Oil pressure HONDA INTEGRA 1994 4.G Service Manual

CAUTION: lf either end ot the comprassol attachm€nt
is sel ovsl an araa ol the spdng retaine. which is unsup-
ported by the retum spring. the letainer may be damag6d,
4. Compress the return spring.
Do not set horo.
RETURN SPRING
5.Remove the snap ring. Then remove the special
tools, spring retainer and return spring.
Wrap a shop towel around the clutch drum and ap-
ply air pressure to the oil passage to remove the
piston. Place a finger tip on the other end while ap-
plying air p.essure.
6.
COMPRESSED AIRHOSE NOZZLEOSHA-approved 30 psirype onry
CLUTCH
S AP RING
PISTON
14-145

Transmission
Cooler Flushing
S!@ ro prevent iniury to tace and eyes, always
wear safety glas$es or a tace shield when using the trans-
mission flusher.
NOTE: This procedure should be performed before rein-
stalling the transmission.
1. Check tool and hoses for wear or cracks before
using.
lf wear or cracks are found, replace the hoses be-
fore using.
2. Using the measuring cup, tillthe tank with 21 ounces
{approximately 213 lulll of biodegradable tlushing
fluid (J35944-20). Do not substitute with any other
fluid.
Follow rhe handling procedure on the fluid container.
Secure the tlusher filler cap and pressurize the tank
with compressed air to between 550-829 kPa(5.6-8.45 kgt/cm,, 80- 120 psi),
NOTE: The air line should be equipped with a water
trap to ensure a dry air system.
Hang the tool under the vehicle.
Attach the discharge hose of the tank to the return
line of the transmission cooler using a clamp.
Connect the drain hose to the inlet line of the trans-
mission cooler using a clamp. Securely clamp the op-posite end of the drain hose to a bucket or floor drain.
6.
DRAIN HOSE
TRANSMISSION
TRANSMISSIONCOOLER FLUSHEBCommorcially AvailabloKENT MOORE #J38405_A
DISCHARGE HOSE
14-168
BUCKET
7. With the water and air valves off. attach the water
and air supplies to the flusher. (Hot water it
available.)
OFF
8. Turn on the flusher water valve so water will tlow
through the oil cooler for 1O seconds. lf water does
not flow through the oil cooler it is completely
plugged, cannot be flushed, and must be replaced.
9. Depress the trigger to mix the tlushing lluid into the
water tlow. Use the wire clip to hold the trigger
oown.
10. While flushing with the water and flushing fluid for
2 minutes. turn the air valve on for 5 seconds every
15-20 seconds to create a surging action.
AIR PRESSURE:
MAX 829 kPa (8.45 kgt/cm,, 12O psi)
1 1. Turn the water valve off. Release the trigger, then
reverse the hoses to the cooler so you can flush in
the opposite direction. Repeat steps 8 through 1O.
12. Release the trigger and allow water only to rinse the
cooler with water for one minute.
13. Turn the water valve off and turn off the water
supply.
14. Turn the air valve on to dry the system out with air
for two full minutes or until no moisture is visible
leaving the drain hose.
CAUTION: Residual moisture in the oil cooler 01
pipes can damage the transmission.
15. Remove the flusher trom the cooler line. Attach the
drain hose 10 a oil container.
16. lnstallthe transmission and leave the drain hose at-
tached to the cooler line.

20 mm (O.79 inl
SUPPORT STRUT
Support Strut Disposal
@ Tha support strut contains nitrog.n gas andoil unde. pr€ssul€.
The pressure must be relieved bsfo.e disposal to prevant
explosion and possible injury wh€n sc.apping.
Place the support strut on a level surface with its rod ex-
tended, and drilla hole 2-3 mm (3/32"1diameter in the
body to release the gas.
@ always w€ar €ye prot6ction to avoid get-
ting motal shavings in your eyea when roloasing th€ gas
fiom the support st.ut.
Trunk Lid
TRUNK LIDOPEN€R CABLE
TRUNK LIDLATCH{see page 20-157}
TRUNK LIOOPENERCABLE
CA : Clip, 5
e-i
_rP ,/
Replacement
NOTE:
a An assistant is helpful when removing the trunk lid.a Take care not to damage the t.unk lid and body.a Open the trunk lid.
1. Disconnect the connectors and trunk lid opener ca-ble. Remove the wire harness and t.unk lid opner ca-ble from the trunk lid.
NOTE: Before pulling out the wire harness, tie astring to the end ot it so you can pull it back in when
the trunk lid is reinstalled.
> : Clip locationg
AD : Clip, 3 B< : Clip, 1
WIRE HARNESS
CONNECTORCONIIECTOR
A
A
(cont'd)
20-149

