Clutch replace ACURA INTEGRA 1994 Service Repair Manual

Lubrication Points
For the details ol lubrication points and type of lubricants to be spplied, reter to the illustrated index and various workprocedure (such as Assembly/Reassembly, Replacement, Overhaul, Instatlation, etc.) contained in each section.
No.LUBRICATION POII\ITSLUBRICAI\IT
IEngineAPI Service Grade: Use SG or SH "Energy Conserving
II" grade oil.
The oil container may also display the API Certifications€al shown below. Make sure it says'For GasolineEngines.'
SAE Viscosity; See chan below.
Transmission Manual
Automatic
API Service Grades: SF or SG
SAE Viscosity: 1O W-3O or 1O W-4O
Honda Premium Formula or DEXRON@ II
Automatic transmission fluid
3Brake line (lncludes Anti-lock brake linelBrake fluid DOT3 or DOT4
4Clutch lineBfake tluid DOT3 or DOT4
Power steering gearboxSteoring grease P/N 08733-BO7OE
Release fork (Manual transmission)Supe. High Temp Urea Grease (P/N O8798*9OO2)
8
Throttle wire end {Dashboard lower Danel holel
C.uise cont.ol actuatot wire end
{Dashboard lower Danel holel
Silicone grease
I
10'I 'l
12
13
14
15
to
17
18
Throttle cable end (Throttle linkl
Cruise control actuator cable end lActuator link)
Brake master cvlinder Dushrod
Clutch master cylinder pushrod
Engine hood hinges and engine hood latch
Batte.v terminals
Fuel fill lid
Hatch hinges or trunk hinges
Door hinges. upper and lowet
Door oDen detent
.Multi-purpose grease
19Rear brake calioersRust-p,eventive agant
20Power steering systemHonda power steering tluid-V
21Air conditioning compressorRetrigerant oit ND-otL8 |PlN 38899-pR7-A01)(For Relrigerant: HFC-134a (R-134a))
-20 0 20 r}() 60 ao loooF
-30 -20 -'to o 10 20 30 40"c
Recolnmendod engine oilEngine oil viscosity torambient tgmpelalure rangos
API CERTIFICATION SEAL

Insrall the left front mount, then tighten the bolts in
the numbered sequence as shown (O-@),
O 12 x 1.25 ]n]n83 N.m 18.5 kst.m,61 lbt.ftlReplace.
@ 12 r 1.25 mm59 N.m {6.0 kgl.n,43 tb{.ftlReplace.
@ 10 r 1.25 mm44 N.m (4.5 kgf.m, 33 lbt.ftl
k-
5-15
a Check that the sp.ing clip on the end of each
driveshaft clicks into place.
GAUTION: Uso oow spring clips.
a Bleed air trom the cooling system at the bleed bolt
with the heater valve open (see page 10-5).
a Adjust the th.ottle cable (see section 1 1).
a Check the clutch pedal tree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
Alternator belt {s€e section 23).
P/S pump belt {see section 17).
A/C comoressor belt (see section 22).
a Inspect tor fuel leakage (see section 1 1).
. After assembling fuel line parts, turn on the ig-
nition switch (do not operate th€ starter) so
that the Juel pump operates for approximat€-
lV two seconds and the tuel line pressurizes.
Repeat this operation two or three times and
check for fuel leakage at any point in the fuel
line.
(cont'd)

Glutch
Speciaf Tools ........ ........ 12-2
fffustrated Index ........ .... 12-3
Clutch Pedal
Adjustment ................12-4
Clutch Master Cylinder
Removal/lnstallation .... 12-5
Slave Gylinder
Removal/lnstallation .... 12-6
Pressure Plate
Removal/lnspection ..... 12'7
Clutch Disc
lnspection/Removal ..... 12-8
Flywheel, Flywheel Bearing
fnspection . 12-9
Replacement ............................... 1 2-9
Clutch Disc, Pressure Plate
Installation 12-10
Release Bearing
Removal/lnspection12-11

