Air condition HONDA INTEGRA 1994 4.G Workshop Manual

MEASUFEMENTSTANDARD I]{EWI
a gnmentCamber FrontRgarCaster FrontTotaltoe FrontRearFront whe€lturning angle Inward whe€lOutwsrd wh€el
-0. 10' 1 1.-0' 15' l$igl1. 10'r t"0i2(010.081rN 3:i (0.121ff)36' 0o' r 2'30. 30'
A1lc€lbearingEnd playFrontRoaa0 - 0.05 (0 - 0.002)0 - 0.05 {0 - 0.002}
Rim runout (Aluminum wheel) AxialRadialRim runout isteelwhgel) AxialRadisl
STANDARD INEWISEBVICE UMIT
0 - 0.7 {0 - 0.03)0 - 0.7 (0 - 0.03)0 - 1.0 {0 - 0.0{)0 - 1.0 (0 - 0.04)
2.0 (0.08)
1.5 (0.06)
2.0 (0.081
r.5 (0.061
SuspensionSestion 18
BrakeSection 19
Air ConditioningScction 22
.1: When using a new bek, adjust dellection or tension to new values. Run the engine tor 5 minules ihen turn it ott.
Readiust detlection or tension to lsed beh values.'2: 81881 engine'3: 818C1 engine
Unit of length: mm {in)
MEASUREMENTSTANDARD {NEWI
trrling brakePlay in strok€ at 200 N {20 kgf, 44 lbt)lever lorceTo b€ lockod when pulled 6 -10
nolchsa
; oot brake,adalPedal heighl lwith floor mat removod)
Free play
M/T160 (6.30)
155 (6.50)
1-5(0.04-0.20)
Vaster cylinderPiston-to-oushrod clearance0 - 0.4 (0 - 0.2)
f,,s4 brakeOisc thickness FrontRe6rDisc runout FrontR6arDisc parallolism Front and rear
Pad lhickness FrontRoar
STANDARD INEWISERVICE LIM]T
20.9 - 21.1 t0.82 - 0.83t8.9 - 9.1 {0.35 - 0.36)
9.5 - 10.5 {0.37 - 0.41}7.0- 8.0 {0.27 - 0.31)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.r0 (0.00a)
0.015 (0.0006t
r.6 (0.06)
1.6 (0.06)
MEASUREMENTSTANDABO IT{EWI
Ar conditioningLubricant capacity mf (ll oz) Cond€nserEvaporatorLine or hoseReceiverLubricant type: NO-OlL8 {P/N 38899 - PR7 - A0l)
25 (5/6)
40 t1 1/3)10 (lBt
10 (1/31
CompressorLubricant capacity m{ (ll oz}Lubricant tvge: ND-O|L8 (P/N 38899 - PR7 - A01)Stator coil resistance at 68'F (20'C) 0Pulley-to-pressure plate clearance
140';u (4-23';")
3.4- 3.80.5 r 0.15 {0.02 r 0.006)
Compressorb€h'rDetlection with 98 N (10 kgf, 22 lbf)betlveen pulleys
7.5 - 9.5 {0.30 - 0.37)with used b€lt*'8.5 - 10.5 {0.33 - 0.41}with t/sod belt'35.0 - 7.0 {0.20 - 0.28) with new belt
Belt t€nsion N (kgf, lbl)Measured with belt lension gauge390 - 540 {r0 - 55, 88 - 120} with used beh*'340 - 490 {35 - 50, 77 - 110} with used belt*3740 - 880 {75 - 90, 170 - 200) with new belt
3-15

