HONDA INTEGRA 1994 4.G Workshop Manual

A/C Compressor Belt
Replacement
Automatic Transmission Type
1. Loosen the adjust pulley bracket pivot bolt and the
adjusting bolt, then remove the A/C compressor
belt from the oullevs.
2, Remove the two mounting bolts from the left front
engine mount, then pass the A,/C compressor belt
through the gap between the body and left front
en9rne mount.
ADJUSTING BOLTADJUST PULLEY BRACKETPIVOT BOLT
10 x 1.25 mm54 N.m (5.5 kgf.m,4(' rbr.ft)
Install in the reverse order of removal, and adjust
the A,/C compressor belt (see page 22-36).
"t.M'
22-35
-la ar-
Manual Transmission Type
1. Loosen the adjust pulley bracket pivot bolt and the
adjusting bolt, then remove the A/C compressor
belt from the pullevs.
2. Remove the two mounting bolts from the left front
engane mount.
Remove the engine mount nut, washer, bolt and theleft front engine mount.
Remove the A,./C comoressor belt.
ADJUSTING BOLT
ADJUST PULLEY BRACKETPIVOT EOLT
l!l',
I
14 x 1.25 mm83 N.m 18.5 kgl.m.61 tbf.ft)
LEFT FRONTENGINE MOUNT
12 x'1.25 mm69 N.m {7.0 kgf.m,51 tbf.ftt
WASHER
Install in the reverse order of removal, and adjust
the Ay'C compressor belt (see page 22-36).
NOTE: When tightening the engine mount nut,
make sure the washer is set properly on the left
front engine mount as shown.
10 x 1.25 mm54 N.m (5.5 kgtm, irc lbf.ft)

A/C Compressor Belt
Adjustment
Dstlsqtion Method
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/C compressor and the
crankshaft Dullev.
A/C Compressor Belt
Us€d Eelt: 81881 engine 7.5 - 9.5 mm (0.3 - 0.4 in)
Bl8Cl engine 8.5 - 10.5 mm (0.3 -0.11 inl
New Belt: 5.0 - 7.0 mm (0.2 - 0.3 inl
Power Stesring Pump Belt
Used Beli: 'l1.5 - 13.5 mm (0.,[5 - 0.53 inl
New 8€lt: 8.0 - 10.0 mm (0 3 - 0.39 inl
NOTE:
. lf there are cracks or any damage evident on the
belt, replace it with a new one.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
for less than five minutes.
2. Loosen the adjust pulley bracket pivot bolt and the
adjusting bolt lock nut of the Ay'C compressor belt.
3. Turn the adiusting bolt to get proper belt tension,
then retighten the adjust pulley bracket pivot bolt
and the adjusting bolt lock nut.
4. Recheck the deflection of the lvc compressor belt
22-36
Tonsion Gauge Method
1. Attach the belt tension gauge to the Ay'C compres-
sor belt as shown below, and measure the tension
of the belt.
A/C Compressot Belt
Used 8€lt: Bl8Bl engine 390 - 540 N
(40 - s5 kgf, 88 - 120 lbfl
Bl8Cl ongine 3il0 - il90 N
(35 - s0 kgf, 77 - 110 lbfl
N€w Belt 7,10 - 880 N {75 - 90 kgf, 170-200lbl}
Powor Steoring Pump Belt
Used Belt: 390 - 5,{l N (40 - 55 kgf, 88 - 120 lbll
N6w Bolt: 74O - 880 N 175 - 90 kgf, 170-200lbt)
NOTE:
. lf there are cracks or any damage evident on the
belt, replace it with a new one.
. Follow the manufacturer's instructions for the
belt tension gauge.
. "Used belt" means a belt which has been used
for five minutes or more.
. "New belt" means a belt which has been used
tor less than five minutes,
2. Loosen the adjust pulley bracket pivot bolt and the
adjusting bolt lock nut of the AVC compressor belt.
3, Turn the adjusting bolt to get proper belt tension,
then retighten the adjust pulley bracket pivot bolt
and the adjusting bolt lock nut.
4. Recheck the tension of the A{/C compressor belt.