lllustrated Index
NOTE:
a Whenever the transmission is removed, clean and grease the release bearing sliding sudace.
a It the pans marked r are removed. the clutch hydraulic system must be bled (see page 12-6).
a Inspect the hoses lor damage, leaks, interterence, and twisting.
*RESERVOIR
HOSEASSISI SPRING
PEDAL PIN
CLUTCH PEDALAdjustment,page 12-4
15 N.m 11.5 kgl.m,11 tbt.ftl
6 x 1,0 mm9.8 N.m ll.0 ksf.m, 7 lbf.tt)
FLYWHEELInspection. page 12-9Replacement, page 12-9
TCLUTCH MASTER CYLINDERRemoval/lnstallation, page 1 2-5
19 N.m ll.9 kgt.m,14 lbf.ftl
.CLUTCH PIPE
15 N.m {1.5 kgl.m,1 1 rbf.ft)
ICLUTCH PIPE
JOtt{T
8 x 1.25 mm25 N.m (2.6 kgl.m,19 lbt.ttl
RELEASE BEARINGRomovaf /lnspection, page 1 2-1 1lnstaffation, page 1 2- 1 2
TRANSMISSIONRomoval. see
CLUTCH DISCRemoval/lnspection. page'1 2-8Installation, page 12-10
8 x 1.25 mm22 N.m (2.2 kgf.m.16 lbl.rr)
section 1312 x 1.0 mm103 N.m llO.5 kgt.m,76 rbf.ftl
PRESSURE PLATERemoval/lnspection. page 1 2-7Installation, page 12,10
TSLAVE CYLINDERRemovaf /lnstallation. page 1 2-632 N.m {3.3 kgf'm,24 tbf.ftl
15 N. m {1.5 kgf.m,'| I tbf.ftl
COTTERBeplace.
I
NInl
9t
v-_fl
ICLUTCH
12-3

Pressure Plate
RING GEAR HOLDER07LAB-PVOOl OO or07924-PD20003
Removal/lnspection
Check the diaphragm spring fingers for height us-
ing the special tools and a feeler gauge.
Standard lNew): 0.6 mm (0.02 inl Max.
Service Limit: O.8 mm {O.O3 in}
FEELER GAUGE
07NAF-PR3010007936-3710100
. lf the height is more than the service limit, replace
the pressure plate.
2. Install the special tools.
3. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936-3710'l OO
PRESSURE PLATE
CLUTCH ALIGNMENT OISCOTJAF_PM7011A
4.Inspect the pressure plate surface
and burning.
Inspect the fingers of the diaphrag
at the release bearing contact ar
DIAPHRAGM SPRING
Inspect for warpage using a stru
er gauge.
NOTE: Measure across the prer
pornls.
Standard (Newl: 0.03 mm (0.0
Sorvice Limit:0.15 mm (0.0O6
STRAIGHT EOGE
FEELER GAUGE
PI
lf the warpage is more than
replace the pressure plate.
6.
I surface for wear, cracks,
diaphragm spring for wear
nracr area.
PRESSURE PLAT€
straight edge and feef
pressure plate at three
0.001 in) Max.
)O6 inl
12-7

Glutch Disc
'1.Remove the clutch disc and special tools.
Inspect the lining of the clutch disc Jor signs oJ slip-
ping o. oil. lf it is bu.ned black or oil soaked, replace
it.
Measure the depth trom the lining surface to the
rivets, on both sides.
Standard (Now): 1.3 mm (O.05 inl Min.
Se.vice Limit: O.2 mm {O.OO8 inl
CLUTCH ALIGNMEI{T SHAFT07NAF-PR30100HAt{DLE07936-3710 t0O
Measu.e the clutch disc thickness.
Standard {Now}: 8.4-9.1 mm (o.33*0.36 inl
Sarvica Limit: 6.0 mm (O.24 in)
It the rivet deDth is less than the service limit,
reolace the clutch disc.
lf the thickness is less than the service limit,
reolace the clutch disc,
CLUTCH DISCCLUTCH DISC
LINING SURFACE
CLUTCH DISC
Removal/lnspection
ctutch Disc I
'.#fu;;
l''
"LUrcH Drsc |
""-*":'-- {o'oo8 inr
I I
=-.--']! ; i , n-
ll
W@*-l @
slbir":ix:l# Ii!fr..;*'::l;'"o^"
|
'=f
I I
3. Measu.e the clutch disc thic