Design Specifications
{cont'd}
lTEMMETRICI€iIGLISHINOTES
TRANSMISSIONTypeEngine typoManual transmission81881 | 818C1
G6ar Ratio 1st2nd3rd4th5thRov€rs€
3.2301.9001.2690.966o.7113.000
3.230r.9(X)1.3601.0340.'t873.000
Fin6l Reduction Gear typeGear ratioSingle helicalge.r4.2664.400
TypeAutomatic transmission
Gear Ratio 'l6t
znd3rd4thRevelse
2.7221.4640.97s0.6381.954
Final R€duction Goar typoGear ratioSingle helic6lgoar4.357
AIRCONDITIONINGCooling Capacity3,570 Kcal/h14,166 BTU/I
Compr6ssor Type/MakeNo. ol CylinderCaPtcityMax. SpsedLubricant C6pacity
Lubricrnt Type
swash-plare/NIPPoNDENSO10150 ml /rcv | 9.15 cu-in/r€v7,600 rpm140 mf | 1-2Bll ozI l.;3 tmp ozND-O|L8 (P/N 38899 - PR7 - A01)
Cond6ns€r TypeCorrugated fin
Evaporator TypeCorrugatod tin
Blower TypeMotor InputSpeed ControMax. Capachy
Sirocco tan200 w12 v4-speed450 m3/h | 15,900 cu lvh
Temperature ControlAirmix type
Compressor Clutch TypePowor ConsumptionDry, singlo plate, poly-V-b€lt driv640 W max./12 V at 68"F {20'C)
Refrigerant TypeOu.ntityHFC-134a (R-134a)
zoo-Ss I 24.7-l.aoe
STEERINGSYSTEMTypeOverall RatioTurns, Lock-to-LockSreering Wheel Dia.
Power assisted, rack and pinion16.12.98380 mm | 15.0 in
SUSPENSIONType Front
Roar
Shock Absorb€r, Front and Rear
Independent double wishbono,coil spring with st6bilizerIndependont double wishbong.coil spring with stabilizerTelescopic, hydraulic nitrogen gas-tilled
3-18

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

Engine Removal/lnstallation
(cont'd)
14.Remove the engine ground cable at the body end.
Remove the adiusting bolt and mounting bolt, then
remove the power steering (P/Sl belt and pump.
a Do not disconnect the P/S hoses.
8 r 1.25 mm24 N.m (2.4 kgf.m. 17 lbl.ftl
6. Loosen the idler pulley bolt and adjusting bolt, then
remove the air conditioning (A/C) compresso. belt.
IDLER PULLEY BOLT10 x 1.25 mm44 N.m 14.5 kgt.m, 33 lbl.ftl
5-6
A/C COMPRESSOR BELT
17. (Manusl transmission) Remove the clutch slave
cylinder and pipe/hose assembly.
a Do not disconnect the pipe/hose assembly.
6 x 1.O rl|mll N.m { 1.1 kgt.m,SLAVE CYLINDER
8.0
8 x 1.25 mm24 N.m {2.4 kgl.m,17 lbt.ftl
18. Remove the transmission ground cable and hose
cramp.
6 x 1.O mm1l N.m 11 ,1 kgt.m,I tbt.ftl

Timing Belt
Removal
I
NOTE:
. Turn the crankshaft pulley so the No. 1 piston is attop d6ad center (TDC) before removing the belt (see
page &12).
a Inspect the water pump when removed the timingbolt {see page 10-9}.
1. Remove thawhe€lwell splash shield (see page 6-18).
2. Loosen ths adjusting bolt and mounting bolts, thenremove the power steering {P/S) pump belt.
MOUivNNG BOLTS8 x 1.25 mm2a N.m 12.4 kgf.m, 1 7 lbt frl
Loosen the adjusting bolt and idler pulley bracket
bolt, then remove the air conditioning (A,/C) com-
oressor belt.
IDLER PUI.IEY BRACKETBOLTl0 r 1.25 mma/a N.m {1.5 kgf.m.33 lbf'ft}
AA,USNNG
ADJUSTING
4, Loosen the adjusting nut and mounting nut, thenremove the alt€rnator belt.
EELTa,l N.m {4.5 kgl.m,33 lbfftl
Remove the cruise control actuator (see page 6-18).
Remove the sid6 sngine mount.
10 x 1.25 mm52 N.m {5.3 kgr'm,38 lbtft}Replace.
MOUNTING NUT10 x 1.25 mm
ADJUSNNG NUT8 x 1.25 mrr2a N.m l2.a lef.m,17 rbl.ftl
12 x 1.25 mm74 N.m 17.5 kgt m,s4 tb{.ftl

