high mount HONDA INTEGRA 1994 4.G Workshop Manual

ITEMMETRICIENGLISHIM)TES
WHEELALIGNMENTCamber
CasterTotalToe
FrontRearFrontFrontRear
-0.10'-0.45'
1'1o'omm | oinIn 2 mm I ln 0.08 in
BRAKE SYSTEMType Front
RearPad Surface Area FrontRearParking Brake Type
Power-assisted selt-adiustingventilated discPoweFassisted self-adjusting solid discio.u cm. x z | /,/5 so tn x z21.0 cm, x2 | 3.26 sq in x 2Mechanical actuating, rear two wheel brakes
TIRESize Front and r€ar
Spare Tire
P195/60R14 858*1P195/55R15 84V*2T115t0D14*3T135/70O15.4
ELECTRICAL8atteryStarterAlternatorFusesIn Under-dash Fuse/Relay BoxIn Under-hood Fuse/Relay Box
In Under-hood ABS Fuso/Rolay BoxHeadlights
Front Side Marker LightsFront Turn SignauParking LightsRear Turn Signal LighlsStop/Ta illig htsHigh Mount Brake Light'5Fear Side Marker LightsBack-up LightsLiconse Plate LightsCeiling LightsCargo Area Lights (3 DOOR)Trunk Lights l4 DOOR)SpotlightsGlove Box LightGauge LightsIndicator Lightslllumination and Pilot LightsHeater lllumination Lights
High
I2V-36AH6HR'12 V -'1.4 kW12V-90A
7.5 A, 10 A, 15 A, 20 A, 30 A7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A50 A, 100 A10A, 15A,20A,40A12V-6sW{HB3}12V-55W(HB4)12V-3CP12V -32n CP12V -32 CP12V -32n CP12V -21W
12V-3CP12V -32 CP12V-8W12V-5W12v-3.4W12V-3.4W12V-5W12V-3.4W12V-3.4Wv - 0.84 w, 0.91 w, 1.12 W, 1.r W, 3 W12 V - 0.84 W. 0.91 W, 1.4 W. LEO12V-1.4W
sAE 168sAE 1157sAE 1 't 55sAE 1157sAE 7440sAE 168sA€ 1156
*1: RS, LS*2: GS-R*3: RS*1: LS, GS-R*5: Except high mount brake light installed in rcar spoiler.
3-19

Fuel Supply System
Fuel Tank
Replacement
@ oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.
1. Relieve the fuel pressure {see page 11-1OO).
2. Jack up the car and support with jackstands.
3. Remove the drsin bolt and drain the fuel into an approved container.
4. Remove the rear seat, access Danels and disconnect the 2P and 3P connectors.
5- Remove the EVAP two way valve cover and tuel hose protector.
6. Disconnect the hoses.
CAUTION:
a Whan disconnacling tho hosos, slide back tho clampr, th6n twist horos as you pull, to lvold drmlglng thcm.
a Clean the tlarod roint ot high plossulo hosos thoroughly brforc roconnccling thsm.
7. Place a jack. or other support, under the tank.
8. Remove the strao nuts and let the straDs tall free.
9. Remove the Juel tank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, caretully pry it off tho mount,
1O. Install a new washer on the dlain bolt, then install psns in the raverse ordgr ot rsmoval.
FUELPUMP
EVAPTWO WAY VALVE
38 l{.m(3.9 kgt'm,28 rbl.ftl
FUELTANK
EVAPTWO WAYVALVECOVER
FUEL TAI{KSTRAPS
tO t{.mll.O kgt'm,7 lbl.frl
11-114

A.
Evaporative Emission (EVAPI Controls
Da.cdptlon
Thg avaporstive omission controls are designed to minimize the smount of fusl vapor escaping to the atmosphero. The
system conaists ot the following compon€nts:
Evlporttly. Emlttbn (EVAPI Control Caniltot
An EVAP control canistor is used lor the temporary storage ot fuel vapor until the fuel vapor can be purged lrom
th€ EVAP control canister into the engin€ and burned.
vlpor hr]gG Cmt]ol Syst m
€VAp control canistgr puroing is accomplished by drawing fresh air through tho EVAP control canister and into a
pon on th6 throttl€ body. Th€ purging vacuum is controllsd by the EVAP purge control diaphragm valve end the
EVAP purge control solenoid valve.
C. Ft|.l Tmk Vlpor Control Systom
When fuel vapor prassure in the fuel tank is higher than the set v8lue of the EVAP two way v8lv6, th€ valve opens
and regulates the flow ol fuel vapor to the EVAP control canister.
(cont'd)
11-135

