Idle adjust HONDA INTEGRA 1994 4.G User Guide

Transmission Housing
Removal
NOTE:
. lf the transmission housing or clutch housing a.ereplaced, the bearing proload must be adjusted(818C1 engine).
. Place the clutch housing on two pieces of wood thickenough to keep the mainshaft from the hitting the
workbench.
1. Remove the back-up light switch.
2. Remove the transmission hanger B,
3. Remove the set screws, the springs, and the steel
balls.
Tna sMtsstoN
SPBINGL. 30 mm11.2 inl
SET SCBEW
WASHERReplace.
4. Remov€ the reverse idler gear shaft bolt,
WASHERReplace.
REVERSE
L
13-10
ATTACHING BOLT
5. Loosen the transmission housing attaching bolts in
a crisscross pattern in several steps. then remove
them.TRANSMISSION
Remove the 32 mm sealing bolt.
Expand the snap ring on ths countershaft ball bear-
ing and remove it from the groove using a pair of
snap ring pliers.
32 mm SEALING BOLT
7.
SNAP RING

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

Reverse ldler Gear
Installation
Parking Brake Stopper
Inspection/Adjustment
1.
2.
Set the parking brake lever in the E position.
Measure the distance between the parking brakepawl shaft and the parking brake lever roller pin as
shown.
STANDARD: 72.9-73-g mm (2.87-2.91 in)
ROLLER PIN
PANKINGBRAKELEVER
PARKING BRAKESTOPPERPARKING BBAKEPAWL SHAFT
lf the measurement is out of tolerance, select andinstall the appropriate parking brake stopper from thetable below.
PARKING BRAKE STOPPER
After replacing the parking brake stopper, make su.e
the distance is within tolerance.
4.
7A\Meaauring\v
MarkPart NumbolLz
124537 - PA9- 0031 1.00 mm
{0.433 in}
11.00 mm
{0.433 in)
224538-PA9 -00310.80 mm(0.425 in)
10,65 mm(0.419 inl
24539- P49,00310.60 mm(0.417 in)
10.30 mm
{0.406 in)
1. Install the reverse idler gear.
Installthe reverse idle, gear shaft holder and needlebearing into the transmission housing, then tightenthe bolts.
6 x l.O mm12 N'm 11.2 kgt.m.4.7 lbf.ft)
14-154

Unovon or rcugh 8te6ring.
3
Adjust rack guide (se€ poge 17-21).
ll the probl6m is not corrected bYadjusting lhe rack guide. replacothe gearbox.
Adiud bolt t€nsion. Roplace b€lt, ifn€c€ssary {s€e page 17-20).
lf the ongin€ stalls when wheel isturned whil€ car is stoDPed ormoving at low spoed, adjust idlesp€€d (soe section 1 1 ).
ldl6 soosd low or orrrtic.
Chock power sieering Iluid levol. Itlgv6l ie excessivoly low, ch€ck forleaks in the system. Add fluid totho spocifiod level.
Air in rssorvoir. or ch€ck pow6a
steoring fluid l6v6l.
lf fluid lev6l is OK, check o-ringsand seals on both €nds of ihopump inlet hose, and th€ oilpump housing mating surfacosfor suction leaks. Reolace oarts65 n€CeSSAry.
Adjust belt tonsion (see page 17-m) or r€Dlaco beh.Pump b6lt slipping on pull6y(pump stops momontarily).
Check if pump prossure is withinthe ranoe 6.400 - 7,100 kPa (65 - 75kgr/cm,, 924 - 1,067 psil and th6gsuge needls travol is 1500 kPa {15kgflctn2, t71 p6i) or less. Check theflow control valve if the needletr.vel €xcoods 1500 kPa {15kg?cm,, i71 psi). lf rhe flow controlvalvo is normal, replace th€ pump
as an assomblv.
Sel the power itooring p.oasuregaug6. Cl066 th€ shut-off v6lv6fully and m€a5uro tho pumppr6ssur6 (6s€ pagg 17-221,
7-1

Place the front wheels in the straight ahesd position and
measure the distSnce the steering wheel can be turned
without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 mm l0 - o.:Xl inl
lf the plsy excseds the service limit, psrform rack guide
adjustment (see page 17-211.
lf the play is still excessive after rack guide adjustment,
inspect the stsering linksgo and gearbox as described
on the next page.
ROTANONAL PLAY
Inspection and Adjustment
Steering OperationPower Assist Gheck with
817-1
Gar Parked
1. Check the power steering fluid level (see page 17-
21) and pump belt tension lsee page l7-20).
2.Start the engine, allow it to idle, and turn the steer-
ing wheel from lock-to-lock sev€ral times to warm
uo the fluid.
Attach a spring scale to the steering wheel. With the
engine idling and the car on a clean, dry floor, pull
the scale as shown and read it as soon 8s the tires
begin to turn,
il. The scal6 should read no more than 33 N (3.4 kgf,
7.5 lbf). lf it reads more or less, ch€ck the gearbox
and pump.