Cylinder Head
Removal (cont'dlI
12.R€move the spark plug caps and distributor from
the cvlinder head.
Remove the upper radiator hose, heater hose and
water bypass hose.
UPPER RAI'IAYOR
14. Remove th6 solash shield.
WATER BYPASS
9.8 N.m {1.0 kgt m.t.2 tbr.frt
sHtEut
15. Remove the engine ground cable.
Remove the adjusting bolt and mounting bolts, then
remove the power steering (P/S) pump belt 8nd P/S
pump.
. Do not disconnect the P/S hoses.
6x1.0mmADJUSTINGBOLT9.8 N.m 11.0 tgfm,7.2 tbf.ftl
8 x 1.25 mm24 .m (2.akstm, 17lbf.ftl
P/S PUMP
Remov€ the air conditioning (Ay'Cl compressor(see pags 6-10).
R€move the alternator belt (see page 6-10).
Ramove the cruise control actuator.
8 x 1.25 mm2a N.m 12.4 kgt m,
belt
17.
t8
ACTUATOR

Removal
NOTE:
. Turn the crankshaft pulley so the No. 1 piston is at
top dead center {TDC) before removing the belt (see
page 6-51).
. Inspect the water pump when removed the timing
belt {see page 10-9).
Remove the wheel well splash shield (see page 6-
57 ).
Loosen the adiusting bolt and mounting bolts, then
remove the power steering (P/S) pump belt.
I x 1.25 mm2a N.m l2.a kgt.m, 17 lbt ttl
Loosen the adjusting bolt and idler pulley bracket
bolt, then remove the air conditioning (Ay'C) com-
oresso. belt.
D1INBOLT10 x 1.25 mmira N.m (4.5 kgf.m, 33 lbf'ttl
AOJUSTING
ADJUSNNG
BELT
4. Loosen the adiusting nut and mounting nut, then
remove the alternator belt.
NUTI x 1.25 mm24 N.m {2.a lgf.rn,17 tbf.ftl
MOUNTING NUT10 x 1.25 mm4,t N.m lia.5 kgl.m,33 tbt ftl
Remove the cruise control actuator (see page G58).
Bemove the side engine mount.
10 x 1.25 mm52 N.m 15.3 kgt m, 38 lbtftl
CNGINCMOUNT
12 x 1.25 mm74 N.m (7.5 kgt m,s4 lbf.trl
(cont'd)
6-49

Cylinder Head
Removal (cont'dl
Remove the heat shield from the P/S bracket (see
page 5-18).
Remove the air conditioning (Ay'Cl compressor belt(see page 6-49).
Remove the alternator belt {s€e page 6-49).
Remove the cruise control actuato..
16.
17.
'18.
'19.
ACTUATOR
20. Remove the side engine mount.
10 x 1.25 mm
SIDE ENGINE
12 x 1.25 mrn7a N.m 17.5 kgl.m,5a rbtftl
8 x 1.25 mmN.m 12.4 kgf.m, 17 lbtftl
21. Remove the cylinder head cover.
22. Remove the timing belt (see page 6-49).
23. Remove the camshaft pulleys and back cover.
24. Remove the exhaust manifold.
SELF.LOCKING NUT8 x 1 .25 mm31 N.m {3.2 kgt m, 23 lbf.ftlReplace.
6-58
'ilffi{

Oil Pump
5.
4.
Removal/lnspection/lnstallation
6. Remov€ the timing belt.
7. R€move the drive pulley.
8. Remov€ the oil pan and oil screen.
9. Remove the oil pump.
Drain the engine oil.
Turn the crankshatt and align the white groove on
the crankshalt pulley with the pointer on the lower
cover.
Remove the cylinder head cover and middle cover.
Remove the power steering pump belt, air condition-
er belt and the alternator belt.
Remove the crankshaft pulley and remove the low-
er cover.
OIL PUMP
OIL PAN
8-10
1O. Remove the screws trom the pump housing, thsn
separate the housing and coveJ.
1 1. Check the inner-to outer roto. radial clearance on thepumP rotor.
Innor Rotol-to-Outor Rotor Radial Cloaranco
StandErd (Newl: O.O4-O.16 mm(0.O02-0.006 in)
Service Limit: O.2O mm (0.008 inl
Check the housing-to-rotor axial clearance
pump rotor.
Housing-to-Botor Axial Claalanc€
Standard (Nowl: O.O2-O.O7 mm(O.OO1 -O.OO3 inl
Service Limit: O.15 mm (0.006 in)
on the12.
HOUSING

