Automatic HONDA INTEGRA 1994 4.G User Guide

Design Specifications
]TEMMETRICENGLISHNOIES
:' vENSTONSOveralllength 3 DOOR
4 DOOR
Ov€rallWidth
Overall Height 3 DOOR
4 DOOR
Wheelbase 3 DOOR
4 DOOR
Track F/R
Ground Clearance
Seating Capacity
4.380 mm
4.525 mm
'1,710 mm
1,335 mm
1,370 mm
2,570 mm
2,620 mm
't,475/1,470 mm
150 mm
Four (3 DOOR)
172.1in
178.1 in
67.3 in
52.6 in
101.2 in
103.1 in
5|8.1/57.9 in
Five (4 DOOR)
,rerght (usA)cross V€hicle Weight Rating {GVWR)3,680lbs
'le,ght {CANADA)Gross Vehicls Weight Rating {GVWR)1,670 kg
:\GINEType81881 engine
818C1 engine
Cylinder Arrangement
Bore and Stroke
Displacement
Compression Ratio
81881
818C1
81881
B18C I
81881
B 18C1
81881
818C1
engrne
engane
engrne
engine
engine
engine
engine
engine
L!brication Systom
OilPump Displacement
Wster Pump Displacement
FuelRequired
81881
B18C 1
81881
B 18C1
91881
engrne
engrne
engine
engine
engine
818C1 engine
Water-cooled, 4-stroke DOHC
gasoline engine
Watercooled, 4-stroke DOHC
VTEC gasoline engine
Inline 4-cylinder, transverse
81.0 x 89.0 mm
81.0 x 87.2 mm
1,834 cm3 (mf )
1,797 cm3 (m{)
3.19 x 3.50 in
3.19 x 3.43 in
112 cu-in
110 cu-in
9.2:1
10.0 : 1
Eelt driven, OOHC 4 valve per cylinder
Belt driven, DOHC VTEC
4 valve per cylinder
Forced and wet sump, trochoid pump
50, {53 US qt, 44 lmp qt)/minute'l
71 f {75 US qt, 62 lmp qt)/minute"
140 f (148 US qt, 123 lmp qt)/minute*!
140 f (148 US qt. 123 lmp qt)/minute*'
UNLEADED gasoline with 86 Pump
Octane Numb€r or higher
Premium UNLEADED gasoline wilh
91 Pump Octane Number or higher
STARTERTypo
NormalOutput
NominalVoltage
Hour Rating
Direction of Rotation
Weight
Gear reduction
1.4 kW
12V
30 seconds
Clockwise as viewed lrom g6ar end
3.7 k9 | 8.3lbs
CLUTCHClutch Type
Clutch Facing Area
M/TSingle plate dry, diaphragm spring
Torq!e converter
203 cm' I 31 sq-in
TRANSMISSIONTransmission Type M/T
Primary Reduction
Synchronized 5-speed forward, 1 reverse
Electronically controlled
4-speed automatic. 1 rcverse
Diract 1 : 1
'1: At 6,000 engine
'2: At 7,600 engine
rpm
rpm
(cont'd)
3-17

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

19. Remove the radiator cap.
@@ u"" care whan removing the ladiatol
cap to avoid scalding by hot engine coolant ol ateam.
20. Raise the hoist to full height.
21. Remove the front tires/wheels and the splash shield.
Drain the engine coolant (see page 1O-5).
a Loosen the drain plug in the radaator.
Drain the transmission oil or fluid. Reinstall the dtain
plug using a new washer.
Drain the engine oil. Reinstall the drain plug using
a new wasner.
CAUTION: Do not overtighten tho drain plug.
22.
24.
6 x 1.O mm9.8 N.m (1.0 kgf'm'7.2 tbf.ft)26.
25. Remove the upper and lower radiator hoses and the
heater hoses.
LOWER RADIATORHOSE
(Automatic transmission) Remove the ATF cooler
hoses.
{cont'd)
UPPER RADIATOR
HOSE
5-7

