1994 HONDA INTEGRA ESP

Power Steering Hoses, Pipes
Replacement
NOTE:
. Connect each hosg to the corresponding pipe securg-
ly until it stops at the stopp€r on the pipe.
Install the clamp or ad,ustable clamp at the specified
distancs from the hose end as shown in the drawing.
. Add the power steering fluid to the specilied level on
the reservoir and check fo. leaks (see page 17-23).

Put ov6r the pipe untilthe hose stops at the$opper.
CAUTION: Chock all clampsfor doterioration 8nd dstor-
mation, and rsplacG with new onss if n6co33!ry,

Put over the pipe untilthehose stops at the stopper.
2.5 - 5.5 mm
{0.01 - 0.22 inl2.0 - 4.0 mm10.08 - 0.16 inl
2.5 - 5.5 mm10.01 - 0.22 in)
OUYI.fT HOSE11 N.m{1.1 kgl.m, 8 lbl.ftl
INI."ET HOSE
ABLE CLAMP
RETURN HOSE
coot"ER
CLAMPS
17 -34
CLAMPS

7.Submerge the valve in a container of power steer-
ing fluid or solvent, and blow in the hose. lf air bub-
bles leak through the valve at less than 100 kPa
11.0 kgf/cm,, 14.2 psi), replace or repair it as follows.
AIR PRESSURE
i- POWER STEEBINGFLUID or SOLVENT
8, Hold the bottom end of th€ valve with a oDen end
wrencn.
9. Unscrew the seat in the top end of the valve, and
remove any shims, the relief check ball, relief valve
and relief valve spring,
REUEF VALVERELIEF CHECK BALL
sHrM(sllf us€d.SEAT13 N.m11.3 ks[.m, I lbf.tt]
Clampthis end ina vise with sott iaws.
FLOW CONTROL VALVE REUEFvALvESPBING
10. Clean all the parts in solvent, dry them off, then
reassemble and retest the valve. Sge page 17-43 for
f low control valve installation.
NOTE: lf necessary, relief pressure is adiusted at
the facto.y by adding shims under the check ball
seat. lf you found shims in your valve, be sure you
reinstall as many as you took out,
')4.
nlll
Pump Rotor Removal
CAUTION: Tho pump components are made ot alu-
minum. B€ car6ful not to damage them when servicing.
1. Remove the inlet joint and O-rjng.
13 x 1.9 mmO.RINGReplac€.
2. Remove the pump cover and O-ring.
PUMP COVER
58.5 x 1.5 mmO.RINGFeplace.
(cont'd)
17-37

41.
Install a puller yoke to the steering gearbox, then
clamp the puller yoke in a vise with soft jaws as
shown.
PULLER YOXE:Commcrcirlly AvrihbloSn.p-Ono T/N Cr123-lorco T/N 7372or aquivrlani
Grease the inside surface of the cylinder end, then
install the cylinder end by screwing it into the cylin-
der housing.
After tightening the cylinder end, stake the point of
the cylinder housing shown below.
NOTE: Stake in the cylinder in the position opposite
from where the stake was removed during disas-
semblv.
Strke point, D.pth: 1.0 mm (0.04 inl
4.0 mm 10.15 inlCYLINDER HOUSING
CYLINDER END
CYLINOER69 N.m 17.0 kgf.m, 51 lbtft)
,t8. Select the 32 mm shim(s).
NOTE: Only reinstall the original 32 mm shim(s)
when the steering gearbox is reassembled without
replacing the pinion shaft, valve housing, and gear-
box housing with new ones.
lf the pinion shaft, valve housing, and gearbox
housing are replaced, select the new shim{s) as fol-
rows.
Shim r€lection:-'1. Set the four 32 mm shims on the b€aring surface of
the gearbox housing. Total thickness of the four
shims should eoual no more than 0.70 mm.
Shim set: tour 32 mm shims (Thickness: 0.10 mm,
0.15 mm, 0.20, 0.25 mm respectivelyl
CAUTION: The tour 32 mm shimr do not hlva
thlckn$s idcntitication mukt. Mo!3ur. tho thicl-
oa33 of rach 3him using a miclomctrl, and mlrk
tho shim lor id6ntific8tion.
-2. Install the valve body unit on the gearbox, and
tighten the flange bolts to the specitied torque
VALVE BODY UNIT
FLANGE BOLT20 N.m {2.o kgtm, 14lbt'ftl
SHIM SET{foul thim.)
Measure the clearance between the gearbox and
valve body unit using a feeler gauge as shown.
NOTE: Measure the clearance at the point midway
between the two mounting bolts.
(cont'd)
17-59