Fuel and Emissions
Spocial Tools ................ 1 1-2
Compon€nt Location
lndex ................. ...... 11-3
System Description
Vacuum Connectiona .......,.................... 1 1 -8
Efectrical Connections ....,.,.,......,...,,.....,'11-12
Syst€m Connectors ...,...,.................-.--. 11-2O
T.oubloshooting
Troubleshooting Guido .......................... 1 1-32
Self -diagnostic Procedures .,..,............... 1 1 -34
How to Road Flowcharts ...................,... 11-39
PGM-Fl System
Systom Description .............................. 1 l-4O
Troubleshooting Flowcharts
Engine Control Moduls ............... ........... 1 1 -42
Heated Oxygon Sensor ......,.................. 1 1-46
Heated Oxyg€n Sonsol Heatel .....,......... 1 1 -47
Fuel Supply System ..............-............... 1 1-50
Manitold Absolute Pressure
Ssnsor ............................................ 1 1-52
Top D6ad Cente./Crankshatr
Position/Cylindor Position sonsor ........ 1 1 -56
Engine Coolant Tempsrature Sonsor ....... 11-58
Throttlo Position Sonsor ........,..,,........... 1 1-60
Intake Air Temperaturs Sensor ............... 11-62
Baromet c Prsssuro Sensor ......,...,...,..,. 11-64
lgnition Output Signal ........................... 1 1 -66
Vehicle Spe€d Sensor ........................... 1 1 -68
Electdcal Load Dotector ....,...,..........,.... 1 1 -7O
Knock Sensor [818C1 engine] ............... 11-74
A/T Fl Signal A/B ................................. 1 1-76
ldle Contlol System
System Troubleshooting Guide .................. 1 1 -78
Systom Description ........ 11-79
Troubloshooting Flowchans
ldl€ Ail Control Valve ........................... 1 1 -82
Ail Conditioning Signal ......................... 1 1 -84
Altemator FR Signal ............................. 1 1 -86
Automatic Transaxle (A/T) Gear
Position Signal ......... 11-88
Brake Switch Signal ............................. 1 1 -9O
Startel Switch Signal ............................ 11-92
Power Steering Pressure Switch Signal ... 11-93
Fast ldle Thermo Valve ...................,......... 1 1 -94
ldls Speed S€tting .................................... 1 1 -95
Fuel Supply System
Systam Tloubloshooting Guid. .................. 1 1 -97
Fuol Linos ...................... 1'l -98
System Description ........ 11-100
Fuol Prassure ................. 11-100
Fu6l Ini6ctors ................. 11-102
Fuel Pressure Ragulato. .,. 11-106
Fuel Filter ...................... 11-108
Fual Pump ..................... 11-109
PGM-Fl Main F6lay ................................... 1 1"1 1 1
Fuel Tank ...................... t 1-114
Intake Air System
System Troubloshooting Guido .................. 1 1 -1 1 5
Systom Dascription ........ 11-116
Air Clean€r .................... 11-117
Throttls Cable ................'11-118
Throttl8 Body ................ 11-120
lntake Air Bypass Cont.ol Systsm
[B18Cl enginal .,......... 11-123
Intake Manilold [B1881 onginol ................. 11-128
Emission Control System
Systsm Troubleshooting Guido .................. 1 1 -1 29
Systam Doscription ........ 11-130
Tailpips Emission ........... 11-130
Thrae Way Catalytic Convortor ...,...,........., 11-131
Positiva CrankcaEo V6ntilation Systcm .,....., 11-134
Evaporativo Emission Contro|,..,..,.,.,,.,,..,.., 1 1-135