Condenser
Replacement
RAOIATOR UPPENMOUNT BRACKETS
Recover the relrigerant with a Becovery/Recycling/
Charging System (see page 22-221.
Remove the coolant reservoir,
NOTE: Do not disconnect the reservoir hose from
the coolant reservoir and the radiator.
COOLANT RESERVOIR
Remo.ve the bolts and the radiator upper mount
brackets, and remove the bolt from thg suction hose
bracket.
9.8 N.m {1.0 kgf.m.7.2 lbtftl
'1Iffi
22-37
6x1.0mm9.8 N.m (1.0 kgl.m,7.2 lbt.ft)
......-.....
CONOENSER LINE
Remove the bolts. and disconnect the discharge line
and the condenser line from the condenser.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the system.
DISCHARGE LINE
Remove the two mounting bolts, then lift out the
condenser as shown.
NOTE: Do not damage the radiator and condenser
fins when removing the condenser.
6x1.0mm9.8 N.m (1.0 kgf.m, 7.2 lbl.tt)
Install in the reverse order of removal. and:
. if you're installing a new condenser, add refriger-
ant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-21t,.
. replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil {ND-OIL 8:
P/N 38899 - PR7 - A01) before installing them.
NOTE: Be sure to use the right O-rings for HFC-
134a (R-134a) to avoid leakage.
a do not damage the radiator and condenser fins
when installing the condenser,
. be sure to install the condenser mount cushions
securely into the holes.
. charge the system (see page 22-39) and test its
performance (see page 22 24!.

A/G System Service
Evacuation
Only use service equipment that is U.L.-listed and is cer-
tified to meet the roquirements of SAE J2210 to remove
HFC-134a (R-134a) lrom the 8ir conditioner system.
CAUTION: Exposulo to 6ir conditioner refligorrnt and
lubricani vapor or mi3t crn i.ritato 9y33, noaa and
thrort. Avoid bratthing ths .ir conditionor rsfrigorrnt
snd lubricsnt vtpor or mist.
lf accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle 8ir conditioner sys-
tems should not be pressure tested or leak tested with
compressed ait.
!@ somo mixtuto3 ot ril and R'134! hav.
been shown to bo combustible at olevltad prossulo3
and can re3ult in fire or explosion crusing inlurY or
property damago, Navor us! comprossod air to prgsauro
test R-13/aa 3orvicr €quipmlnl or vohiclo air conditionol
sy3lems.
Additional health and safety information may be ob-
tained from the retrigerant and lubricant manufactures.
1. When an Ay'C System has been opened to the atmo-
sDhere, such as during installation or repair, it must
be evacuated using a R-134a refrigerant Recovery/
Recycling/Charging System. {lf the system has been
open for several days, the receiver/dryer should be
replaced.l
2. Connect a R-134a refrigerant Recovery/Recycl-
ing/Charging System to the car, as shown, follow-
ing the equipment manufacturer's instructions.
NOTE; lf tow pressure does not reach more than
93.3 kPa (700 mm Hg, 27.6 in'Hg) in 15 minutes,
there is probably a leak in the system. Partially
charge the system and check tor leaks {see Leak
Test).
R.cov.ry/R.cycling/Chtroing Syttom
PRESSUREaotnSIDE
2234

Charging
Only use service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner svstsm.
CAUTION: Exporuro to rir conditionor .etrigorant and
lubric8nt yapor or misl can irritats cyos, no36 and
throlt. Avoid broathing tho lir conditionor rofrig6rant
lnd lubricant vlpor or mbt,
It accidental system discha.ge occurs, ventilate work
area before resuming service. Additional health and
safety information may be obtained from the refrigerant
and lubricant manufactures.
Rofrigerant capacity: f00:3n g (24.7:l,oz)
CAUTION: Do not ovorchlrgo thc syrtem; tho compr6s-
sor will be damagad.
Connect a R-134a refrigerant Recove.y/Recycling/
Charging System to the car, as shown, following the
equipment manufacturer's instructions.
R.cov.rylRccacling/Ch.rging Syrtom
22-39

