check oil HONDA INTEGRA 1994 4.G Manual PDF

Motor, Drain Tube and Frame Replacement
CAUTION: Be carotul not to damago th€ seats, dash-
board and other int6rior trim,
1. Remove the glass (see page 2O-86) and headliner(see page 20-10O).
Disconnect the motor connector, and remove the
clips securing the ceiling light wire harness.
NOTE: To remove the motor, remove the screws.
Disconnect the drain tubes.
Loosen the front bolts.
Remove the bolts, then remove the trame from the
car.
NOTE:
a You may require assistance when removing the
trame.
a Take care not to bend the sunshade rails.
TUBECLIP
DRAIN TUBETo install, slade the drain tube ov6rthe frame nozzle at least 10 mm lO.4 in).
SUNSHADERAILS
Pullthe drain tubes out of the tront and rear oillars.
NOTE: Before pulling out the drain tube, tie a string
to the end of it so it can be reinstalled.
Installation is the reverse of the removal grocedure.
NOTE:
a Install the tube clips with the ends facing the side to easea Clean the surtace of the frame.
a Check the frame seal.
a Check for water leaks.
a Make sure the sunshade moves smoothlv.
SCREW
4.
\/
Make sure the sliders areparallel when installing themotor,
CONNECTOR
FRAME
BOLT6 x 1.0 mm9.8 N.m (1.O lg{.rn.7.2 tbt.ttl
Loosen the tront bohs
Fo?w!?d
tt.
FRONTDRAIN VALVES
installation of the headliner.
20-87

Retainers and WeatherstriP
Replacement
CAUTION: Wear gloves to lemov€ and install tho i€tain€rs'
NOTE: Take care not to bend the retarners.
< : Screw localions, 19 < : Clip locations, I
| .€\
!:
l{SHOP TOWELq
CENTER PILLARMOLDING
Boot side section:
I
RETAINER
lnstallation is the reverse of the removal procedure.
NOTE:
a Check the weatherstrip lor damage or deterioration, and replace if necessary'
a After installing the weatherstrip, check for water leaks'
a lf necessary, adjust the position of the door glass (see page 20-40)
a It necessarv, replace any damaged clips.
Center oillar section:
FRONT CENTER PILLAR
CENTER PILI-ARMOLDING
NOTE: The numbers atter the part names
show the quantities ot the parts used
!9
RETAINER
WEATHERSTRIP
REAR CLIP
RETAINER
WEATHERSTRIP
20-158

Troubleshooting
Gompressor
R6move the comPressor clutch
refay and test it (see Page 22-19l..
Measuro the voltage bgtlveen th€
WHT wire terminal {+) and body
ground {-}.
Rap.ir op.n in ih. WHT wit.
batwaan tha undar-hood fuaa/
ralay box and thg comptaalol
clutch r.l.y.
Connect tho WHT and 8€D wire
terminals with a jumPer wire.
Disconnect the comPressor
clutch 1P connsctor.
Check for continuity in the RED
wiro botween the comPressorclutch relay and the comPressorclutch.
Replir op.n in th. REO wi.c
batwaan tho comPrdaor clutchrol.y and the compr.33oi clulch.
Inapact tha compter3oa clutchclelranca !nd ihc comPacaaorctutch fi€ld coil {!.. P.9.22'32}.
BLK/YEL {+l
WHT l+l
BLK/RED
View from wir€ side
View lrom wire side
To page 22-15
22-14

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.