Timing Belt
Inspection
Remove the cylinder head cover.
. Reler to page 6-3'l when installing.
Inspect the timing belt for cracks and oil or coolant
soaking.
NOTE:
. Replace the belt if oil or coolant soaked.
. Rsmove any oil or solvent that gets on the belt.
Rotate pulley
and inspscr bell.
After inspecting, retorque the crankshaft pulley bolt
to 177 N'm ('18.0 kgf'm, 130 lbt'ft).
Tension Adjustment
CAUTION: Always Ediust timing belt tonsion with tho
cngin. cold.
NOTE:
. The tensionet is spring-loaded to apply proper ten-
sion to the belt automaticallv after making the follow-
ing adjustment.
. Always rotate the crankshaft counterclockwise when
viewed trom the pulley side Rotating it clockwise
may result in improper adjustment ot the belt ten-
sion.
Remove the cylinder head cover. (Refer to page
6-31 when installing.)
Set the No. 1 piston at TDC (see page 6-12).
Rotate the c.ankshaft 5 - 6 revolutions to set the
bslt.
4. Set the No. I piston at TDC.
3.
ADJUSNNG BOLT54 N.m (5.5 kqf.m,a0 rbr.ftlFor adiustment only,do not remove,
5.
6.
7.
8.
Direction olrolatlon.
Loosen the adiusting bolt 1/2 turn (180') onlv
Rotate the crankshaft counterclockwise 3-teeth on
the camshaft pulley.
Tighten the adjusting bolt to the specified torque.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgl.m. 130 lbf.ft).
6-9

Remove the fuel return hose and positive crankcase
ventilation (PCV) hose.
Remove the brake booster vacuum hose, water
bypass hose and vacuum hose.
ERAKE BOOSTERVACUUM HOSE
HOSE
VACUUM HOSE
HOSE
9.
10.
Remove the throttle cable.
Remove the throttle control cable (automatic trans-
mission only).
NOTE:
. Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one.
. Adjust the throttle cable and throttle control
cable when installing (see section 11 and 14).
THROTTLE CONTROLCABLE
Remove the engine wire harness connectors and
wire harness clamps trom the cylinder head and the
intake manifold.
Four fuel injector connectors
Intake air temperature (lAT) sensor connector
Engine coolant temperature (ECT) sensor con-
necror
TDC/CKP/CYP sensor connector
lgnition coil connector
ECT gauge sending unit connector
Throttle position (TP) sensor connector
Manifold absolute Dressure (MAP) sensor con-
nector
ldle air control (lAC) valve connector
EVAP purge control solenoid valve connector
11.
a
a
a
a
a
a
a
a
a
(cont'dl
ATI'USTING
6-17

Timing Belt
lnspection
Remove the cylinder head cover.
. Refer to page 6-78 when installing.
Inspect the timing belt for cracks and oil or coolant
soaking.
NOTE:
. Replace the belt if oil or coolant soaked.
. Remove any oil or solvent that gets onthe b€lt.
Rotate pulleyand inspect b6lt.
After inspecting. retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf.m, 130 lbf.ft).
Tension Adjustment
CAUTION: Always adlust timing bslt tsnsion with th6
engine cold.
NOTE:
. The tensioner is spring-loaded to apply proper ten-
sion to the belt automatically after making the follow-
ing adjustment.
a Alwavs rotate the crankshaft counterclockwise when
viewed trom the pulley side. Rotating it clockwise
may result in improper adjustment of the belt ten-
sion.
Remove the cylinder head cover. (Refer to page 6-
78 when installing.)
Set the No. 1 piston at TDC (see page 6-51).
Rotate the crankshaft 5-6 revolutions to set the belt.
Set the No. 1 piston at TDC.4.
AINUSTING AOLT5/a N.m 15.5 kg{.m, to lbtftlFor adjustment only,
5.
7.
8.
A
.//\v-/
Directionrotat|on,
Loosen the adjusting bolt 1/2 turn (180') only.
Rotate the crankshaft counterclockwise 3 teeth on
the camshaft pulley.
Tighten the adjusting bolr.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf.m, 130 lbf'ft).
6-48