A/C System Service
Leak Test
Only use service equipment that is U.L.-listed and is cer-
tified to meet the requirements of SAE J2210 to remove
HFC-134a (R-134a) from the air conditioner system.
CAUTION: Exposura to air condition ratrigerant and
lubaicant vapor or mist can irritato oyes. nose and
throat. Avoid br€athing tho sir conditionsr reftigolant
and lubricant vapor or mist.
lf accidental svstem discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comoressed air.
@ some mixturos ot air and R'13'la have
b.6n shown to b€ combustible at glsvated pressur€s
and can result in firo or sxplo3ion causing iniury or
proporty damage. Ngvar uso compress€d tir to pro33ure
tost R-134a $rvics oquipmont or vohicl€ air Gonditionsr
systcms.
Additional health and satetY information may be ob-
tained from the refrigerant and lubricant manufactures'
1. Connect a R-134a retrigerant Recovery/Recycling/
Charging System to the car. as shown, following
the equipment manufacturer's instructions.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system before
chargtng.
2. Open high pressure valve to charge the system to
about 98 kPa (1.0 kgf/cm', 14 psi), then close the
supply valve.
3. Check the system for leaks using a R-134a refriger-
ant leak detector with an accuracy of '!4 g {0.5 oz)
per year or better.
4. lf you find leaks that require the system to be
opened (to repair or replace houses, fittings, etc.),
recover the system according to the Recover
Procedure on page 22-22.
5. Aiter checking and repairing leaks, the system must
be evacuated (see System Evacuation gn page 22-
38).
Rocov.ry/R.cycling/Ch.tging Sy3tcm
LOW PRESSURESIDE
HIGHSIDE
22-40

Electrical
Special Tools
Troubleshooting
Tips and Precautions ................................ 23-3Five-stop Tloubleshooting ..............,...-..-... Z3-sSchematic Symbols ................................_. 23-6wire Color Cod€s ..................................... 23-6Relay and Control Unit Locations
Engine Compartment .........,............ ... --. 23-7Dsshboard and Door ..,,......................... 23-gDashboard and Floor ............................. 23-t OOuaner Panel .....-.....23-12Connector ldentification and WireHarness Routing ........ 23-i 3
Index to Circuits and Systems
Airbag ............... ...-..-... 2g-26sAir Conditioning ....,.. Section 2lAltelnator ......_.............. 23-99Anti-lock Brake Systsm (ABS) Section 19Automatic Transmission Section 14Battery .............. .......... 23-66Chafging System ........... 23-98rCigalstte Lighter .....................-...-......-..-.. Z3-2O4Cfock ................. ..........23-197rcruise Controf .......--..-... 23-242Distributor .................... 23-87Fan Controls ................. 23-1ogFuel and Emissions ... Section 1i*Fuses
Under-dash Fuse/Relay Box ................... 23-48Undor-hood ABS Fuse/Retay Box ............ 23-51Under-hood Fuse/Relay Box,.................. 23-52rGauges
Engine Coolant Temperature {ECT)Gauge ................ ..23-126Fuef cauge ............... 2g-123'Gauge Assembly ....--.23-113Speedometer .....-...,,. 23-114Tachometer .....,.....-.. 23-114Ground Distribution ........ 23-60Heater ,,,........,.... ..... Section 2lrHorn ................. ........... 23-199*fgnition Switch ............. 23-70fgnition Syst6m .......-..-.. 23-A7lgnition Timing .............. 23-89Indicator Lights"A/T Gear Position .............. ................... 23-1 32B1ak6 System ...,..,..-.23-127Engine Oil Pressura .............................. _ 23-1 51Low Fuel ............ ......23-125Malfunction Indicator Lamp {MlL} ...,,. Section I l
tfnteglated Control Unit ...29-144*lnterlock System ...................................... 23-1 3gLights, Exteriol
Back-up Lights ........... 23-179Brake Lights .............. 23-t8ltDaytime Running Lights {Csnada} ........... 23-156Front Palking Lights ............................. 23-1 65Flont Side Marker Lights ....................... 23-165Front Turn Signal Lights ........................ 23-1 65*Hazard Warning Lights .........................- 2g-1A4Headlights ................. 23-t6tLicense Plate Lights .............................. 23-1 69Taillights(Harchback) .......... 23-166
{Sedan) .............. .. 23-167Lights. Inteliol
Cargo Area Light {Hatchback) ...... -.. -.. -... 23-177Ceifing Light ........-..-.23-175
Dash Lights Blightness Controt .............. 23-t70Glove Box Lighr ................................... 23-1 69Spotfighr ............ ....-.23-174Trunk Light (Sedanl ............... .............. - 23.-177*Lighting Sysrem .......-.-... 23-152:Moonroof ,,.,.......,..,,,,,.-.23-211PGM-FI Systom ........ S€crion 11Power Distribution .,.-..--..23-54Power Door Locks .............,,..................... 23-233Power Mirors ..,..,....-...- 23-216Power Relays ...........,..... 23-68Power Windows ............ 29-222*Rear Window Defogger ........,... ..........,..... - 23-20,6Reminder Systems
Key-in Remindel System ....,.............,.... 23-1 50Lights-on Reminder System ................... 23-l 5f*Maintenance Reminder system ..,,.... -.. - -. 23-.1 2gSeat Belt Reminder System ..................- 23-125*Side Markel/Turn Signal/Hazard
Ffasher System .,..,..-.23.-1A4Spark Pfugs .........-...-..... 23-97Starting System ....,,.....-. 23-73*Stereo Sound System ...,.......................,,.. 23-l gg
Supplemental Restraint System {SRS} ......... 23-265Vehicfe Speed Sensor {VSS) .............--..-.... 23-122*Wiper/Washer Systom ...............--.........-..- Zg-254
rRead SRS pi€cautions on Page 23-271 betore workingin these areas.
-+