NOTE: Perform rack guide adjustment with the wheels
in the straight ahead position.
Loosen the rack guide screw locknut with the spe-
cialtool, then loosen the rack guide screw.
Tighten the rack guide screw until it compresses the
spring and seats against the .ack guide, then loosen
it.
Retighten the rack guide screw to 3.9 N.m {0.4
kgf'm, 2.9 lbf.ft), then back it off to specified angle.
Specified R6turn Angle: 20 t 5"
Tighten the locknut while holding the rack guide
screw.
1.
6.
RACK GUIDE SCREW
25 N.m12.5 kgf.m, 18lbtftl
L(rcKNUT WRENCH, 40 mm07916 - SAs(xtOl
Check for tight or loose steering through the com-
plete turning travel.
Perform following inspections:
. Steering operation (see page 17-18).
. Power assist with car parked.
Check the reservoir at regular intervals. and add fluid as
necessary.
GAUTION: Use only Genuine Honda Power Stosring
Fluid-V. Using othsr fluids such as ATF or other manu-
facturer's power stoering fluid will damags ths systcm,
SYSTEM CAPACITY:
LO6 litor (1.12 US. qt, 0.93 lmp.qtl
at disasssmbly
RESERVOIR CAPACITY:
0.79 lit6r (0.8:l US. qt, 0.70 lmp.qt)
UPPER LEVEL UNE
LOWER LEVEL LINE
,l
Raise the reservoir and disconnect the return hose
that goes to the oil cooler.
Connect a hose of suitable diameter to the discon-
nected return hose and put the hose end in a suit-
able container.
CAUTION: Tako caro not to 3pill tho tluid on tho
body and parts. Wipe off the spilled tluid at onqe.
Start the engine. let it run at idle. and turn the steer-
ing wheel from lock-to-lock several times. When
fluid stops running out of the hose, shut off the
engine. Discard the fluid,
Refit the return hose on the reservor.
Fill the reservoir to the uDoer level line.
Start the engine and run it at fast idle, then turn the
steering from lock-to-lock several times to bleed air
f.om the system.
Recheck the fluid level and add some if necessary.
CAUTION: Do not lill the roservoir beyond tho
uppgr lovel line.
7.

lnspection and Adjustment
Pump Pressure Check
Check the fluid pressure as follows to determine
whether the trouble is in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belt tension,
CAUnON: Dilconn€st the high pros3uro ho3s with cale
!o e3 not to spill tho powor stooring fluid on th6 lramo
lnd olhor parG.
1. Disconnect the outlet hose from the oumo outlet fit-
ting, 8nd install the pump joint adapter on the
pump outlet.
2, Connect the hose joint sdapter to the power steer-
ing pressure gauge, then connect the outlet hose to
the adaotor.
3. Instsll the power steering pressure gauge to the
pump joint adaptor as shown.
OUTLET HOSE FlTnNG
HOSE ATTACHING BOLT1l Nm11.1 kg{ m 8lbf.ftl
6 x 1.0 m.n BOLT{P!rt of tooll11 N.m11.1 kgtm,8lbf.ftl
P/S JOINT ADAPTOR IPUMPIo?NAK - SmolrA
PUMP OUTI.TTFITIING
Open the shut-off valve fully.
Open the pressure control valve fully.
17 -22
1.
Start the engine and let it idle.
Turn the stee.ing wheel from lock-to-lock several
times to warm the fluid to operating temperature.
Measure steady-state fluid pressure while idling
with the shut-off valve fully open. lf the pump is in
good condition, the gauge should read less than
1500 kpa (15 kgf/cm,,213 psi).
lf it reads high, check the feed line or valve body
unit (see General Troubleshooting l7-10).
Close the shut-off valve. then close the pressure
control valve gradually until the pressure gauge
needle is stabl6, Read the pressure.
lmmediately open the shut-off valve fully.
CAUTION: Do not keep the shut-ott valvs closod
moro thgn 5 soconds or th9 pump could b6 dam"
agod by over-h6ating,
lf the pump is in good condition, the gauge should
read at least 6.400 - 7,400 kpa (65 - 75 kgIlcm,,924- 1,067 psi). A low reading means pump output is
too low for full assist. Repair or replace the pump.
10.
P/S PRESSURE GAUGE