InspectionReplacement
Flywheel, Flywheel Bearing
Inspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the
flywheel fo. wear, cracks, and burning.
Measure the flywheel runout using a dial indicator
through at least two full tu.ns. Push against the
Ilywheel each time you turn it to take up the crank-
shaft thrust washe. clearance.
NOTE; The runout can be measu.ed with engine in-
stalled.
Standard (ttlervl: O.O5 mm (O.002 inl Max.
Service Limit: 0.15 mm 10.006 inl
RING GEABFLYWHEEL
DIAL II{DICATOR
It the runout is more than the service limit, leplace
the flvwheel.
Turn the inner race of the flywheel bearing with your
finger. The bearing should turn smoothly and quiet-
ly, Check that the bearing outer race fits tightly in
the flvwheel.
FLYWHEELBEARING
It the race does not turn smoothly, quietly, or fit
tight in the flywheel, replace the flywheel bearing.
Install the special tool.
Remov€ the flywhe€l mounting bolts in a criascross
pattern in several steps 8s shown, then remove the
tlywheel.
MOUI{TII{G BOLTS
3. Remov€ the flywheel bsaring from th€ tlywheel.
(cont'd)
FLYWHEEL
12-9

Clutch Disc,
l.
t
Flywheel, Flywheel BearingPressure Plate
Replacement (cont'd)Installation
Install the ring gear holder.
Apply grease to the spline of the clutch disc, theninstall the clutch disc using the special tools assnown.
NOTE: Use only Super High Temp Urea Grease (P/N
08798-9OO2).
CLUTCH DISC
RING GEAR HOLDEROTLAB-PVOOI O0 ot07924-PD20003
3. Instali the pressure
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936-3710100
plate.
CLUTCH ALIGNMENT SHAFToTNAF-PR30100HANDLE
PRESSURE PLATE
12-10
4. Drive the new flywheel bearing into the flywheel us-
ing rhe special tools as shown.
DRIVER07749-O010000
ATTACHMENT.32x35mm07746-OOlO100
o.
5.
FLYWHEEL
Align the hole in the flywheel with the crankshaft
dowel pin and installthe flywheel. Installthe mount-
ing bolts finger-tight.
Install the special tool as shown, then torque the
flywheel mounting bolts in a crisscross pattern in
several steDs as shown.
MOUNTING BOLTS12 x 1.0 mm103 N.m 110.5 kgf.m,76 tbf.fr)
FLYWHEEL BEARING
FLYWHEEL
07936-3710100
t\_

Manual Transmission
Special Toofs ............. 13-2
Maintenance
Transmission Oi1,...,........,........,.,..... 13-3
Back-up Light Switch
Replacement ......... 13-3
Transmission Assembly
Removal ..,.......,...... 13-4
lllustrated Index ................................... 13-8
Transmission Housing
Removal ...........,..... 13-10
Reverse Change Holder, Reverse ldler Gear
Glearance lnspestion ....................... 13-1 1
Removaf ................. 13-12
Change Holder Assembly
Clearance Inspection ....................... 1 3-1 3
Removal ................. 13-15
Disassembly/Reassembly ............... 13-16
Mainshaft, Gountershaft, Shift Fork
Removal ...,............. 13-17
Shift Rod
Removal ................. 13-18
Shift Fork Assembly
Index ................ ...... 13-19
Clearance Inspection ....................... 13-20
Mainshaft Assembly
Index ................ ...... 13-21
Clearance f nspection ....................... 13-22
Disassembly .......... 13-25
Inspection .............. 13-26
Reassembly ........... 13-21
Countershaft Assembly
Index ................ ...... 13-28
Clearance Inspection ....................... 13-29
Disassembly .......... 13-30
Inspection .............. 13-31
Reassembly ........... 13-32
Synchro Sleeve, Synchro Hub
Inspection .............. 13-34
Installation ............. 13-34
Synchro Ring, Gear
lnspection .............. 13-35
Clutch Housing Bearing
Replacement ......... 13-36
Mainshaft Thrust Clearance
Adiustment ............ 13-38
Transmission
Reassembly ........... 13-tl1
Transmission Assembly
lnstallation ............. 13-46
Gearshift Mechanism
Overhaul ................ 13-50

Removo tho clutch pip€ bracket and th€ slave cylin-
oer.
NOTE: Do not operate the clutch pedal once th€
slavg cvlinder has been r€moved.
R€move the three uppor transmission mounting
bolts 8nd lower staner motor mounting bolt.
STARTEBMOTOBMOUNNNGBOLT
MOUNNNGBOLTS
10. Remove the engine splash shield.
11. Disconnect the heated oxygen sensor (HO2S) con-
nector, lhsn rsmove the exhaust pipe A, and the
three way catalytic converter (B18Cl Engine).
HO2Sco NEctoRSELF.LOCK IIUTRopl.ce.
EXHAUSTPIPE A
THBEE WAYCATALYTICCONVEEIER1818C1 engin6)
SELF.LOCK NUTReplace.
13-5