Description
Outline
The air conditioner system delivers cooled air into the passenger compartment by circulating refrigerant through the sys-
tem as shown below.
CONDENSOR
This car uses HFC-134a {R-134a) refrigerant which does not contain chlorofluorocarbons Pay attention to the following
service items:
. Do not mix refrigerants CFC-I2 (R-l21 and HFC-134a (R-134a) They are not compatible'
. Use onty the recommended potyatkytenegtycol {PAG) refrigerant oil (ND-OIL 8: P/N 38899-PR7-A01) designed for the R-
134a compressor. Intermixing the recommended (PAG) refrigerant oil with any other refrigerant oil will result in com-
pressor tailure.
.A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve.
o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts.
. Use a halogen gas leak detector designed for refrigerant R-134a'
. R-.12 and C-l34a refrigerant servicing equipment are not interchangeable. Only use a Recovery/Recyclins/Charging
System that is U.L.-listed and is certifLd to meet the requirements of sAE J2210 to service R-134a air conditioning sys-
rems.
. Always recover the refrigerant R-134a with an approved Recover/Recycling/Charging System before disconnecting any
A,/C fitting.
coMpRESsoR -coNDENSER - RECEIVER/DRYER
High temperature/
high pressure gas
Suction and comPression
Less moisturized
low pressure vaPor
High temperature/ Traps debris High temperature/
hilh pressure liquid and removes high pressure liquid
Radiation of heat molsture
More liquidified
low Pressure vaPor
Absorption of heat
EVAPORATOR <-'----------.- EXPANSION VALVE
EVAFORATOR
22-6

A/C Service Tips and Precautions
The air conditioner system uses HFC-134a (R-134a) .efrigerant and polyalkyleneglycol (PAG) retrigerant oil (ND-OIL g: p/N
38899 - PR7 - A0l ), which are not compatible with CFC-12 \R-'12) refrigerant and mineral oil. Do not use R-12 refrigerant ormineral oil in this system, and do not attempt to use R-'12 servicing equipment; damage to the air conditioner system oryour servicing equipment will result.
only use service equipment that is u.L,-listed and is certified to meet the requirements of sAE J2210 to remove R-134afrom the air conditioner svstem.
CAUTION: Exposure lo air conditioner refrigorant and lubricanl vapor or mi3t cln irritato gyos, nose and throat. Avoidbreathing lhe air conditioner refrigerant and lubricant vapor or mist.
lf accidental system discharge occurs, ventilate work area befor€ resuming service.R-134a service equipment or vehicle air conditioner systems should not be pressure tested or leak tested with compressedair.
@ some mirtures of air and R-l3ifa have been 3hown to be combu3tible at slsvated prossuros and can relultin fire or explosion causing inlury or property damage. Never use complessod ai. to prgssure t€|st R-134a service equip-ment or vehicle air conditiongr systems.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.'1. Always disconnect the negative cable from the battery whenever replacing air conditioning pans.
2. Keep moisture and dust out of the system. When disconnecting any lines, plug or cap the fittings immediately; don'tremove the caps or plugs until just before you reconnect each line.
3. Before con necting a ny hose or line, apply a few drops of refrigerant oil (ND-OIL 8: P/N 38899 - PR7 - AO1) to the O-ring.4. When tightening or loosening a fitting, use a second wrench to support the matching fitting.5. When recovering the system, use a R-134a refrigerant Recovery/Recycling/Charging System; don't release refrigerantinto the atmosDhere.
6. Add refrigerant oil (ND-OlL 8: P/N 38899 - PR7 - A01) after replacing the following parts:
NOTE:
. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refriqer-ant orls.
. lmmediately after using the oil, replace the cap on the container and seal ittoavoid moisture absorption,. Do not spill the refrigerant oil on the car; it may damage the paint; if the re{rigerant oil contacts the paint, wash itoff immediately.
Condenser ..................... 25 m/ (5/6 fl.oz, 0.9 lmp.oz)
Evaporator ................. ilo mf 17 113fl.oz,1.4 lmp.oz)
Line or hose 10 ml (1/3 fl.oz. o.il lmp'ozl
Receiver/Dryer .....,.,,...., 10 m{ l1l3 tl.oz, 0.4 lmp.ozl
Leakage repair .............. 25 mf (5/6 fl.oz, 0.9 lmp.ozl
Compressor For compressor .eplaco-
m€nt, subtract the volumo of oil drained from tho
removed compressor trom 140 ml 11 213 ll.oz, 1,9
imp.ozl, and drain the calculalgd volume of oil from
tho new compressor: 140 mf 11 213 ll. oz, 1.9
imp.ozl- Volume ot removod compressor = Volume
to drain from n€w compressor.
NOTE: Even if no oil is drained from the removed
compiessor, don't drain more than 50 ml 11 213
fl.oz, 1.8 lmp .oz) from the new comDressor.
O Dischargo hose to the compresso. (6 x 1.0 mml .............................. 9.8 N.m {1.0 kgt.m, 7.2 lbf.ft)(, Discharge hosa to ths condenser (6 x 1.0 mm) . 9.8 N.m {1.0 kgf.m, j.Z lbl.ftl@ Condenser pipe to tho condenser (6 x 1.0 mml 9.8 N.m n.O kaf.m,t-2tbl.ftl
@ Condenser pipe to the receiver/dryer (6 x 1.0 mm) ......................... 9.8 N.m (1.0 katm,7.2 lbf.ft)@ Receiver pipe A to tho receiver/dryer 16 x 1.0 mm) ......................... 9.8 N.m (1.0 kttm. 7.2 lbt.ft)@ Receiver pipe A to th6 receiver pipe B ......................................
O Receiver pipe B to the receiver pipe C .............................................. 13 N.m {1.3 kgt.m. 9.4 lbt'ft)
13 N.m {1.3 kgf.m.9.4 lbf'ft)@ Receiver pipe C to the evaporator (6 x 1.0 mm) 9.8 N.m {1.0 kgf.m , j.Zlbl.ftl
@Suaion pip€ B to the evaporator {6x 1.0 mm) ................ ................ 9.8 N.m tt.O t!f.-, r.Z tUt tt}@ Sustion pipe A to the suction pipe B .................. 3t N.m (3.2 klnm,23 lbf.ft)(, Suction hose lo the suction pipe A ................ ...... 31 N.m (3.2 kgf.m, 23 tbf.ftl
OA Suction hose to the compressor {5x 1.0 mm} ................ ................. 9.8 N.m 11.0 kgt.m,7.2 lbf.ft)
ET
22-21