Power Steering Pump
lnstallation
1.Connect the inlet and outlet hoses. Tighten the
pump fiftings securely.
Loosely install the pump in the pump bracket with
mounting bolts.
11N.m11.r kgf.m, 8lbf.ftlOUTIIT HOUSE
INI.TT HOSEO-RINGReplaco.
ADJUSTINGBOLT
PUMP MOUNTING BOLTS2,r N.m {2.4 kgl.m. 17 lbf'ft}
Install the DumD belt.
CAUTION:
. Make surs that thg powor gtooring bslt i!
securgly on the grooyos of ths pulloy!.
. Do not get powor stggring fluid o. groaso in thg
power steering bclt or pulley trc6. Cloan oft 8ny
tluid or groa36 belore installation.
POWER STEERING BELT
PULI..EY
5.
Adjust the pump belt (see page 17-201.
Fill the reservoir to the uoDer level line.
NOTE; Take care not to spill the fluid on the body
and parts. Wipe off the spilled fluid at once.
GAUTION: Uro only Ganuino Honda Powor Stsor.
ing Fluid-V. Using othor tlui& 3uch a3 ATF or oiher
manutacturor's powor steering tluid will drm89e
the rystgm.
SYSTEM CAPACITY:
1.06litor (1.12 US.qt, 0.93 lmp.qt)
RESERVOIR CAPACIW:
0.79 litor (0.1|:| US.qt, 0.?0 lmp.qtl
UP?ER I.fVEL LINE
IEVEI LINE
- Start the engine, let it run at idle, then turn the
steering wheel lock-to-lock severaltimes to bleed
air from the system.
- Recheck the fluid level and add some if neces-
s8ry.
CAUTIONT Do not fill tha .63ervoir boyond th6
upp€r lcvol lino.
17 -44

lgnition System
lgnition Timing lnspection and
Setting (cont'd)
5. To adjust ignition timing, loosen the distributor
mounting bolts, and turn the distributor housing
counterclockwise to advance the timing, or clock-
wise to retard the timing.
MOUNN G BOLTS24 N.m (2.4 kgl.m, 17 lbt'ftl
Tighten the adjusting bolts and recheck the timing.
Remove the SCS short connector trom the service
check connector.
2.
ldle Speed Inspection
Shift to neutral or Ll] and start the engine. Hold the
engine at 3,OOO rpm with no load until the radiator
fan comes on, then let it idle.
Connect a tachometer to the test tachometer con-
nector.
ldle sp6od
M/T: 750 t 50 rpm in neuttal
A/T: 75O t 50 rpm in @ or @
NOTE: Allelectrical systems should be turned OFF.
Adjust the idle speed il necessary (see section 1 1).
b.
23-90

Charging System
Altornator/Regulator Test
NOTE; Mske sure the battery is sufficiently chargod (sa€
page 23-66).
NO
tropagezJ-ruJ,
O IOAD
VOLTTESTSELECTONswlTcH
II{DUCTIVE
FULL FIELDTESTEBLEAD (BLUILOAD ADJUSTERICARBON PILE)
FICK.I.|PIGR '
VOLTMETERt{EGATIVELEAD (8LK}
VOLTMETERPOStTtVELEAD IREDI
EGATIVE TESTER
CABLE (BLKI
INDUCTIVEPICK.UP
B TERMI]TALWIRE
23-102
Connoct tho Sun VAT4O {otooulvslont lgrt equipmonl) andtum tho s6l6ctor rwitch ro posi_
tion I |rtarting).
shift to neurralorlPland start theengino. Hold the ;;gine at 3oO0rpm wiih no load until the radia_
tor lan com€s on. then let it idle.
Raise the engine speed to 2OOOrom and hold il there.
ls lhe voltage over 15.1V?
Release the accelerator pedal andlet the engino idle.
Make sure all electrical systemsare turned otf. Turn the selectorswilch to position 2 (charging).
Remove the inductive pick-up and
zero the ammeter.
Place the inductive pick-uP overthe B terminalwire oI the altgrna-tor so that the arow Doints awaytrom the alternator.
Raise the engins speed lo 20OOrpm and hold it there.
T..t itr b.ttry (.- 9|e. 8€Al.ls the voltage less than 13.9V?