Page 98 HONDA INTEGRA 1994 4.G Workshop Manual

Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnesses are coverod with
yollow in3ulation.
. B€tore disconnocting 8ny part of tho SRS wire har-
nsss, conngqt th€ 3hort connestor{sl.
. Roplaca ths entire aftected SRS harness a$embly if
it has an op€n circuit or damaged wiring.
lcove.ed with yellow insulation)
Recover the refrigerant with a Recovery/Recycling/
Charging System lsee page 22-22]-.
Femove the bolts, and disconnect the receiver line
and the suction line from the evaporator.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the svstem.
2.
L
6x1.0mm9.8 N.m {1.019f.m,1.2 tbl.ttl
SUCTION LINE
RECEIVEB LINE
3.Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.
Disconnect the connector from the Ay'C thermostat,
and remove the wire harness clips from the evapo-
rator.
Remove the four self-tapping screws, mounting bolt
and the mounting nut.
Disconnect the drain hose, and remove the evapo-
rator.
1.
6x1.0mmAPORATOR9.8Nm{1.0kg{.m,7.2 tbtft)
a
a
8. Install in the reverse order of removal. and:
it you're installing a new evaporator, add refrig-
erant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-2'll.
replace the O-rings with new ones at each fitting.
and apply a thin coat of refrigerant oil (ND-OlL 8:
P/N 38899 - PR7 - A01l before installing them.
NOTE: Be sure to use the right o-rings for HFC-
134a {R-134a} to avoid leakage.
apply sealant to the grommets.
make sure that there is no air leakage.
charge the system (see page 22-39) and test its
performance (see page 22-241.
22-26

Overhaul
L Pull out the Ay'C thermostat sensor from the evapo-rator fins.
2. Remove the self-tapping screws and clamps fromthe housing.
3. Carefully separate the housings and remove theevaporator.
4. lf necessary, remove the expansion valve.
NOTE: When loosening the expansion valve nuts.use a second wrench to hold the expansion valve orevaporator pipe. Otherwise, they can be damaged.
Assemble in the reverse order of disassembly, and:
. feplace 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.. install the expansion valve capillary tube withthe capillary tube in contact with the suction linedi.ectly, and wrap it with tape.. reinstall the Ay'C thermostat sensor to its originallocation.
A/C THERMOSTATTest. page 22-19
8 N.m (0.8 kgf'm, 6 lbf.ftl
CAPILLARY TUBE
5.
EVAPOAATORblow dirt out of finswith compressed air.
16 N,m 11.6 kgl.m,12 tbt.ttl
24 N.m (2.i1 kg{.m,17 rbt.ftl
EXPANSION VALVE
TAPEReplace.Make sure there is no foreign matter stuck betweenthe capillary tube and outlet line.
6 th fin trom inlet 3id6
12015 mm14.72 ! 0.2 inl
LOWER HOUSING
22-27

lllustrated lndex
CENTER BOLT
CLUTCHSETInspoc!on,page 22-32
SNAP RING AReplace.
-t COMPRESSOR COMPLETE
f-- lDo nor disassemble)
colLInspection, pag6 22 32
RELIEF VALVE
'-f
Replacement, page 22-34
22-29

Compressor
Glutch Inspection
Check the plated parts ot the pressure plate tor color
changes. peeling or other damage. lf there is dam-
8ge, replace the clutch set.
Check the pulley bearing play and drag by rotating
the pulley by hand. Replace the clutch set with a new
one if it is noisv or has excessive play/drag
Measure the clearance betlveen the pulley and the
pressure plate all the way around. lf the clearance is
not within specified limits, the pressure plate must be
removed and shims added or removed as required.
Jollowing the procedure on page 22-33.
Clearrnce: 0.50 t 0.15 mm {0.02 i 0.01 inl
NOTE: The shims are available in three thicknesses:
0.1 mm, 0.3 mm and 0.5 mm.
22-32
Check resistance of the tield coil.
Fisld Coil Rosistance: 3.6 t 0.2 ohm at 68"F {20'C)
lf resistance is not within specifications, replace the
field coil.

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)

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/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.
-+

Power Distribution
Circuit ldentification
IGNITION SWITCH
+page 23-
r 1 No.24115A): 81881 engin€No.24 l20A): Bl8C1 6ngin.
N0.40 {504)FUSE(From pago 23 - 551
UNDER - DASH FUSE/REIAY BOX
sRs FusE 81-0cK
No.25l10Al
No.14l20A)
No.l5 {1041
Chuging sY3l.m lightlln tho g6ug€ s3€mblyl
Cruis€ controlunitCdis6 msin 3whch itdicttor light
PGM - Fl mlin r6lry
) lrrmmirdon control modulo [ICM)
Vohag6 rcoulatorVehiclo sp.€d somor IVSS)E|.l) unit IUSA)Crube conttol unit
Moonrcof rclayWind.hicld wipot motorWirdlhi€ld waah6. motorR6ar window ws3hor motot {HrtchblctlInt.gGtod control unit
Power wirdow tclaY
Int6lrat€d contrcl unit- R6af window wipor motol(H3tchbtck)
571
GRNiEI(GRNAt(
GRN/8I..K
BLKffEt
-EiT"h#,H#J:r"
Shitt lock solenoU {MlEack -up lights
option conn€ctor: C924
Daytimo running lights conttol unit
YEt..--
lrcz
Ml t -'-
\'- _ ^ACC
23-56
*2 No.17 {1041bor sockstl

lgnition Switch
CAUTION:
a All SRS electdcal wiring harnessss aro covotod whh
yollow insulation.
a Botore disconnocting any part ot th6 SRS wiro har-
n6ss. connoct tha shon connoctor(t).
a Replac€ tho ontiro affected SRS hames! asllmbly It
it has an op6n circuit 01 damagod widng.
1. Remove the dashboard lower cover and knee bolster.
KNEE BOLSTERDASHBOARD LOWER COVER
Disconnect the 5-P connector flom the undsr-dash
fuse/relav box and the 7-P connector from the main
wire harness.
23-70
SRS MAIN HARI{ESS(Cov6red with Yollow inrulltiori)
J.Chsck tor continuity b€tween the terminals in each
switch position according to the table.
4. lf continuity checks do not agre€ with the tabl6,
reolace the €lectrical part of the switch lsee page
23-72t.
Terninal
P6itionBATtG1ST
--o
o-
I