and com
it with a
a
a
a
a
4t l\-N
r-

-l/
Compressor
Clutch Overhaul (cont'dl
Remove the screw from the field coil ground terma-
nal. Remove snap ring A with snap rjng pliers, then
remove the field coil.
NOTE:
. Be careful not to damage the field coil
pressor during removal/installation.
. Once snap ring A is removed, replace
new one.
SNAP RING AReplace.
FIELDcorL
5. lnstall in the reverse order of removal, and:
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaces
with non-petroleum solvent.
check the pulley bearings for excessive play.
make sure the snap rings are in the groove prop-
efly.
apply locking agent to the threads of the center
bolt, and tighten it securelY
make sure that the pulley turns smoothly after
it's reassembled.
1. Remove the relief valve and the O-ring.
NOTE:
. Do not let the compressor oil run out.
. Make sure there is no foreign matter in the sys-
tem.
RELIEF VALVE13.2 N.m {1.35 kgtm,9.76lbtftl
2. lnstall and tighten the relief valve.
Clean the mating surfaces.
Replace the O-ring with a new one at the relief
valve, and apply a thin coat of refrigerant oal
(ND-OIL 8: P/N 38899 - PR7 - A01) before install-
ing it.
NOTE:
. To avoid contamination, do not return the oil
to the container once dispensed, and never
mix it with other refrigerant oils.
. lmmediately after using the oil, replace the
cap on the container, and seal it to avoid
moisture absorption.
. Do not spill the refrigerant oil on the car; lt
may damage the painu if the refrigerant oil
contacts the paint, wash it off immediately.
Check for leaks, and insert the cap in the top of
the valve.
22-34

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

Starting System
Startel Test
NOTE: The air temDerature must be between 59 8nd
10OoF (15 and 38oC) before testing.
Recommendsd Procodure:
a Use a staner svstem tester.
a Connect and operate the equipment in accordance
with the manutacturer's instructions.
a Test and troubleshoot as described.
Altohato Procedure:
a Use the following equipment:- Ammeter. 0-4OO A- Voltmeter, O- 20 V {accurate within 0.1 volt)
- Tachometer, O- 120O rpm
a Hook up voltmeter and ammeter as shown'
NEGATIVE TERMINAL
NOTE: After this test, or any subsequent repair,
reset the ECM to clear any codes (see section 1 1)
23-76
2.
Chock Stan€r Engag6ment:
1. Disconnect the 2-P connector (ignition coil primary
lead) from the distributor.
Press the clutch pedal allthe way in (M/T), and turn
the ignition switch to "Start". The starter should
crank the engine.
NOTE: On cars equipped with manual transmission,
the engine will not crank unless the clutch pedal is
fully depressed.
lf the staner does not crank the engine go to step 3.
Check the baftery, battery positive cable, ground,
and the wire connections for looseness and cor-
rosion,
Test again. lf the starter still does not crank the en-
gine, go to step 4.
Bvpass the ignition switch citcuit as follows {make
sure the transmission is in neutral):
Unplug the connector (BLK/WHT wire and solenoid
terminsl) trom the starter. Then connect a jumper
wire from the battery positive ( + ) terminal to the
solenoid terminal. The starter should crank the
engrne.
a lf the starter still does not crank the engine,
replace it and diagnose its internal problems.
a lf the starter cranks the engine, go to step 5.
J.
4.

Starting System
Clutch Interlock Switch Test
1 . Remove the dashboard lower cover and knee bolster
(see page 23-70), then disconnect the 2-P connec-
tor from the switch.
2. Check tor continuity between the terminals accord-
ing to the table.
lf necessary. replace the switch or adjust the switch
oosition (see section 12).
Starter Solenoid Test
1. Check for continuitv between the tetminals accotd-
ing to the table.
HOLD - |l{ COIL
23-78
Tsrminal
CoilMDHousing
HOLD- INo----c
PULL- INo----.oClutch Pedal
T€rminalAB
RELEASED
PUSHEDoo
Pt LL- tt{ coll

Starting System
Armature Inspection and Test
1 . Inspect the armature for wear or damage due to con-
tact with the field coil magnets.
Inspect tor damage
A dirtv or burnt commutator surface may be l€sul-
faced with emery cloth or a lathe within the follow-
ing specilications.
Commutator Diamet€r
Stsndald (N6w): 29.9-3O.O mm (1.17-1.18Inl
Selvico Limit: 29 mm (1.14 lnl
VERNIEB CALIPER
23-82
3.
4.
Commutrtor Runout
Standard (Naw): 0-O.O2 mm (0-O.OO08 inl
Sowico Limit: 0.O5 mm (O.O02 inl
lf the commutator runout and diamete. are within
limits, check the commutator tor damage or for car-
bon dust or brass chips between the segments.
lf the surf6c6 is dirty, recondition it with # 50O or
# 600 sandpsper.
COMMUTATOR