lllustrated Index
NOTE:
. Apply liquid gasket to the mating surfaces of the right
side cover and oil pump housing before installing
them.
. Use liquid gasket, Pan No.08718 - 0001.
. Clean the oil pan gasket mating surfaces before
installing it.
Bl8Bl engine: wAsHEF
Lubricate all internal parts with engine oil during
reassemory.
6x1.0mm12 N.m (1.2 kgf.m,I lbf.ftl
6x1.0mm11 N.m (1.1 kgf.m,8lbtft)
OIL SCREEN
11 x 1.25 mm76 N.m17.8 kgl.m, 56 lbf ftlApply engine oilto the bolt
threads and the washers.NOTE: After torquingeach cap, turn crankshaftto check lor binding.
DRAIN PLUG44 N.m {4.5 kgf.m,33 tbtfr)
GASKETReplace.
6x1.0mm1'l N.m {1.1 kgt.m, I lbtft)
OIL PAN
O.RING
GASKETReplace.
BEARING CAP
12 x 1.0 mm103 N.m (10.5 kgf.m, ?6lbf ft)
MANUALFLYWHEEL
'12 x 1.0 mm74 N.m {7.5 kgt m,54lbf.ftlTorque sequence, page 7 7
DRIVE PLATECheck for cracks,
AUTOMATIC TRANSMISSION
WASHER
6x1.0mm11 N.m {1.1 kgl.m,8 tbf.frt
CRANKSHAFTEnd play, page 7-12Runout, Taper, andOut-of-Round, pages 7 12, 13Instsllation, page 7 22
MAIN BEARINGRadial clearance, page 7-8
Sel€ction, page 7-8NOTE: New main bearingsmust be selected by matching
crank and block identificationmarkrngs.
Apply liquid gasket
to block mating surface.
OIL SEALInstallation, page 7-25,
RIGHTSIDE COVERDOWEL PINSOIL PUMPOverhaul, page 8-9THRUST WASHERSGrooved sides face outward.NOTE: Thrust washer thicknessis tixed and must not be changedby grinding or shamming.
8 x 1 .25 mm2,1 N.m {2.4 kgt m,17 tbt.ft)
OIL SEALInstallation, page 8-11Apply engrneorl.Replace.
Apply liquid gasket
to block mating
6x1.0mm'11 N.m {1.1 kgf'm, 8 lbl ft)(conr'dl
7-3

Flywheel and Drive Plate
Replacement
Manual Transmission:
Remove the eight flywheel bolts, then separate the lly-
wheel from the crankshaft flange. After installation,
tighten the bolts in the sequence shown.
r10.5 kgi.m,76lbt.ftl
RING GEAR HOLOERo?LAB - PV00100,07924 - PO2IX)03 or07924 - PD20/m2
\
n.t=?4
fut!!-+-rt=tz-21I lvaz'Z-+
ENGINEBLOCK
o -o.r \
/ oo^t,
\..?bi
/ AK{:{AAo
rs#*ffi_9
Automatic Transmission:
Remove th€ eight drive plate bolts, then separate the
drive plate from the crankshaft flange, After installation,
tighten the bolts in the sequence shown.
r t.0 mmt,l N.m(7.5 kg{.m, 54 lbf.ft}
7-7

lllustrated Index
@ sy"t". is under high plessure when engine
is hot. To avoid dsnger of relsssing scalding engine
coolant. remove cap only when engine is cool.
Total Cooling System Capacity (lncluding heater and
r€servoirl
Bl8Bl engine:
Mfl: 6.4 | {6.8 US qt, 5.6 lmp qt}
AlTt 6.7 | {7.1 US qt, 5.9 lmp qt}
Bl8Cl engine:
Mfi: 6.7 t {7.1 US qt, 5.9 lmp qt}
CAUTION: lf any engine coolant spills on paint€d por-
tions ot the body, rinse it ofl immediately.
NOTE:
a Check all cooling system hoses for damage. leaks or
deterioration and replace if necessary.
a Check all hose clamps and retighten if necessary.
a Use new O-rings when reassembling.
CONDENSERFAN SHROUD{soe soction 221
6 x 1.O mm7 N.m (O.7 kgt.m. 5 lbf.ftl
ATF COOLERHOSES{81881 6ngine)
RADIATOREngine coolant refilling and bleeding,page 10-5Leak test, page 'l0-6
Inspect soldered joints andseams for leaks.Elow out dirt from betweencore fins with compressed air.lf insects, etc., are clogging.adiator, wash them off withlow pressure water,
S!
P
R
U
COOLANTRESERVOIR
5x0.8mm4.4 N.m (O.45 kgf.m,3.3 lbl.fr)
M/T: Manual t.anamiaaionA/T: Automatic t.ansmiasionATF: Automatic t.ansmission fluid
\*
*)
FAN SHROUD
10-2