valve cover HONDA INTEGRA 1994 4.G User Guide

[":::,::-'
Eecause of its compact impeller design, the fuel pump is installed inside the fueltank, thereby saving space
ng the fuel line system.
FUEL PUMP
FUEL FILTER
FUEL PUMP BRACKET
FUEL PUMP CROSS SECTION lsido vi6rvl
IMPELLERS
CHECK VALVEPUMP CASING
The fuel oumo consists of a DC motor, a circumference flow pump, a relief valve for ptotecting the fuel lir
a check valve for retaining residual pressure, an inlet port, and a discharge port. The fuel pump assembly
the impellers (driven by the motor), the fuel pump casing {which forms the pumping chsmber), and the fuel p
OPERATION(1 ) When the engine is started. the PGi/t-Fl main relay actuates the fuel pump, and the motor turns togeth
impellers.
Differential pressure is generated by the numerous grooves around the impellers.
(2) Fuel entering the inlet porr flows inside the motor from the pumping chambe. and is forced through th
port via the check valve.
lf tuel flow is obstructed at the discharge side of the tuel line, the relief valve will open to bypass the
inlet port and prevent excessive fuel pressure.
(3) When the engine stops, the tuel pump stops automatically. However, a check valve closes by gravity t
residual pressure in the line, helping the engine to aestan more easily.
and simplify-
N lTop vi6w)
PORT
GROOVES
fuel line systems,
embly consists of
fuel pump cover.
together with the
rgh the discha.ge
ss the fuel to the
avitv to retain the
(cont'd)
PUMP COVER
FUEL PUMP ASSEMBLY CROSS SECTION
D|SCHARGE FORT ^ . tNLEr P
IMPELLER
11-109

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

Automatic Transmission
'l4-2
14-3't 4-6
14-8
14-14
14-23
Hvdraulic Flow ...--...... 14-24
Lock-up System ........ 14-38
Eloctrical Systom
Component Location ............,...,................ I 4-45
Circuit Diagram ............. 14-46'Troubleshooting Procedures ........,..........., l4-48
Symptom-to-Component Chart
Electrical System ...... 14-50
Electrical Troubleshooting
Troubleshooting Flowchart .................... 14-52
Lock-uo Control Solenoid Valve A/8
Test .................. --.... \4-82
ReDlacement ,...,...,..,. 14-82
Shift Control Solenoid Vslve A/B
Test .................. ...... 14-83
Reolacement .............. 14-83
Transmission Control Module (TCM)*ReDlacement ........... 14-84
Mainshalt/CountershaJt SDeed Sensors
Reolacement ............. 14-85
Hydraulic Systom
Symptom-to-Component Chart
Hydraulic System
Road Test
Slall Speed
Test ..................
Fluid Level
Checking/Changing
Pressu.e Testing
Transmission
Transmission
Removal ............. ...... 14-99
lllustrated Index
Right Side Cover .................................. 1 4- 1 04
Transmission Housin9 ..................,,....... I 4-1 06
Torque Converter HousingNalve
Body .................. ... 14- 1O8
Right Side Cover
Removal ............. ...... 14-110
Transmission Housing
Removal ............. .-..-. 14-112
Torque Convener HousingNalve Body
Removal ............. ...... 14-114
Valve Caps
Description ................ 14-116
Valve Body
Repair ................ ...-.. 14-117
Valve
Assembly ...........
Oil Pump
Main Valve Body
Disassembly/lnspection/Reassembly
Regulator Valve Body
Disassembly/lnspection/Reassembly
Lock-up Valve Body
Disassembly/lnspection/Reassembly .......
Secondary Valve Body
Disassembly/lnspection/Reassembly .......
Servo Body
Disassembly/lnspection/Reassembly .......
1st-hold Accumulator/Right Side Covet
Oisassembly/lnspection/Reassembly .,..,..
Mainshaft
Disassembly/lnspection/Reassembly -.. -... 1 4- 1 29
lnsDection ................. 14- 130
Countershaft
Disassembly/lnspection/Reassembly ....... 14-132
Disassembly/Reassembly ....................... 1 4-1 33
lnsDection ................. 14-134
One-way Clutch/Parking Gear
Disassembly/lnspection .................... -.. -. 1 4-137
Sub-shaft
Disassembly/lnspection/Reassembly ....... 14-138
Disassemblv/Reassemblv ....................... 1 4-1 39
Sub-shaft Bearings
Replacement ............. l4-140
Clutch
fllustrated lndex ................. -..-...-.......... 14-1 41
Disassembly ,,,.,,........ 14-144
Reassembly .............. 14-146
Torque Converter Housing Bearings
Mainshaft Bearing/Oil Seal
Reolacement ......... 14-1 50
Countershaft Bearing Replacement .......,, 14-1 5l
Transmission Housing Bearings
Mainshsft/Countershaft Bearing
Repfacement ...-..-..14-152
Sub-shaft Bearing Replacement .............. 1 4-1 53
Reve.se ldler Gear
lnstallation ................ 14-154
Parking Brake Stopper
lnspection/Adjustment ..........................'14-'154
Transmission
Reassemblv .............,. .14_156
Toroue Converter/Drive Plate ..,..,............... 1 4- 1 63
Transmission
14-120
14-122
14-123
14-124
14-126
14-124
14-86
14-90
't4-92
14-93
14-94
lnstallation
Cooler Flushing'Shitt Cable
Removal/lnstallation ..............................
Adiustment ...-..-......-. 14-'171*Gearshift Selector
Disassembly/Reassembly .....................,. 1 4-17 2*Shift Indicator Panel
Adjustment -..........-...14-173
Throttle Control Cable
fnspection .......,..,...... 14-17 4
Adjustment .............. 14-176
14-164
14-168
14-'t 7 0
Inspection