Rear Wndow
-r
lnstallation
Scrape the old adhesive smooth with a knife to a
thickness of about 2 mm (O.O8 in) on the bonding
surface around the entire rear window opening
flange.
NOTE:
a Do not scrape down to the painted surface of the
body; damaged paint will interfere with proper
bonding.
a Remove the upper and lower fasteners trom the
hatch.
a Mask otf surrounding surtaces before applying
primer.
Clean the hatch bonding surface with a sponge
dampened in alcohol.
NOTE: After cleaning, keep oil, grease or water trom
getting on the surface.
lI the old rear window is to be reinstalled, use a put-
ty knile to scrape ott all traces ot old adhesive, then
clean the rear window surface with alcohol where
new adhesive is to be applied.
NOTE: Make sure the bonding surface is kept tree
of water, oil and grease.
CAUTION: Avoid s€tting ths rear window on its
edges; small chips may lator devalop into cracks,
NOTE: Clean the shadowed area,
REAR WINDOW
20-62
---
UPPER SEAL
4.Apply the upper seal to the inside face of glass as
snown.
Glue the upper tasteners, lower fasteners and side
spacers, to the inside tace ot the rear window on
each side.
FASTENER,2' / FASTENER,2ALIGNMENT
G||le the lower fasteners and upper Jasteners to the
hatch, as shown.
sroESPACER, 2

Rear Window
lnstallation (cont'd)
4. Apply the double-faced adhesive tape to the inside
o{ the rear window, as shown
Glue the molding around the edge oi the rear win-
dow, as shown.
5OO mm 119.7
MOLDING
lnside
0.16 mm (0.006 inl
500 mm (19.7 in)5OO mm 119.7 in)
MOLDING
ALIGNMENT MARKS
6. Install the upper fasteners and glue the lower
fasteners to the bodY, as shown.
NOTE: The numbers atter the parts names show
quantity of the Part used.
7. Glue the side and lower spacers and tasteners to the
inside face ot the rear window and molding, as
shown.
NOTE: The numbers after the part names show the
quantities of the Parts used.
> : Spac6r, lastonel locations
SIDESPACER,4 ^
lo, \./O
lq
4!9!llEN,r_r\,ry!s
la, Loqrcen.t
(4relycv!|I!"
l$;*
\'*'w
o.f9!T.nl "1"*"
ALIGNMENTMARKS
'7:^ c
rs
--
s-."
20-70
"-

Troubleshooting
Tips and Precautions (cont'dl
a lnsert the connector all the way and make sure it is
securely locked.
a Position wires so that the open end of the cover taces
down.Facaopon andcown
V
Handling Wir€s and Hamorao8
a Secure wires and wile harnesses to the frame with
their respective wire ties at the designated locations'
a Remove clips carefully; don't damage their locks'
Stip pliers under the clip base and through the hole at an
angle, then squeeze the expansion tabs to release the
clio.
SI'IAP-ANG PLIERS
a After installing harness clips, make su.€ the hatness
doesn't interfe.e with any moving parts.
a Keeo wire hatnesses away from exhaust pipes and
other hot parts, ftom sharp edges of brackets and
holes, and from exposed screws and bolts.
23-4
GOOD ]TOT GOOD
n,/r/ll ,,' ll ,,
s*j -:ut*/-.w-- --ry\
il,,
Tosting and Ropails
a Do not us€ wires or harness€s with broken insulation.
Replace them or repair them by wrapping th€ break
with electrical tape.
a After installing pans, make sure that no wir€s are
Dinched undsr them.
a When using electrical test €quipment, follow the
manufacturer's instructiona and those dsscribed in
this manual,
a It possible, insert the probe of the toster from the wire
side {except waterproof connector).
a Seat grommets in theil grooves properly.
a Use a probe with a tapered tip.
Refer to the instructions in the Honda Terminsl Kit for
identification and .eplacement o{ connector telminals'

lgnition Coil Test
With the ignition switch OFF, remove the distribu-
lor cap.
Remove the two screws to disconnect the BLK^/EL
and WHT/BLU wires from terminals A (+ ) and B ( - )respectively.
3. Using an ohmmetet, measur€ tesistance betwe€nthe terminals, Replace the coil if the resistance is notwithin specifications.
NOTE: Resistance will vary with th€ coil t€m9er-ature; sp€cifications are at 68oF l20oC)
Prlmary Winding Rosistanco(8otwo6n tho A and B torminalsl: 0.6-0.g ohmsSecondary Winding Rssistanc6(Botwoon the A and socondary winding tomlnalsl:12.8 - 19.2 kO
lgnition Coil Replacement
1 . With the ignition switch OFF, remove the disrribu-
tor cap, rotor, and cap seal, then remove the leak
cover.
Remove the two screws to disconnect the BLK/YEL
and WHT/BLU wires from the coil.
Remove the two screws and slide the ignition coil
out of the distributor housing,
CAP SEAL
3.
A l+)
I
t
l
11
L
WHT/BLU WIRE
B {-}
23-95