window HONDA INTEGRA 1994 4.G Workshop Manual

Emission Control System
SystemDescription
The emission control system includes a Three Way Cata-
lytic Convener (TWC), Positive Crankcase Ventilation(PCV) system and Evaporstive Emission {EVAP) Contfol
syst€m. The emission control system is designed to meet
federsl and stats emission standards.
Tailpipe Emission
Inspection
f!fifil oo nor amoro ou]rng rnr! Foacqurr. ^!op
any open flame away from yout wotk atca.
Start the engine. Hold the engine at 3,OOO rpm with
no load (A/T in @ or@ position, M/T in neutral) until
the radiator fan comes on, then let it idle,
Connect a tachometer.
Check and adiust the idle speed, if necessary (sss
page 1 1-95).
Warm up and calibrate the CO meter according to
the meter manutacturer's inst.uctions.
Check idle CO with the headlights, hester blower,
rear window defogger, cooling fan, and air condition-
er otf.
NOTE: (Canada) Pull the parking br8ke lever up.
Stan the engine, then check that the headlights are
off.
CO meter should indicate 0.1 maximum.
11-130

15. After the clearances have been adjusled properly.
reinstall the weatherstrip.
16. Check that the glass contacts the weatherstrip
evenly.
NOTE: Measuring points are described on page
20-42.
Conter Pillar soction:
WEATHERSTRIP
17.Check for water leaks.
NOTE; Do not use high pressure water.
18. Route the door harness and connectors, and fasten
them to the door (see pages 20-22, 331.
19. Disconnect the oowef window switch from the doo.
harness, then install the power window switch on
the door panel (see page 20-41).
2O. Attach the plastic cover, then install the door panel
(see pages 2O-2O, 321.
2047

Windshield, Rear Window, Ouarter Glass
lndex
NOTE: The numbers after the part names show the quantities of the parts used.
Hatchback
RIGHT SIDE
UPPER RUBBER DAM
CLIP E. 2 Whir€
Cl-lP F, 2 Loft. WhitoRight. Bluo
CLIP A, I Rod
RETAINER, 6 Orengo
CLIP B, 2 O.an96
CLIP C, 2 Black
LEFT SIDE MOLDING
CLIP D. 2 G.6en
AINER, 2 Ysllow
UPPER SEAL
UPPER FASTENER, 2(S€lt-adh.sive-type, glass sid6l
UPPER FASTENER, 2(Self-6dhosiv6-type, hatch sidel
e.'.
RET
REAR WINDOW MOLOINGReplacement, page 2O-65
SIDE RUAAERDAM. 2
SIOE SPACER. 2
REAR WINDOWRemoval, page 20'6'1Instaflataon, page 20-62
f ? *
""'^i^r.{"'/\
LOWER FASTENER. 2{Self-adh6siv€-type,glass sidel
LOWER FASTENER, 2{Selt-adhosive-1ype,hatch sid6)TAPE B, 2
20-53
UPPER MOLOING
Removal, page 20-55Installation, page 20-56
ADHESIVE

Windshield, Rear Window
lndex
part names show the quantities of the parts used.
RIGHT SIDE MOLDING
WINDSHIELDRemoval, page 20-55Installation, page 20-56
CLIP F, 2 L6ft. WhltoRighl. Bluo
CLIP A, I Rod
€
e
&...- *aro,nr*. 6 o'!.gc
CLIP B, 2 B?own
AINER. 2 Yollow
,@
/'GLASS BRACKET, 2
REAR WINDOWRemoval, page 20-68Installation,page 20-69
NOTE: The numbers after the
Sodan
bq
UPPER MOLDII{GUPPER RUEBER OAM
cLtP E, 2 Whir6
A
\
RET
REAR WINDOW MOLOING
R.-.......-"-.owER FA'TENER. 2

lsolf-.dhe3ivo-type, sla$ sidol
LOWER FASTENER, 2(Solt-rdhe.lvo-typo. body sidol
UPPER FASTENER, 2
{S.ll-.dho!lvo-typo, gh$ .ldcl
g
.qB.....--
urra" FAslEr{ER, 2(Cllp-typo, body .ld.l
&'.....- r,o, sPAcER, 4
20-54
LOWER COVER
ffit*--

Rear Window
Removal
Hatchback
CAUTION;
a Use covsrs to avoid damaging tho interior.
a Wear gloves to romove and install the glass.
a Do not damags the defroster grid linss.
a Tako care not scratch th€ raar window molding,
1. To remove the rear window. first remove the:a Rear shelt (see page 20-91)
a Hatch side trim and hatch trim panel (see page
20-146)
. High mount brake light (see section 23)a Rear wiper and wiper motor (see section 231
2. Remove the rear window trim and disconnect the
connectors.
3. Apply protective tape to the inner and outer edges
of the hatch.
Using an awl. make a hole th.ough the adhesive trom
the inside. at the top ot the hatch. Push piano wire
through the hole, and wrap each end a.ound a piece
of wood.
CONNECTOR
MOLOING
4.With a helper on the outside, pullthe piano wire back
and forth in a sawing motion, and carefully cut
through the adhesive the along the top and the sides
oJ the rear window.
CAUTION: Hold ths piano wire as clos€ to the roat
window as possible to prevont damage to the body
and molding.
PROTECTIVE TAPE
Cut the adhesive with a knife at the bottom of the
aear window.
NOTE: Do not use piano wire in this area.
6. Carefully remove the rear window.
NOTE: Replace the fasteners with new ones
whenever the rear window has been removed.
PROTECTIVE TAPE
20-61

