ABS HONDA INTEGRA 1994 4.G Workshop Manual

Design Specifications
{cont'd}
lTEMMETRICI€iIGLISHINOTES
TRANSMISSIONTypeEngine typoManual transmission81881 | 818C1
G6ar Ratio 1st2nd3rd4th5thRov€rs€
3.2301.9001.2690.966o.7113.000
3.230r.9(X)1.3601.0340.'t873.000
Fin6l Reduction Gear typeGear ratioSingle helicalge.r4.2664.400
TypeAutomatic transmission
Gear Ratio 'l6t
znd3rd4thRevelse
2.7221.4640.97s0.6381.954
Final R€duction Goar typoGear ratioSingle helic6lgoar4.357
AIRCONDITIONINGCooling Capacity3,570 Kcal/h14,166 BTU/I
Compr6ssor Type/MakeNo. ol CylinderCaPtcityMax. SpsedLubricant C6pacity
Lubricrnt Type
swash-plare/NIPPoNDENSO10150 ml /rcv | 9.15 cu-in/r€v7,600 rpm140 mf | 1-2Bll ozI l.;3 tmp ozND-O|L8 (P/N 38899 - PR7 - A01)
Cond6ns€r TypeCorrugated fin
Evaporator TypeCorrugatod tin
Blower TypeMotor InputSpeed ControMax. Capachy
Sirocco tan200 w12 v4-speed450 m3/h | 15,900 cu lvh
Temperature ControlAirmix type
Compressor Clutch TypePowor ConsumptionDry, singlo plate, poly-V-b€lt driv640 W max./12 V at 68"F {20'C)
Refrigerant TypeOu.ntityHFC-134a (R-134a)
zoo-Ss I 24.7-l.aoe
STEERINGSYSTEMTypeOverall RatioTurns, Lock-to-LockSreering Wheel Dia.
Power assisted, rack and pinion16.12.98380 mm | 15.0 in
SUSPENSIONType Front
Roar
Shock Absorb€r, Front and Rear
Independent double wishbono,coil spring with st6bilizerIndependont double wishbong.coil spring with stabilizerTelescopic, hydraulic nitrogen gas-tilled
3-18

ITEMMETRICIENGLISHIM)TES
WHEELALIGNMENTCamber
CasterTotalToe
FrontRearFrontFrontRear
-0.10'-0.45'
1'1o'omm | oinIn 2 mm I ln 0.08 in
BRAKE SYSTEMType Front
RearPad Surface Area FrontRearParking Brake Type
Power-assisted selt-adiustingventilated discPoweFassisted self-adjusting solid discio.u cm. x z | /,/5 so tn x z21.0 cm, x2 | 3.26 sq in x 2Mechanical actuating, rear two wheel brakes
TIRESize Front and r€ar
Spare Tire
P195/60R14 858*1P195/55R15 84V*2T115t0D14*3T135/70O15.4
ELECTRICAL8atteryStarterAlternatorFusesIn Under-dash Fuse/Relay BoxIn Under-hood Fuse/Relay Box
In Under-hood ABS Fuso/Rolay BoxHeadlights
Front Side Marker LightsFront Turn SignauParking LightsRear Turn Signal LighlsStop/Ta illig htsHigh Mount Brake Light'5Fear Side Marker LightsBack-up LightsLiconse Plate LightsCeiling LightsCargo Area Lights (3 DOOR)Trunk Lights l4 DOOR)SpotlightsGlove Box LightGauge LightsIndicator Lightslllumination and Pilot LightsHeater lllumination Lights
High
I2V-36AH6HR'12 V -'1.4 kW12V-90A
7.5 A, 10 A, 15 A, 20 A, 30 A7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A50 A, 100 A10A, 15A,20A,40A12V-6sW{HB3}12V-55W(HB4)12V-3CP12V -32n CP12V -32 CP12V -32n CP12V -21W
12V-3CP12V -32 CP12V-8W12V-5W12v-3.4W12V-3.4W12V-5W12V-3.4W12V-3.4Wv - 0.84 w, 0.91 w, 1.12 W, 1.r W, 3 W12 V - 0.84 W. 0.91 W, 1.4 W. LEO12V-1.4W
sAE 168sAE 1157sAE 1 't 55sAE 1157sAE 7440sAE 168sA€ 1156
*1: RS, LS*2: GS-R*3: RS*1: LS, GS-R*5: Except high mount brake light installed in rcar spoiler.
3-19