The Automatic Transmission is a combination of a 3-e,ement torque convefter and triple-shaft electfonically controlled
automatic transmission which provides 4 speeds forward and 1 speed reverse. The entire unit is positioned in line with
the engine.
Torque Converter, Gears and Clutches
The torque converter consists of a pump, turbine and stator assembly in a single unit, The torque converter is connected
to the engine crankshaft so they turn together as a unit as the engine turns. Around the outside of the torque converter
is a ring gear which meshes with the starter pinion when the engine is being staned. The entire torque converter assem-
bly serves as a flywheel while transmitting power to the transmission mainshaft.
The transmission has three parallel shafts, the mainshaft. countershaft and sub-shaft. The mainshatt is in line with the
engine crankshaft.
The mainshaft includes the clutches for 1 st, and 2ndl4th, and gears for 3rd. 2nd, 4th, reverse and l st (3rd gear is in-
tegral with the mainshaft, while reverse gear is integral with the 4th gear).
The countershaft includes the 3rd clutch and gears Ior 3rd, 2nd,4th, reverse, lst and parking. Reverse and 4th gears
can be locked to the countershaft at its center, providing 4th gear or reverse, depending on which way the selector is moved.
The sub-shaft includes the lst-hold clutch and gears for 1st and 4th
The gears on the mainshait are in constant mesh with those on the countershaft and sub-shaft. When certain combina-
tions of gears in the transmission are engaged by the clutches, power is transmitted from the mainshaft to the counter-
shaft via the sub-shatt to provide @, E, tr. tr and @ position.
Electronic Control
The electronic control system consists of the Transmission Control Module {TCM), sensors, and 4 solenoid valves. Shift-
ing and lock-up are electronically controlled for comfortable driving under all conditions.
The TCM is located below the dashboard, behind the left side kick panel on the driver's side.
Hydraulic Control
The valve bodies include the main valve body, secondary valve body, regulator valve body. servo body, and lock-up valve
body throuqh the respective separator plates.
They are bolted on the torque converter housing.
The main valve body contains the manual valve, 1-2 shift valve, 2-3 shift valve, Clutch Pressure Cont.ol (CPC) valve,
4th exhaust valve, relief valve, and oil pump gears.
The secondary valve body contains the 4-3 kick-down valve,3-2 kick-down valve,2-3 orifice cont.ol valve, 3-4 shitt
valve, orifice control valve. modulator valve, and servo control valve
The regulator valve body contains the pressure regulator valve. lock-up control valve, torque converter check valve, and
cooler check valve.
The servo bodv contains the servo valve which is integrated with the reverse shift fork, throttle valve B, and accumulators.
The lock-ug valve bodv contains the lock-up shift valve and lock-up timing B valve. and is bolted on the secondary valve
body.
Fluid from the regulator passes through the manual valve to the various control valves.
Shitt Control Mochanism
Input to the TCM i.om various sensors located throughout the car determines which shift control solenoid valve should
be activated.
Activating a shift control solenoid valve changes modulator pressure, causing a shift valve to move. This pressurizes
a line to one of the clutches. engaging that clutch and its corresponding gear.
Lock-up Mechanism
In @ position. in 2nd, 3rd and 4th, and E position in 3rd, pressurized tluid can be drained from the back of the tor-
que converter through an oil passage, causing the lock-up piston to be held against the torque converter cover. As this
takes Dlace, the mainshaft rotates at the same speed as the engine crankshatt. Together with hydraulic control, the TCM
optimizes the timing ol the lock-up mechanism.
The lock-up valves control the range of lock-up according to lock-up control solenoid valves A and B, and throttle valve B
When lock-up control solenoid valves A and B activate, modulator pressure changes. Lock-up control solenoid valves
A and B are mounted on the torque converter housing, and are controlled by the TCM.
(cont'd)
14-3

