Idle HONDA INTEGRA 1994 4.G Service Manual

Emission Control System
Positive Crankcase Ventilation (PCVI System
Description
The Positive Crankcase Ventilation (PCV) system is
designed to prevent blow-by gas {rom escaping to the
atmosphsre. The PCV valve contains a spring-loadsd
plunger. When the Bngine starts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into th€ intak€
manifold.
FCV VALVE
.F: ILOW-BY VAFORer FRESH AIR
11-134
Insp€cdon
1. Check th€ PCV hos6s and connections tor lsaks and
clogging.
At idle, mak6 sur€ th6fe is a clicking sound from th6
PCV valve when the hose between rcV valve and
intake manifold in lightly pinched with your fingors
or oli€rs.
a lf thera is no clicking sound, ch6ck the PCV valve
grommet for cracks or damage. ll the grommet
is OK, reolace the PCV valve and recheck.
2.
SREATHER
Gontly pinch hero.

(From page 1 1-137)
lTo page 1 1-'l39)
Start the engine. Hold the engineat 3,OOO rom with no load lA/T in
E orE position, M/T in neutrsl)unlil lhe radiator tan comes on.then let it idle.
Check lor vacuum at # 7 vacuumhose alter starting the engine.
Oisconnect the 2P connoctor fromthe EVAP purge control solenoid
Intpoct vacuum hoaarcuting.It OK, reolrco tr|c EVAP
Purge contlol lolanoid
ls there manifold vacuum?
Inrpoct for a short i|t RED wire bo-lwoen ECM {A2Ol and th6 con-noclor.ll wiro la OK, substituto a known-good ECM 6nd .echock. lf symp-tom goes away, loplace tho origi-nal ECM.
Ropair opon in YEL/BLKwirc b.tw..n EVAPpurgo control rolanoidvrlvo and th. xiM-Flmlin r6lay.
ls there baftery voltage?
Inspoct RED wirc for 6n opon totrody g.ound botween ECM lA20)and th6 conn6ctor.It wir. b OK, substiluto a known-good ECM and rochock, It sym-ptom 9o6s away, roplaco thooriginal ECM,
Emission Gontrol System
Evaporative Emission (EVAP) Gontrols (cont'd)
{From page 11-137}
11-138

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 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

Measure the clearance between the reverss idler
gear and the reverse change holder.
Standard: 0.5 - 1.1 mm (0.02 - 0.04 inl
Sorvico Limit: 1.8 mm (0.07 inl
4.lf the clearance is more than the service limit, mea-
sure the width ofthe reverse change hold6r.
St.ndrrd: 13.0 - 13.3 mm (0.512 - 0.52/t inl
lf the width is not within the standard, replace
the reverse change holder with a new one.
lf the width is within the standard, reolaco the
reversa idler gear with a new one.
REVERSE CHA'{GE HOLDER
REVERSE CHANGE HOTI'ER
Reverse Change Holder, Reverse ldler Gear
Clearance Inspection lcont'd)Removal
1. Removo the reverse change holder.
2. Remove the revorss idler g€ar, th€ rev6rs6 idlsrgear shaft, and the washor {B18Cl engine}.
REVERSE IDI.TRGEAF SHAFT
13-12
REVERSE CHAMiE HOII'ER

Transmission
Reassembly (cont'd)
11. Install the change holder assembly.
6x1.0mm15 N.m (1.5 kgf.m,11 tbf.ftl
CHANGE HOLDERASSEMBLY
Install the shift piece
the shift piece shaft.
and the interlock, then install12.
13-42
13. Measure the distance @ after mounting the shiftpiece shaft. lf it's incorrect, check the installation.
Distance O: 11.9 - 12.3 mm 10.47 - 0.48 in)
14.lnstall the washer (B18C1 engine), the reversegear. and the reverse idler gear shaft.
idlo.
REVERSE IDLER GEAR

32 mm SEALING BOLT25 N.m {2.5 kgl'm,
24.Installth€ 32 mm sesling bolt.
NOTE: Apply liquid gasket (P/N 08718 - 0001) to the
threads.
26. Tight€n ths teverse idler gear shaft bolt.
REVERSE IDI.^CRSHAFT IOLTl0 r 1.25 rnm5a t$m 15.5 kg{.m. (} lbtftl
13-45
{
27.
28.
Install the stesl balls, the sp.ings, and the set
screws.
lnstall the back-up light switch and the transmission
hanger B.
8 x 1.25 mmBAC|(-UP LTGHT SWITCH 24 N.m (2.4 kgfm,2s N.m {2.5 kg{.m, 18lbtft) 17 lbtftl
,*"""."'" /HAiIGER B I
l/SPRIMiL. 30 mm
{1,2 in}
12 x 1.0 mm22 N.m (2.2 kgi.m.10 tbtft)

llj Po.ltbn
1. Hydraulic pressure is swilched by the manual valve to the se.vo v8lve, which moves the reverse shilt tork to the
r€verse position. The reverse shiJt fork engages with the reverse selector, reverse selsctor hub,and the countershaft
raverss g€ar.
2. Hydraulic pr6ssure is also appli€d to the 4th clutch. Power is transmifted from the mainshaft reverse gear via the
revetse idler g6ar to the countershaft reverse gear.
3. Rotation dirsction ol the countershsft reverse gear is changed via the .everse idler gear.
4. Powef b transmitted to the linal drive gear and drives the final driven gear.
TOROUE CONVEBTER
4TH CLUTCHMAI SHAFT REVERSEGEAR
COUNTERSHAFf
REVERSE SELECTORHUBFII{AL DRIVE GEAR
REVEFSE SELECTOR
COUIITERSHAFTREVERSE GEAR
14-17