A/C System Service
Recovery
Onlv 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: Expo3ute to air conditioner rcfrigelant rnd
lubricant vapor or mist can irritatc oyo!, no3o and
throat. Avoid bresthing the lir condhionot rofrigorlnt
and lubricant vapor or misl.
lf accidental system discharge occuts, 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 Eir and R'134. hsvc
bsen shown to be combu3tible st elavllcd prs33urc3
and can result in fire or oxplosion cau3ing iniurY or
property damage, Nsvor u36 comprg3Sod lir to P|'3turl
test R-134a servic€ equipmont o. vohiclc rir condhioncr
3ystems.
Additional health and safety information may be
obtained from the refrigerant and lubricant manufac-
rures.
'1. Connect a R-134a refrigerant Recovery/Recycling/
Charging System to the car, as shown, following
the equipment manufacturer's instructions.
2. Measure the amount of refrigerant oil removed
from the A/C system after the recovery process is
comoleted.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system befote
charging.
R.cov.rylR.cycling/Ch.rging sy.t m.
Pf,ESSUFE
22-22

Pressure Test Chart
NOTE: Performance Test on page 22-24.
TEST RESULTSRELATED SYMPTOMSPROAABLE CAUSEREMEDYDischsrge(high) pressureabnormallynrgn
AftEr stopping compressor, pressuredrops to about 200 kPa (2.0 kof/cmr. 28psi) quickly, and then falls gr;dua y.
Air in systemRecover, evacuate and recharqowith sDecified amount. -
Evacuation: see Daqe 22-38Charoino: se6 D;op--2?-?qNo bubbles in sight g16ss when con-denser is cooled bv water.E-\cessive refrigerant in sys-Recover, evacuate and recharqewith specitied amount. -
Reduced or no air flow through con-oenser.Clogged condenser orradiato. finsCondenser o. radiator fannot working properly
CleanCheck voltage and fan rpmunecK lan ofeclton
Line to condenser is excessivelv hot.Restricted flow of refriger-ant In syslem. Restricted lines
Discharge pres-su re abnormal-Excossive bubbles in sight glass;condenser is not hot.Insuff icient refrigerant insyslemCheck for leakCharge systemHigh and low pressures are balancedsoon after stopping compressor. Lowside is higher than normal,
Faulty compressor dis-cnarge vaNsFaulty compressor seal
Replace the compressor.
Outlet of expansion vslve is not frost-ed, low pressure gauge indicates vacu-um,
. Faulty expansion valve. Moisture in sysiem. Replace. Recover, evacuate and recharoewith specified amount. -
Suction (lowlpressureabnormally low
Excessive bubbles in sight glass;conqenser rs not hot_Insuff icient ref rigerantReoair the leaks.Reaover, evacuate and recharoewith sDecifisd amount. -
Charqe as required.Expansion valve is not trosted and lowpressur€ line is not cold. Low pressuregauge Inorcates vacuum.
Frozen expansion valveFaulty expansion valveReplace the expansion valve.
Discharge temperaturg is low and theair flow from vents is restricted.Froren evaporatorRun the tan with comoressor oftthen check Ay'C thermostat.Expansion valve is frost€d.Clogged expansion valveCl€an or replace.Receiver/dryer outlet is cool and inletisrryarm (should be warm during oper-Clogged r€ceiver/dry€rReplace
Suction pres-su re abnormal-ly high
Low pressure hose and check joint arecooler than the temDeraturo aroundevaDorator.
'
ffin"nsion u"lu" oD"n too
. Loose expansion capillary
Repair or replace.
Suction pressure is lowered when con-denser is cooled by water,Excessive refrigerant in sys-remRecover, evacuate and recharqewith sDecifi€d amount. -