Description
Clutches
The four speed automatic transmission uses hydraulically actuated clutches to engage or disengage the transmission gears.
When clutch pressure is introduced into the clutch drum, the clutch piston is applied. This presses the iriction discs and
steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack tojts hub-mounted gear.
Likewise, when clutch pressure is bled from the clutch pack. the piston releases the friction discs and steel plates, and
they are {ree to slide past each other while disengaged. This allows the gear to spin independently on its shaft, transmit-
ting no power.
1st ClutchThe l st clutch engages/disengages 1st gear, and is located at the end of the mainshaft, just behind the right side cover.
The 1st clutch is supplied clutch pressure by its oil feed pipe within the mainshaft.
1st-hold clutchThe 1st-hold clutch engages/disengages 1st-hold or I Fosition, and is located at the center ol the sub-shaft. The 1st-
hold clutch is supplied clulch pressure by its oil feed pipe within the sub-shait.
2nd ClutchThe 2nd clutch engages/disengages 2nd gear, and is located at the center of the mainshaft. The 2nd clutch is joined
back-to-back to the 4th clutch. The 2nd clutch is supplied clutch pressure through the mainshaft by a circuit connected
to the regulator valve body.
3rd Clutch
The 3rd clutch engages/disengages 3rd gea.. and is located at the end oJ the countershaft, opposite the right side cover.
The 3rd clutch is supplied clutch pressure by its oil feed pipe within the countershaft,
4th clurch
The 4th clutch engages/disengages 4th gear. as well as reverse gear, and is located at the center of the mainshaft.
The 4th clutch is joined back-to-back to the 2nd clutch. The 4th clutch is supplied clutch pressure by its oil feed pipe
within the mainshalt.
One-way Clutch
The one-way clutch is posjtioned between the parking gear and 1st gear. with the parking gear splined to the counter-
shaft. The 1st gear provides the outer race, and the parking gear provides the inner race surface. The one-way clutch
locks up when power is transmitted from the mainshaft 1st gear to the countershaft lst ggel _The 1st clutch and gears remain engaged in the 1st. 2nd. 3rd, and 4th gear ranges in the @, E or E position.
However, the one-way clutch disengages when the 2nd. 3rd, or 4th clutches/gears are applied in the E, lD.l o, Eoosttton.
This is because the increased rotational speed of the gears on the countershaft over-ride the locking "speed range" of
the one-way clutch. Thereafter, the one-way clutch free-wheels with the lst clutch still engaged.
COUNTERSHAFT 1ST GEAR
FREE
:>
LOCKS
aF
NOTE:View trom right side cover side.
14-6

Hydraulic Control
The valve bodies include the main valve body, secondary valve body, regulator valve body, servo body and lock-up valve
body.
The oil pump is driven by splines behind the torque converter which is attached to the engine. Oil flows th.ough the
regulator valve to maintain specified pressure through the main valve body to the manual valve, directing pressure to
each of the clutches,
SHIFT CONTROL SOLEIIOIDVALVE ASSEMBLY
RTGHT SIDE COVER
LOCK.UP VALVE BODY
VALVE BODY
REGULATOR VBODY
SOLENOID VALVEASSEMBLY
4<.__i: )o.-
OIL PUMP GEARS
14-23

