section 23 HONDA INTEGRA 1994 4.G Owner's Guide

Fuel Supply System
Fuel Pump (cont'dl
Tc.ting
@E o" not smoko during tho tesr. Koop openflrmo away fiom your work area.
lf you susp€ct a problem with the tuel pump, check thatthe lusl pump actually runs; when it is ON, you will hearsome noise if you hold your ear to the luel lill oon withthe fuel fill cap remov6d. The fuel pumD should run fortwo seconds, when ignition switch is first turned on. llthe fuel pump does not make noiss, check as tollows;
1. Removo the rear seat (see section 2O).
-'2. Remove the access panel.
3. Disconnect the 2P connector from the fuel pump.
CAUTION: 86 lure to tum th6 ignition switch OFFbotor6 disconnoctlng th€ wilos,
4. Connect the BLK|yEL @ wire 8nd YEL/GRN @ wirewith a iumpe. wire 8t the PGM-FI main relav con-
nectot.
l.t, .--/ re -Fl. . MAll{ RELAY
BL&YELJumper
Check that battery voltage is available at the tuel
pump connector when the ignition switch is turned
ON (positive probe to the YEL/GRN wire, negativeprobe to ths BLK/WHT wire).
ACCESSPANEL
side
YEL/GRN
a lf battery voltage is available, replace the fuel
pump.
a It there is no voltage, check the tusl pump ground
and wire harness {see page I 1-1 l2).
11-110
Roplacomont
@ oo not smoks whilo worklng on fuel syr-
tem. Kaop opon llamos away from your wolk araa.
1. Remove the rear ssats {soe section 2O).
2. Remove the access oanel.
3. Disconnect the 2P connector from the fuel pump.
4. Remove the fuel pump mounting nuts.
5. Remove the fuel pump trom the luel tank.
6. Install a new washer on the banio bolt, then install
Darts in the revers€ order of removal.
6 N.mlO.6 kgl.m,.4 tbt.ftl
27 .m(2.4 kgt.m,21 tbt.ftl

Intake Air System
Throttle Body (cont'dl
11-122
Dirarssmbly
GAUTION:
a Ths throttlo stop scrow is non-adrustablo.
a Aftar reassombly, adiust rhr throttlo Gablo (pago 11-118, 1 19). and A/T throttlo contlol cabl6 (section 14) for c!r8
rYith A/T.
a Tho TP sonaor ir not lomovablo
MAPSENSORTroubleshootingpage 11-52
TPSETSORTroubleshootingpoge 1l-60
O.BING
I
d^'%
IDLE ADJUSTINGSCREW
o-RtftGReplace.
FAST IDLETHERMOVALVEInspection, page 11-94
1O N.m11.O kgl.m.7 tbf.ftl

Emission Control System
Three Way Catalytic Converter (TWC) (cont'dl
Inspection
lf sxcessive oxhaust system back-pressure is suspected. remove the TWC trom the car and make a visual check for plug-
ging, melting or cracking of ths catalyst. Replace the TWC if any of the visible area is damaged or plugged.
81881 ongino:
TI{REE WAYCATALYTICCONVERTER {TWCIRemovsl/installation, see section 9
Inspect housing for cracks orother damage.Inspect element tor cloggingby looking through the inside.
HEAT SHIELD
11-132
T SHIELO

lllustrated Index
NOTE:
a Whenever the transmission is removed, clean and grease the release bearing sliding sudace.
a It the pans marked r are removed. the clutch hydraulic system must be bled (see page 12-6).
a Inspect the hoses lor damage, leaks, interterence, and twisting.
*RESERVOIR
HOSEASSISI SPRING
PEDAL PIN
CLUTCH PEDALAdjustment,page 12-4
15 N.m 11.5 kgl.m,11 tbt.ftl
6 x 1,0 mm9.8 N.m ll.0 ksf.m, 7 lbf.tt)
FLYWHEELInspection. page 12-9Replacement, page 12-9
TCLUTCH MASTER CYLINDERRemoval/lnstallation, page 1 2-5
19 N.m ll.9 kgt.m,14 lbf.ftl
.CLUTCH PIPE
15 N.m {1.5 kgl.m,1 1 rbf.ft)
ICLUTCH PIPE
JOtt{T
8 x 1.25 mm25 N.m (2.6 kgl.m,19 lbt.ttl
RELEASE BEARINGRomovaf /lnspection, page 1 2-1 1lnstaffation, page 1 2- 1 2
TRANSMISSIONRomoval. see
CLUTCH DISCRemoval/lnspection. page'1 2-8Installation, page 12-10
8 x 1.25 mm22 N.m (2.2 kgf.m.16 lbl.rr)
section 1312 x 1.0 mm103 N.m llO.5 kgt.m,76 rbf.ftl
PRESSURE PLATERemoval/lnspection. page 1 2-7Installation, page 12,10
TSLAVE CYLINDERRemovaf /lnstallation. page 1 2-632 N.m {3.3 kgf'm,24 tbf.ftl
15 N. m {1.5 kgf.m,'| I tbf.ftl
COTTERBeplace.
I
NInl
9t
v-_fl
ICLUTCH
12-3