High and low pressure are equalizedas soon as the compressor is stopped,and both gauges fluctuate while run-nrng.
Faultv oasketFaulty Figh pressure valveForeign particle stuck inhigh pressure valve
Replace the compressor.
Suction anddischarg€ pres-sufes aonor-mally high
Reduced air flow through condenser.. Clogged condenser orradiator fins. Condenser or radiator fannot working properly.
Clean condenser and radiatorCheck voltage and fan rpmCheck fan direcrion
No bubbles in sight glass when con-cl€nser is cooled bv water.Excessive refrigerant in sys-remRgcover, €vacuate and recharoewith sp€cified amount.Suction snddischarge pres-su r€ abnormal-
Low pressure hose and metal endafeas are cooler than evaDorator.Clogged or kinked tow pre€-sure nos€ pansFepair or replace.
Temperature around expansion valveis too low compared with that aroundrecerver/orver.
Clogged high pressure lineRepair or replace.
Refrig€rantleaksCompressor clutch is dirty.Compressor shaft seal leak-IngReplace the comDressor.
Compressor bolt(s) are dirty.Leaking around bolt(s)Tighten bolt(sl or replace com-pressor.Compressor gasket is wet with oil. IGasket leakingReplace the compressor.
22-23

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 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

Gonnector ldentification and Wire Harness Routing
Engine Wire Harness {B1881engine)
Connector 01
Terminal
Number of
CavitiesLocationConnects ioNotes
c10'l
c102
c103
c104
c 105
c106
c107
c108
c108
c109
c110
c111
c113
c114
c115
Lt to
c117
c118
c119
c't 20
c121
c122
c123
cl24
c125
c't26
c127
c128
c129
c130
10
14
6
1
1
2
2
8
2
3
t
1
2
2)
2
8
14
2
2
Right side of engine compartment
Right side of engine compartment
Right side of engine compartment
Right side ol engine compartment
Right side of engine compartment
Right side of engine
Right side ol engine
Transmission
Transmission
Middle of engine
lvliddle of engine
Right side ot engine
Right side of engine compartment
ldiddle rear of engine compartment
Middle of engine
Middle ol engine
Middle of engine
Middle of engine
Middle ot engine
Left side of engine
lvliddle of engine
Middle of engine
Middle of engine
Middle ot engine
Middle ol engine
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Transmission
Transmission
Transmission
Main wire harness (C221)
Main wire harness {C222}
Main wire harness (C223)
Main wire harness {C220)
Starter solenoid
Engine coolant temperature {ECT)
sensor
Engine coolant temperature (ECT)
gauge sending unit
Back'up light switch
Lock-up control solenoid valve A and B
lgnition coil
Top dead center/Crankshaft
position/Cylinder position
(TDC/CKP/CYP) sensor
Engine coolant temperature (ECT)
switch
Vehicle speed sensor (VSS)
Heated oxygen sensor (HO2S)
MAP sensor
Throttle position (TP) sensor
ldle air control (lAC) valve
Evaporative emission (EVAPI purge
control solenoid valve
Engine oil pressure switch
Alternator
Intake air temperature {lAT} sensor
No. 'l fuel injector
No. 2 tuel injector
No. 3 fuel injector
No. 4 fuel injector
Junction connector
Engine compartment wire harness
(c304)
Engine compartmenl wire harness
(c305)
Shift control solenoid valve A and B
Countershait speed sensor
Mainshaft speed sensor
M/T
NT
NT
NT
T 101
r102
Lelt side oI engine
Right side of engine compartment
Alternator
Under-hood tuse/relay box
G 101Right side of engineEngine ground, via engine wire
harness
23-16