Special Tools
Rel. No. I Tool NumbolDescriptionOty. I Pago R6toronce
o
o
@
@.'
@'
@'
o--
@
@
07HAZ-SG00400
07JAA-001000c
07JGG-001010A
07LAZ-S140300
oTLAZ-S140400
oTMAZ-S100500
oTMAZ-SP00500
oTNAC-SR20100
oTPAZ-0010100
Deployment Tool
Antenna Nut Wrench
Belt Tension Gauge
Test Harness C
Test Harness D
Test Harness A
Test Harness B
Fuel Sender wrench
SCS Short Connecto.
23-300
23-195
23-108
23-201 ,248,285
23-247
23-241
23-244
23-124
23-89
lncluded in SRS Tool Set oTHAz-SGoOooA
Included in SRS Tool Set OTMAZ-SLOo10A
o
@@
o
@
I
z3-2

Troubleshooting
Tips and Precautions
Before Troubloshooting
a Check applicable fuses in the appropriate fuse/relay
DOX.
a Check the battery for damage, state of charge, and
clean and tight connections.a Check the alternator belt tension.
CAUTION:
a Do not quick-charg€ a battery unless the batteryground cabla has be€n disconnoctsd. oth€rwisoyou will damage the alternator diodss.a Do not att6mpt to crank the engine with the bat-tery ground cable loosely connectsd or you will se-vorsly damag€ tho widng.
a The original radio has a codod thatt plotection ci.-cuit. Be sul€ to got tho customor's code numbet
before- disconnecting th€ battery.- lomoving tho No. 32 (7.5 Al tuso f.om the
under-hood tuse/lelay box.- removing tho radio.
Aflor s€lvic€. reconn€ct powet to tho radio and
turn it on. Whon the word "CODE" is displayed,
€nt€l the customer'E s-digit codo to .astore ladio
operation.
Handling Connectors
a Make sure the connectors are clean and have no loose
wire terminals.
a Make sure multiple cavity connectots are packed withgrease (except watertight connectors).a All connectors have push-down release type locks.
LOCKII{G TAA
LOCKING TAB
a Some connectors have a clio on their side used to at-
tach them to a mount bracket on the body or on
another component. This clip has a pull type lock.
a Some mounted connectors cannot be disconnected
unless you first release the lock and remove the con-
nector from its bracket.
LOCKINGPAWL ONOTHERHALF OFPull toorsengageCONNECTORBRACKET
23-3
a Never try to disconnect connectors by pulling on thei.
wires; pull on the connector halves instead.
a Always reinstall plastic covers.
Belore connecting connectors, make sure the lermi-
nals are in Dlace and not bent.
a Check tor loose retainer and rubber seals.
RETAINER
a The backs of some connectors are oacked with
grease. Add grease if needed. It the grease is contami-
nated, reDlace it.
(cont'd)

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'