- Transmission Oil
NOTE: Check the oil with the engine OFF, and the car on
level ground.
1. Remove the oil filler plug, then check the level and
Maintenance
condition of the oil.
OIL FILLER PLUG44 N.m lia.5 kgf.m,
ORAIN PLUG$ N.m 14.0 kgf.m.29 lbf.fr)
33 tbtftlProper Level
2. The oil level must be up to the filler hole. lf it is
below the hole. add oil until it runs out, then rein-
stall rhe oil filler plug.
3. lf the transmission oil is dirty, remove the drain
plug and drain the oil.
4. Reinstall the drain plug with a new washer, and
refillthe transmission oil to the proper level.
NOTE: The drain plug washer should be replaced at
every oil change.
5 Reinstall the oil filler plug with a new washer.
OilCapacity
2.2 ( ''2.3 US.qt,1.9 lmp.qt) at oil chang€.
2-3 I l2.1Us.ql,2.0lmp.qtl at oyerhaul.
Use only SAE 10 w - 30 or '10 W - 40, API Service
SF or SG grade.
OIL FILLER PLUGa4 N.m l{.5 kgf.m, 33 lbf.ftl
Back-up Light Switch
Replacement
NOTE: To check the back-up light switch,
1. Disconnect the connector, then rem(
light switch connector trom the conn
2. Remove the back-up light switch.
BACX-UP LIGHT SWITCH25 N.m 12.5 kg[.m, 18 lbf.ftl
lnstall the new washer and the back-
Check the transmission oil level (see
Replace.
/itch, see section 23.
remove the back-up
]onnector clamp.
-up light switch.
) page 13-3).
Replace.
13-3