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

7.Set the rear window upright on the hatch, thencenter it in the opening. Make alignment marksacross the rear window and body with a grease pen-
cil at the tour points shown.
ALIGNMENT MARKS
Remove the rear window.
Center and glue the side rubbe. dams to the insideface of the rear window, as shown, to contain theadhesive during installation.
NOTE:
a Glue the side rubber dams, using the printed dotsas a guide-
a Be careful not to touch the rear window, whereadhesive will be applied.a Mask off surrounding surfaces before applyingpnmeI.
8.
cl
REAR WINDOW
1O. Install the rear window trim.
1 1. With a sponge, apply a light coat of glass primer
around the edge of the rear window, then lightly
wipe it ott with gauze or cheesecloth.
NOTE:
a Do not apply body primer to the rear window, and
do not get body and glass primer sponges mixed
up.
a Never touch the primed surfaces with your hands.
lf you do, the adhesive mav not bond to the rear
window properly, causing a leak after the rear
window is installed.
a Keep water, dust. and abrasive materials awav
from the primed surlace.
//// , appV glass primor hero.
NOTE: Apply the glass primer,using the printed dots as aguroe.
MOLOING
UPPER 15 mm
(0.0a inl
15 mm{0.6 in}
(cont'd)
10.6 inl
MOLDING
REAR WINDOW
20-63

Rear Window
Installation (cont'd)
12.
10 mm
{0.4 in)
With a sponge, apply a light coat ol body primer to
the original adhesive remaining around the rear win-
dow opening flange. Let the body primer dry tor at
least 10 minutes.
NOTE:
a Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.
a Never touch the primed surfaces with your hands
16 mm {0.63 inl
t|nm(O.35 Inl
Thoroughly mix the adhesive and hardener together
on a glass or metal plate with a putty knife'
NOTE:
a Clean the plate with a sponge and alcohol befole
mixing.
a Follow the instructions that came with the
adhesive.
Before lilling a cartridge, cut the end of the nozzle'
as shown.
1O mm {0.39 inl
7//, I Applv body p.lmor h.]o.
40 mm 11.6 Inl
16 mln 10.63 Inl
1 mm {0.04 inl
fu.:*1",
I J.
14.
7 mm (0.27 inl
.-
it.E\,",1/: ADHESTVE
NOTE: Apply the adhesiv€,using the printed dots aaa guide.
15. Pack adhesive into the cartridge wilhout air pock-
ets to ensure continous delivery. Put the cartridge
in a caulking gun, and run a bead of adhesive around
the edge of ihe rear window, as shown.
UPPERSEAL
-C=
/\/ MOLDINGGLASS
5mm10.19 Inl
8mm10.31 inl
MOLDING
lO.Oa inl
)E--lT-*-\
MOLDING

ALIGNMEI{T MARKS
REAR WINDOW
16. Use suction cups to hold the rear window over theopening, align it with the alignment marks made instep 7, and set it down on the adhesive. Lightly pushon the rear window until its edges are fulty seatedon the adhesive all the way around,
NOTE: Do not open or close the doors until theadhesive is drv.
17. Scrape or wipe the sxcess adhesive otf with a Dut-ty knife or towel,
NOTE: To remove adhesive lrcm a painted swfaceor the rear window, use a soft shop towel damDenedwith alcohol.
1 8. Let the adhesivs dry tor at least one hour, then spraywatgr over the raar window and check tor leaks.Mark leaking areas and let the rear window dry, thenseal with sealant.
NOTE: Let the car stand for at least tour hours al_ter rear window installation. lf the car has to be usedwithin the first four hours, it must be driven slowlv.
19. Reinstall all remaining removed parts.
Rear Window Molding
Replacement
1. Remove the rear window, then remove the uppGrseal.
2. Place the rear window on its surface, as shown, witha helper holding the rear window.
CAUTION: Avold setting the rea? ryindow on h!odgos: small chips may latol dovolop into cracka.
3. Cut the inner side rubber portion O olf the molding,then cut the top rubber portion @.
REARwtNDow
4. Turn the rear window over, then cut the outer siderubber portion @ of the motding.
5. Scrape all traces of old molding trom the chamterededges of the glass.
NOTE: Be sure to scrape all traces of old moldingthoroughly.
6. Clean the rear window su.tace with alcohol wherenew molding is to be installed.
NOTE: Make sure the su.face is kept tree of waler,oil and grease.
{cont'dl
20-65

Rear Window Molding
Replacement (cont'd)
8.
7. With a brush. apply a light coat of glass primer
around the edge of the glass.
NOTE: Scrape otl excess glass primer with a putty
knife after installing new molding.
6mm1O.23 Inl
SUBFACE
INSIDE SURFACE6mm(0.23 inl
Degrease the inner surfaces ol new molding
thoroughly, then apply a light coat ot glass primer
to the surtaces.
NOTE:
a Apply glass primer around the entire groove of the
new molding,
a Do not apply glass primer to the outer surface.
L Run a bead oJ adhesive in the groove of the molding'
20-66
MOLDING
^--
JOINT
1 O. Place the rear window outside-up. then align the joint
ot the molding with the "T" mark at the top ot the
glass as shown.
MOLOING
11.
wtNDOW
Press the molding into position around the entire
edge of the rear window.
NOTE: Check that the molding is not wrinkled or lift-
ed awav at corners.
MOLDING