Symptom-to-Component Chart
Electrical System
Number of @indicator light
blinks while
Service Check
Connector is
connected with
the special tool.
@] indicaror
lightPossible CauseSymptomRefer to
page
BlinksDisconnected lock-up control solenoidvalve A connector
Short or open in lock-up control sole-noid valve A wire
Faulty lock-up control solenoid valve A
Lock-up clutch does not
engage.
Lock-up clutch does not
disengage.
Unstable idle speed.
14-52
BlinksDisconnected lock-up control solenoidvalve B connector
Short or open in lock-up control sole-noid valve B wire
Faulty lock-up cont.ol solenoid valve B
. Lock-up clutch does not
enga9e.
14-54
Blinks or
OFF
Disconnected throttle position (Tp)
sensor connector
Short or open in TP sensor wireFaully TP sensor
. Lock-up clutch does not
engage.14-56
4BlinksDisconnected vehicle speed sensor(VSS) connector
Short or open in VSS wire
Faulty VSS
. Lock-up clutch does not
engage.'t 4-57
Blinks. Short in A/T gear position switch wire. Faulty A/T gear position switch
. Fails to shift other than
2nde4th gears.. Lock-up clutch does not
engage.
14-58
OFFDisconnected A/T gear position switch
connector
Open in A/T gear position switch wireFaulty A/T gear position switch
Fails to shift other than
2nd-4th gears.
Lock-up clutch does not
en98ge.
Lock-up clutch engages
and disengages alter-
nately.
14-60
7BlinksDisconnected shift control solenoidvalve A connector
Short or open in shitt control solenoidvalve A wire
Faulty shift control solenoid valve A
. Fails to shift (between
1st-4th, 2nd-4th or
2nd-3rd gears only).. Fails to shift (stuck in
4th gear).
14-62
8BlinksDisconnected shitt control solenoid
valve B connector
Shon or open in shift control solenoidvalve B wi.e
Faulty shift control solenoid valve B
. Fails to shiJt (stuck in
lst or 4th gears).'t 4-64
aBlinksDisconnected countershatt speed sen-sor connector
Short or open in the countershaft
speed sensor wire
Faulty countershaft speed sensor
. Lock-up clutch does not
engage_
14-50

Symptom-to-Component Chart
Hydraulic System
SYMPTOMCheck these items on the
PROBABLE CAUSE ListCheck these items
on the NOTES List
Engine runs, but car does not move in any gear.1, 6, 7, 16K,L,R,S
Car moves in @ and @, but not in @, @ or Iposataon.a, 29, 44. 4ac,M,o
Car moves in E, @, [, @, uut not in E position.9,30,49C, L
car moves in p:1, [o-il, [2-], [!, uut not in E position.1, 11, 22, 34, 38, 39, 40c,L,o
Car moves in N position.1, 8, 9, 10, 11,46,47C,D
Excessive idle vibration.5, 1'1B,K,L
Slips in all gears.6, 7, 16C,L
No engine braking in E position.12C,D,L
Slips in 1st gear.8, 29, 44, 4Ac,N,o
Slips in 2nd gear.9, 20, 23, 30, 49C, L
Slips in 3rd gear.10, 21 , 23, 31 , 49C,L
Slips in 4th gear.11, 23, 32, 44C,L,N
Slips in reverse gear.11,32,34,44C,N
Flares on 1-2 upshilt.3, 15, 23E,L,V
Flareson2 3 upshilt.3, 15, 23, 24, 49E,L,V
Flares on 3-4 upshift.3, 15, 23, 25, 49E,L,N,V
No upshift; transmission stays in 1st gear.14,19,G, L
No downshift to lst gear.12. 19G, L
Late upshift.14
Erratic shitting.2, 14,26
Harsh shift (up and down shiftingl.2, 4, 15, 23, 24, 25, 26, 27,
47A,E, H, I, L,V
Harsh shitt {1-2).2, 9. 15, 23C,D,E,V
Harshshilt (2-3).2, 10, 15, 23, 24C,D,E,H,L,V
Harsh shift (3-4).2,| 1, 15, 23, 25C, D, E, I,L,V
Harsh kick'down shifts.2, 15, 23, 26, 27. 2AE,L,O,V
Harsh kick-down shift 12 1)48o
Harsh downshift at closed throttle.2, 15, 23FT
Harsh shift when manually shifting to E] position.33L
Axle{s} slips out of transmission on turns.43,50
Axlels) stuck in transmission.43L,O
Ratcheting noise when shifting inro E position.6,7,38,39,40K,L,O
Loud popping noise when taking ott in E position.3a,39,40L,O
Ratcheting noise when shifting from E to E position or from Eto N I oosition.38,33,40,45L,O
Noise from transmission in all selector lever positions.6, 11K,L,O
Noise trom transmission only when wheels are rolling.39, 42L,O
Gear whine, rpm related (pitch changes with shitts).a, 13, 41K,L,O
Gear whine, speed rel6ted (pitch changes with speed).38, 42L,O
Transmission will not shift into 4th gear in @ position1,21,24.32L
Lock-up clutch does not lock-up smoothly.17, 36, 37L
Lock-up clutch does not operate properlV.2.3. 14, 15. 18, 35, 36, 37E,L,V
Transmission has multitude of problems shitting.
At disassembly, large particles oI metal are found on magnet.43L,O
14-86