S6rvo Body
The servo bodv is located on the secondary valve body.
The servo valve is integrated with the shiit fork shatt, throttle valve B. and accumulator pistons, which are all assembled
in the servo bodv.
SERVO VALVE/SHIFT FORK SHAFT
THROTTLE VALVE BSERVO BODY
Accumulator Pislons
The accumulator pistons are assembled in the servo body and right side cover. The l st-hold clutch accumulator piston
is in the right side cover, and the 1st, 2nd 3rd, and 4th accumulator pistons are assembled in lhe servo body.
RIGHT SIDE COVER
THROTTLE LONG VALVE
1ST-HOLD ACCUMULATOR
4TH ACCUMULATOR
IST ACCUMUI-ATOR
2ND ACCUMULATOR PISTON3RD ACCUMULATOR PISTON
14-27

2nd Sgeed
The llow of fluid up the 1-2 shift valve is the same as in 1st speed. As the speed of the car reaches the prescribed
value, the solenoid valve A is tulned on by means ot the TCM. As a result, the 1-2 shift valve is moved to the left
and uncovers the port leading to the 2nd clutch; the 2nd clutch is engaged'
Fluid flows by way of:- Line Dressure l4l - 'l-2 Shift Valve - 2-3 Shitt Valve - 2nd Clutch Pressure (2'1) * 2nd Clutch
The hvdraulic pressure also flows to the 1st clutch, However, no power is transmitted because of the one-way clutch.
NOTE:. When used, "lett" or "right" indicates direction on the flowchart
. SOL-@: Shift Control Solenoid Valve A
. SOL@: Shift Control Solenoid Valve B
. SOL-@: Lock-up Control Solenoid Valve A
. SOL-@: Lock-up Control Solenoid Valve B
{cont'd)
14-33

Description
Hydraulic Flow (cont'd)
3rd Speed
The tlow of fluid up to the 1-2 and 2 3 shift valves is the same as in 2nd speed. As the speed of the car reaches
the prescribed value, the shift control solenoid valve B is turned off {shilt control solenoid valve A remains on). The
2-3 shift valve is then moved to the left, uncovering the oil port leading to the 3rd clutch. Since the 3-4 shitt valve
is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.
Fluid tlows by way of:- Line pressure l4l - 1-2 shift valve - 23 Shift Valve * 3rd ctutch pressure (31) - 3-4 shift valve(not controlled) 3rd Clutch Pressure (3O) - 3rd Clutch
The hydraulic pressure also flows to the l st clutch. However, no power is transmitted because of the one-way clutchas in the 2nd speed.
NOTE:. When used, "lett" o( " tight" indicates direction on the flowcharl.. SOL-@: Shift Control Solenoid Valve A. SOL-@:Shift Control Solenoid Valve B. SOL-O: Lock-up Control Solenoid Valve A. SOL-@: Lock-up Control Solenoid Valve B
14-34

Lq4 Position
4. 4th Spe6d
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valves is the same as in 3rd speed. As the speed of the car reaches
the prescribed value, the shift control solenoid valve A is turned oJt (shift control solenoid valve B remains off).
As this takes place, 3-4 shift valve is moved to the left and uncovers the oil port leading to the 4th clutch. Since
the 1-2 and 2-3 shift valves are kept on the left side, the fluid flows through the 4th clutch; the power is transmitted
through the 4th clutch.
Fluid flows by way of:- Line Pressure l4l - 'l'2 Shift Valve -t 2-3 Shitt Valve - 3rd Clutch Pressure (31) - 3-4 Shift Valve
4th Clutch pressure (41) - Manual Valve 4th Clutch Pressure {4O) - 4th Clutch
The hvdraulic pressure also tlows to the '1st clutch. However, no power is transmitted because of the one-way clutch
as in 2nd and 3rd soeed.
NOTE:. When used, "left" or "right" indicates direction on the flowchan.
. SOL-@: Shitt Control Solenoid Valve A
. SOL-@: Shift Control Solenoid Valve B
. SOL-O: Lock-up Control Solenoid Valve A
. SOL-@: Lock-up Conttol Solenoid Valve B
(cont'dl
14-35