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\_

Transmission Assembly
1. Inst€llthe dowel pins on the clutch housing.
2. Apply grease to the parts as shown, then install the
release fork and release beaaing.
NOTE: Use only Super High Temp Urea Grease(P/N 08798 - 9002).
3. Install the release fork boot.
lnstallation
22 tbt-ttl
BELEASE FORK BOLT29 N.m (3.0 kgl.m,tPlN 08798 - 90021
RELEASEBEARING
@
I
{P/N 08798 - 90021
Place the transmission on the transmission iack,
and raise it to the engine level.
Install the transmission mounting bolts and the rear
mount bracket bolts sELF-LocKrNG BoLT
RELEASE REEASEFORK FORKBOOT
12 x 1.25 mm6it N.m 16.5 kgl.m, 47 lbf.ftl
Replace.14 x 1.5 mm
13-46
6, Raise the transmission, then install the transmission
mounI.
NOTE: Torque the mounting bolt and nuts in the
sequence shown.
CAUTION: Check that the bushings are not twistod
or offset,
O 12 x 1.25 mm54 N.m {6.5 kgt m,47 tbtfrl
7. Install the three upper transmission mounting
and lower starter motor mounting bolt.
bolts
10 x 1.25 mm44 N.m lil,s kgt m,33 tbf.ftl
@ 12 x 1.25 mm7,1 N.m 17.5 kg{.m,5/r lbtftl
12 x 1.25 mm64 N.m 16.5 kgf.m, 47 lbf.ftl

NOTES
A.See flushing procedure, page l4-168 and 169.
B.Set idle rpm in gear to specitied idle speed. lf still no good, adiust motor mounts as outlined in engine
section of service manual.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the clutch pack is seized or is excessively worn, inspect the other clutches Jor wear, and check the
orifice control valves and throttle valves for free movement.
E.It throttle valve B is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed, the transmission will not upshift. lI stuck open, the transmission
has no lst gear.
H.lf the 2-3 orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressure control valve is stuck closed, the transmission will not shilt out of 1st gear.
K.improper alignment or main valve body and torque converter housing may cause oil pump seizure. The
symptoms ale mostly an rpm-related ticking noise or a high-pitched squeak.
L.ll the ATF strainer is ctogged with panicles of steel or aluminum, inspect the oil pump and ditferential
pinion shaft. lt both are OK and no cause lor the contamination is found, replace the torque converter.
M.lf the 1st clutch feedpipe guide in the right side cover is scored by the mainshaft, inspect the ball bear-
ing for excessive movement in the transmission housing. lf OK. replace the right side cover as it is dent-
ed. The O-ring under the guide is probably worn.
N.ReDlace the mainshstt if the bushing for the 4th feedpipe is loose or damaged.
It the 4th feedpipe is damaged or out ot tound, replace the right side cover'
Replace the subjshaft it thtbushing for the 1st-hold Jeedpipe is loose or damaged.
lf the 1st-hold feedpipe is damaged or out of round, replace it.
Replace the mainshaft if the bushing lor the 1st feedpipe is loose or damaged.
lf the lst feedpipe is damaged or out ot round, replace it.
o.A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse, such as rocking the car in snow.
P.InsDect the frame for collision damage.
o.Inspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamters of countershaft 4th and reverse gear.
3. Shift fork for scutt marks in center.
4. Differential Dinion shaJt for wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replace items 1 , 2, 3 and 4 it worn or damaged. lf transmission makes clicking, grinding or.whirring
noise, atso replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to
1,2,3ot4.lf ditiersntial Dinion shaft is worn, overhaul differential assembly, and replace ATF strainel, and thoroughly
clean transmission, tlush torque convertet, cooler and lines.
lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and tinal
driven gear.
R.Be wry careful not to dsmage the torque converter housing when replacing the main ballbearing. You
may al;o damage the oil pump when you torque down the main valve body. This will result in oil pump
seizure it not detected. Use proper tools.
qInstall the main seal tlush with the torque converter housing, lf you push it into the torque converter
housing until it bottoms out. it will block the oil return passage and result in damage.
T,Harsh do\/vnshiJt"\./l,'hen coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustment may clear this problem.
ifuitle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cable adjusted too long will result in throttle pressure being too low for the amount of engine torque
input into ihe trsnsmission and may cause clutch slippage. A cable adjusted too short will result in too
hi;h throttle pressure which may cause harsh shitts, erratic shrfts and torque con
14-89