12 N.m (1.2 kgim,9 lbnft)
15 N.m (1.5 kgnm, 11 lbf.ft)
15 N.m (1.5 kgf.m, 11 lbf.ft)
24 N.m (2.4 kgf.m, 17 lbf'ft)
27 N.m (2.8 kgnm,20 lbnft)
30 N.m (3.1 kgf.m, 22 lbf'ft)
Bolt Size
,l
{
@@69
@
@@@@@@@@6Dq0
o€xv0@
@0!@@@@al
61@
B
c
D
E
F
6x1.0mm
6x1.0mm
I x 1.0 mm
8 x 1.25 mm
8 x 1.25 mm
8 x 1.0 mm
i) BALL BEARINGe sroPPER R|NG9 TAPER RINGA NEEDLE EEARINGO SPACER.d SYNCHRO RINGt sYNcHRo SPR|NG!) 5TH/REVEFSE sYNcHRo SLEEVEO 5TH/REVERSE SYNCHRO HUB[0 sYrucxao nlrucii i) 5TH GEARO 38 x 43 x 26 mm NEEDLE BEARINGt3 SPACEE COLLARO 4TH GEAR.iB SYNCHRO FING.Ii9 SYNCHRO SPRING{, 3RD/,ITH SYNCHRO HUB
@ 3RD/4TH SYNCHBO SLEEVEt9 3RD GEARO MAINSHAFTO wasHER@) SPRING WASHER40 BALL BEARINGO 28 x 41 x ? mm OIL SEAL Replace.ad 35 x 56 x 8 mm OIL SEAL Replace.a0 14 x 20 mm OOWEL PIN@ OIL CHAMBER PLATE'A BEVERSE IDLEN GEAR SHAFT@ wasHER t-2).A REVERSE IDLER GEAFO REVERSE CHANGE HOLDER3A sTH/REVERSE SHIFT PIECEO 1ST/2ND SHIFT FORK04 3RD/.TH sHlFr FoRK@ 5TH/REVERSE SHIFT FORKO9' OIL GUTTER PLATE6' SNAP RING@ 72 mm THRUST SHIM) OIL GUIOE PLATEi!0 10 mm WASHER Replace..4i] REVERSE IDLER GEAR SHAFT BOLT54 N.m {5.5 kgt m, 40lblftl) TRANSMISSION HANGER B(3 BREATHER CAP@ TRANSMISSION HANGER A63 BACK.UP LIGHT SWITCH25 N.m (2.5 ksf.m, 18lbfftl@r 14 mrn waSHER Replace.67 16 mm SEALING BOLT29 N.m (3.0 kgl.m, 22 lbf ft)@ 32 mm SEALING BOLT25 N.m (2.5 kgf.m. 18lbt'ft|@ 40 x 62 x 9 mm OIL SEAL Replace.D STEEL BALL D. 5/16 inGl SPRING L. 30 mm {1.2 in}
@ 12 mm WASHER Replace.63) SET SCREW22 N.m 12.2 kgl.m, 16 lbt'ft,@ OIL ORAIN PLUG39 N.m {4.0 kgt.m, 29 lbf'ftl€9 WASHER Replace.@ oIL FILLER PLUG4,1N.m 14.5 kgJ m, 33 lblftl
*1:81881 engine*2:B18Cl engine
WASHER Beplace.TRANSMISSION HOUSING80 mm SHIM (*1)79.5 mm SHIM {*21THRUST SHIM {*2IT. 2.0 mm (0.079 in)BEARING OUTER RACE {*2}SHIFT PIECE SHAFTINTERLOCKSHIFT PIECESHIFT ARM HOLDERSELECT ARMSELECT RETURN SPRING10 mm SHIM10 mm WASHERLOCK COLLAR3 x 16 mm SPRING PIN Replace.8 mm SPRING WASHERCHANGE PIECESET SCREW22 N.m {2.2 kgf.m, 16 lbf.ft}SPRING L.25.6 mm {1.01 inlSTEEL BALL D. 5/16 inMAGNETCLUTCH HOUSING14 x 25 x 16 mm OIL SEAL Replace.SHIFT RODDIFFERENTIAL ASSEMBLYSee section 15BEARING OUTER RACE I*2ITHRUST SHIM I*2)T. 2.5 mm (0.098 in,SHIFT ROD BOOTOIL GUID€ PLATE33 x 60 x 20 mm NEEDLE BEARINGBEARING RETAINER PLATELOCK WASHER Replace.COUNTERSHAFTTHRUST SHIM37 x 42 x 25 mm NEEDLE BEARINGlST GEARFRICTION DAMPERSYNCHRO RINGSYNCHRO SPRINGlST/2ND SYNCHRO HUBREVERSE GEARDOUBLE CONE SYNCHRO I*2ISYNCHRO BING I*1)FRICTION DAMPERSPACER42 x 6? x 24 mm NEEDLE BEARING2ND GEAR3RD GEAR4TH GEAS5TH GEARNEEDLE BEARINGBALL BEARINGSPRING WASHERLOCKNUT Replace.108 - 0- 108 N.m(11.0 - 0* 11.0 kgt m,80- 0- 80lbf.ft)5 x 22 mm SPRING PIN Replace.00
13-9

Transmission Assembly
14. Install the intermediate shaft and the driveshafts(see section 16)-
NOTE: Replace the set rings with new ones.
Installation (cont'd)
-Sl
SET RINGReplace.
INTERMEDIATESHAFT
Replace.10 x 1.25 mm38 N.m (3.9 kgt m,28 tbtft)
15. Install the ball joints onto the lower arm (see sec-
tion 18).
16. Install the right damper fork (see section 18).
10 x 1.25 mm43 N.m {4.o ksf.m.32 lbf.ft)
RIGHTDAMPERFOBK
SELF.LOCKING NUTReplace.12 x 1.25 mm64 N.m {6.5 kgf.m,47 tbtft)
tLOWER ARM
:\
COTTER PIN
CASTLE NUT12 x 1.25 mm49 - 59 N.m 15.0 - 6.0 kgf m. Reptace.36 - 43 tbf.frl
13-44
DNIVESHAFTS
::.t
L
17. lnstall the exhaust pipe A, and the three way cat-
alytic converter (Bl8C'1 engine), and connect theheated oxygen sensor (HO2S) connector.
SELF-LOCKING NUTHO2SCONNECTORReplace.10 x 1.25 mm33 N.m (3.4 kgt.m,2s tbtftt
GASKETReplace.SELF.LOCKING NUTReplace.8 x 1.25 mm
SELF.LOCKING NUTReplace.THREE WAYCATALYTICCONVERTER1818C'l enginel
16 N'm 11.6 kgt m, 10 x 1 25 mm
l2tbt.ftl 54 N.m 15.5 kgt m,iro lbf.ftl
18. Install the engine splash shield.
GASKET

