack guide
screw.
1.
6.
RACK GUIDE SCREW
25 N.m12.5 kgf.m, 18lbtftl
L(rcKNUT WRENCH, 40 mm07916 - SAs(xtOl
Check for tight or loose steering through the com-
plete turning travel.
Perform following inspections:
. Steering operation (see page 17-18).
. Power assist with car parked.
Check the reservoir at regular intervals. and add fluid as
necessary.
GAUTION: Use only Genuine Honda Power Stosring
Fluid-V. Using othsr fluids such as ATF or other manu-
facturer's power stoering fluid will damags ths systcm,
SYSTEM CAPACITY:
LO6 litor (1.12 US. qt, 0.93 lmp.qtl
at disasssmbly
RESERVOIR CAPACITY:
0.79 lit6r (0.8:l US. qt, 0.70 lmp.qt)
UPPER LEVEL UNE
LOWER LEVEL LINE
,l
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: Tako caro not to 3pill tho tluid on tho
body and parts. Wipe off the spilled tluid at onqe.
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,
Refit the return hose on the reservor.
Fill the reservoir to the uDoer level line.
Start the engine and run it at fast idle, then turn the
steering from lock-to-lock several times to bleed air
f.om the system.
Recheck the fluid level and add some if necessary.
CAUTION: Do not lill the roservoir beyond tho
uppgr lovel line.
7.

Remov€ the circlip, then remove the drive shaft
assembly from the pump housing using a plastic
namm€r.
Remove the seal spacer and oil seal.
Inspect the pump housing for damage on the seal-
ing surfaces.
/-clRcLlP
Q'/
ra -,"
DRIVE SHAFTfor bend,damage or wear,
PUMP HOUSING
11. lnspect the bearing by rotating the outar race slow-
ly. lf any play or roughness is felt, replace the bear-
ing.
Remove and discard the bearing using the
tool and a gress.
Pra3s
+
special
13.Install the new bearing
press.
I{UB DIS/ASSEMBLY BASE07GAF - SD40700
using the special tool and a
Press
+
Installwith thered shielded sidelacing down.
07GAF - SDis)700NOTE: Support the inner racewith the tool securely.
17-39

Pump Rotor Installation
L Coat the lip of the new oil seal with steering grease
(Honda P/N 08733 - 8070E).
Install the new oil seal in the pump housing by
hand, then install the pump seal spacer.
NOTE: Insert the oil seal with its grooved side fac-
ing in.
Install the pump drive shaft assembly with the spe-
cialtool.
Install the 38 mm circlip with its tapered side facing
out,
3.
4.
DRIVER ATTACHMENT07947 - 6:1io50038 mmcrncuP
- DRIVE
fu'/'i,Ert\=zl4
I"J PUMP SEALIf /sprcen
x,tY -ot seal
-Gll
ATTACHMENT, 37 x ,r0
07t,16 - dt102d,
5. Coat the side plate grooves with the recommended
power steering fluid, then position the 16.8 x
1.9 mm and 54 x 1,9 mm O-rings on the side plate.
16.8 x 1.9 mmO.RING
5a x 1,9O.RING
l
SIDE PLATE
17-41
6. Install the preload spring in the pump housing.
7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in
the pump housing.
8. Set the side plate over the roller and install it on the
pump housrng.
9. Set the 5 x 26.8 mm roller in the 5 mm hole in the
side plate.
5 x 26.8 mmROLLER
5 mm HOLE
SIDE PLATE
PRELOADSPRING
,1.5 mm
10.Assemble pump rotor to the drive shaft with the "o"
mark on the rotor facing upward.
Set the 10 vanes in the grooves in the rotor.
NOTE: 8e sure that the round ends of the vanes are
in contact with the sliding surface of the cam ring.
PUMP ROTOR
(cont'd)
11.

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
Disassembly (cont'dl
25. Using a cutter or an equivalent tool, cut and remove
the four seal rings from the sl6eve.
CAUTION: Bc clroful not to drmrg. ths .dgc. otthc alcava g1oov6 whan rcmoving the 3cd rings
lnd O.ring.
Using a cutter or an gquivalent tool, cut the valve
seal ring and O-ring Et the groove the pinion shaft.Remove the valv€ saal ring 8nd O-ring,
CAUTION: Br crrltul not to drm.gr thc cdgct ofthc plnion rhdt grooya whcn rcmoving the vllvc
!.!l ring rnd O-ring.
26.
SI-EEVE
Cutting slot position.
17.52
Remova the valve oil seal 8nd backup ring from thepinion shaft.
NOTE:
. Inspect the ball bearing by rotating the outer
race slowly. lf thsre is excessive play, replace thepinion shaft and sleeve as an assembly.. The pinion shaft and sleeve are a precise fiu donot intermix old and new pinion shafts and
steev8s,
28, Press th6 valve oil s€al and roller besring out ofthe
valve housing using a hydraulic press and specialtool shown below.
PILOT COLLARO?GAF - PHTO1OO

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.