System Description
Steering Pump (cont'dl
Flow Control
The flow control valve in the pump performs the follow-
ing steps @ through O to control the flow of fluid, i.e. to
increase the discharge volum€ wh6n engine speed is
low and to decrease it when the engine speed increases.
The assistance thrust of the steering gearbox changes in
compliance with the change in the discharge volume.
When the engine starts, fluid discharged from the
discharge port starts to run through the metering
orifice in the pump. The discharge volume increas€s
as the engine speed increases,
As the flow has already been regulated by the
metering orifice when the engine speed is at or near
the idle speed, a constant and regulated amount ot
fluid is discharged until the engine speed reaches
the middle speed range. As the engine speed
increases, the pressure difference between the ends
of the metering orifice increases. A pressure differ-
ence is created between the top and bottom ends ofthe flow control valve, too, pushing the flow control
valve to open the by-pass passage. This allows the
excess fluid to return to the inlet pon preventing
pressure at the discharge port trom rising exces-
sively.
As the engine speed continues to increase, the tlow
control valve is pushed back further. When the
engine speed reaches a given speed. the return pas-
sage outside the metering orifice is connected to
the inlet port, and the opening to the inlet port
widens in proportion to the increase in engine
speed. This makes pan of the fluid regulated by the
metering orifice return to the inlet pon of the pump;
there by discharged fluid from the pump is
decreased slowly by this amount.
The orifice in the return passage regulates and
maintains the flow of fluid discharged from thepump at a given level until the engine speed reach-
es the high speed range.
.5IJ
lot=ro
FLOW CURVE
PUMP R.P,M.
o
@
VALVE
@
@
17-6

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

Roar pillar tlim panel/Rear shell trim panel/Rsar she removal:
1. Remove both seat-back side bolsters {see page
20-1 1 1).
2. Remove the upper portion of the rear door sill mold-ing, then pull the rear door trim awav on each side.
REAR PILLAR TRIM PANEL
3. Remove both rear pillar trim panels.
> i Clip localionr, 12
W.,
NOTE: When installing, make sure
REAR PILLARTRIM PANEL
the rear window defogger wireharness is .outed properly.
> : Clip locations, 2
4. Bemove the rear shelf trim panel.
V : Clip locrtions, 2
frl
^affi-_--.]-"t't
Y,r\-J/ '/ - REAR sHEr-F- TRIM PANEL
5. Slip the rear seat belr through the slit in the rear shelf.
REAR SHELF
6.Remove the seat lock cover {see page 20 11 1)and
high mount brake lighr (see section 23).
(cont'd)
20-95

Hatch
Replacement
NOTE:
a An assistant is helpful when removing the hatch.
a Take care not to damage the hatch and body.
a Take care not to scratch the hatch side trims and hatch
tnm paner.
a Open the hatch.
a Remove the high mount brake light {see section 23).
1. Remove the hatch side trim on each side.
HATCH< : Clip locations, 8
2. Remove the hatch trim panel.
A : Clip localions
AA : Clip, 11 BV : Clip, 3
W', dtri
::::/ _:_/
HATCH TRIM PANEL
NOTE: Detach the clips by sliding the hatch trim panel
forward, then remove it.
3. Remove the hatch spoiler as described on page
20-159 (for some type).
4. Disconnect the connectors, then remove the wire
harnesses from the hatch.


: Speclal boltlocetlons,2
V : Clip locations
Av : Clip, 3 BA: CliP, 6
4
t+Ltfrl
l'R@t
,/ L,/
A
@
l
)
NOTE: Before pulling out the wire harness, tre a
strinq to the end of it so you can pull it back in when
the hatch is reinstalled.
HATCI{WIRE I{ARNESSES
CONNECTORS
CONNECTOR
WIREHARNESS
20-146
5. Remove the rear wiper motor (see section 23).