'19.Install the slave cylinder, then install the clutch pipe
bracket.
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 - 9002).
CLUTCH PIPE6x1.0mm9.8 N.m {1.0 kgf.m, 7 lbf ft)
8 x 1.25 mm22 N-m 12.2 kgl.tr't,16 rbf.ftl
20.
21.
tPlN 08798 - 90021
VSS CONNECTOR
Connect the vehicle speed sensor (VSS) conneclor
and the starter motor cables.
Install the wire harness clamPs.
6x1.0mm9.8 N.m (1.0 kgt m,7 lbf ftl
WIREHARNESSCLAMPS
8 x 1.25 mm8.8 N.m 10.9 kgf.m,6.s tbf.ft)
STARTERMOTORCABLES
22, lnstall the lower radiator hose clamp on the trans-
mission hang€r B.
23. Connect the transmission ground wire and the
back-up light switch connector.
16 tbf.fttBACK.UP LIGI{TSWITCH CONNECTOR
GROUND WIRE HANGER B
Install the air cleaner housing assembly and the air24.
intake duct.
AIR CLEANERHOUSINGASSEMALY
6x1.0mm9.8 N.m 11.0 kgt'm,7 lbtftl
AIR INTAKE DUCT
Refill the transmission with oil (see page 13-3).
Connect the positive (+) cable first, then connect the
negative ( - ) cable to the battery.
Check the clutch operation.
Shift the transmission. and check for smooth opera-
tron.
29. Check the front wheel alignment (see section 18).
9\
\<
27.
28.
13-49

Electrical Troubleshooting
Troubleshooting Flowchart
ls the MIL blinking?
fs the voftage 4.75 5.25 V?
Possible Cause
. Disconnected lock-up controlsolenoad valve A connector. Short or open in lock-up controlsolenoid valve A wire. Faulty lock-up control solenoid
NO
YES
Repair open or shorl in WHT/BLK wir€ botwe€n th€ D18 termi-nal and the ECM.
(-)
| | o " q " " o o o o o o o q litigse.*grq$:,1:d:sd:siia:l " "" o " " o o oo " I
I ro'r+ r rz6 r-tL--- l /trtr-- l
ls there voltage?
NO
ooooooooooo
oooooooo9oo
oooooooooooo
oooooooooooo
A25
Turn the ignition switch ON.
Check whether the MalfunctionIndicator Lamp (MlL) blinks (see
section I 1).
Repair the PGM-FI System (see
section 1 l ).
Turn the ignition switch OFF.
Disconnect the 26P and 22P con-nectors from the TCM.Connect the Test Harness "A"
and "D" connectors to the wireharness only, not to the TCM {seepage 14-49).
Turn the ignition switch ON.
Measure the voltage between theD18 and A25 or 426 terminals.
Measure the voltage between the46 and A25 or A26 terminals-
Repail short to power sourco inYEL wi.e between the A6 termi-nal and the lock-up control sole-noid valve A.
Turn the ignition switch OFF.
To page 14'53
14-52

Electrical Troubleshooting
Troubleshooting Flowchart (cont'dl
Turn the ignition switch ON.
Check whether the MalfunctionIndicator Lamp (MlL) blinks (seesection 1 1).
Ropair tho PGM-FI Sysrom (se€soction 11).ls the MIL blinking?
Turn the ignition switch OFF.
Disconnect the 26P and 22P con-nectors trom the TCM.Connect the Test Harness "A"
and "D" connecto.s lo the wireharness only, not to the TCM (seepage 14-49).
Turn the ignition switch ON.
Measure the voltage between theD'18 and A25 or 426 terminats_
Rapair opon or shon in WHT/BLK wi.e botweon the O18 te.mi-nal rnd the ECM.
ls the voltage 4.75-5.25 V?
lvleasure the voltage between the44 and A25 or 426 rerminals.
Ropsir shon to power source inGRN/BLK wi.o betwoon the A4t6.minal and th€ lock-up controlsolonoid valve B.
Turn the ignition switch OFF.
14-54
Possible Cause
. Disconnected lock-up conlrolsolenoid valve B connector. Short or open in lock-up controlsolenoid valve B wire. Faulty lock up control solenoidvalve B