Engine Removal/lnstallation
@a Make sure jacks and safety stands aro placed ploper-
ly and hoisl brackots arg attachod to the correct po-
sitions on tho engine (se€ ssction 1).
a Mak€ sure tho car willnot roll off stands and tallwhile
you are wotking under it'
CAUTION:
a Use fendet covals to avoid damaging painted
sudaces.
r Unspecified itsms alo common
a Unplug tho widng connectots carefully while holding
the couplor and tha connector portion to avoid
oamage.
a Mark all wiring and hoses to avoid misconnection.
Also, be sulo that thsy do not contact other wiring
or hoses, or interfere with oth€l parts.
NOTE: Anti-theft radios have a coded theft ptotection
circuit. Be sure to get the customer's code number beJore
- Disconnecting the batterY.
- Removing the No. 32 (7.5 A) fuse from the under-
hood tuse/relay box.- Removing the radio
Atter service, reconnect power to the radio and turn it
on. When the word "CODE" is displayed, enter the cus-
tomer's 5-digit code to restore radio operataon.
1. Remove the hood (see section 2O).
2. Remove the strut brace
8 x 1.25 mm24 N.m (2.4 kgf.m,17 rbt.ft)
Disconnect the battery negative terminal lirst. then
the positive terminal.
Disconnect the battery cables from the undel-hood
fuse/relay box and under-hood ABS fuse/relay box.
6 x l.O mm9.8 N.m (1 .O kgf'm,7.2 rbl.ftl
{cont'd)
STRUT ERACE
BATTERY CABLES
5-3

Remove the fuel return hose and positive crankcase
ventilation (PCV) hose.
Remove the brake booster vacuum hose, water
bypass hose and vacuum hose.
ERAKE BOOSTERVACUUM HOSE
HOSE
VACUUM HOSE
HOSE
9.
10.
Remove the throttle cable.
Remove the throttle control cable (automatic trans-
mission only).
NOTE:
. Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one.
. Adjust the throttle cable and throttle control
cable when installing (see section 11 and 14).
THROTTLE CONTROLCABLE
Remove the engine wire harness connectors and
wire harness clamps trom the cylinder head and the
intake manifold.
Four fuel injector connectors
Intake air temperature (lAT) sensor connector
Engine coolant temperature (ECT) sensor con-
necror
TDC/CKP/CYP sensor connector
lgnition coil connector
ECT gauge sending unit connector
Throttle position (TP) sensor connector
Manifold absolute Dressure (MAP) sensor con-
nector
ldle air control (lAC) valve connector
EVAP purge control solenoid valve connector
11.
a
a
a
a
a
a
a
a
a
(cont'dl
ATI'USTING
6-17

Valve Guides
Replacement {cont'd}
7. SliD a 6.5 mm {0.25 in) stsel washor and the correct
driver attachment over the end of the driver {The
washer will absorb some of the impact and extend
the life of the driver).
.,F-q-re
tt-T-IIttlDRVEn 6,5 mm t0.25 in) ATTACHMENT
WASHER
8, Install the new guide(s) from the camshaft side of
the head; drive each one in until the attachment
bottoms on the head. lf you have 8ll sixteen guides
to do, vou may have to reheat the head one or two
more I|mes.
Valv6 Guida Instsllod Hcight:
lntaks: 13.75 - 14.25 mm
(o.sal - 0.561 inl
Exhru3t: 15.75 - 16.25 mm
{0.620 - 0.640 in}
Reaming
NOTE: For new valve guides only.
Coat both reamer and valve guide with cutting oil.
Rotate the reamer clockwise the full length of the
valve guide bore.
Continue to rotate the reamet clockwise while
removing it from the bore.
Thoroughly wash the guide in detergent and water
to remove any cutting residue.
Check clearance with a valve (see page 6-24).
. Verify that the valve slides in the intake 8nd
exhaust valve guides without ex€rting pressure.
VALVE GUII'E REAMER, 6.6 MM
079E4 - 667ot0c
REAMER HANDLE
s

ll.Remove the engine wire harness connectors and
wi.e ha.ness clamps from the cylinder head and the
intake manitold.
Four fuel injector connectors
Intake air tempe.ature {lAT) sensor connector
Engine coolant temperature (ECT) sensor con-
nector
TDC/CKP/CYP sensor connector
lgnition coil conn€ctor
ECT gauge sending unit connector
Throttle position (TP) sensor connector
VTEC solenoid valve connector
VTEC Dressure switch connector
Manifold absolute pressure (MAP) sensor con-
nector
ldle air control {lAC) sensor connector
EVAP purge controlsol€noid valvo connector
Intake air bypass {lABl control solenoid valve
conneclor
a
o
a
o
a
a
a
a
a
a
a
a
a
12.
13.
Remove the spsrk plug caps and distributor from
the cylinder head.
Remove the upper radiator hose, heat€r hose and
water bypass hose.
WATER BYPASS
HOSE
6r1.0mm9.8 N.m (1.0 kgt m,1.2 tbtftl
14. Remove the sDlash shield.
Remove the engine ground cable.
Romovo the adjusting bolt and mounting bolts, then
remove the power steering (P/S) pump belt and P/Spump.
. Do not disconnect the P/S hoses.
(cont'dl
15.
6x1.0mm9.8 N.m 11.0 kgl.m,7.2 tbt.ttl
6-57
,l

Valve Guides
Replacement (cont'dl
7. Slip a 6 mm {0.2 in) steel washer and the correct
driver attachment over the end of the driver (The
washer will absorb some of the imDact and extendthe life of the driver).
:=:-/--PDRIVER6 mm 10.2 int ATTACHMENTWASHER
Install the new guide(s) from the camshaft side ofthe head; drive each one in until the attachment
bottoms on the head. lf you have all sixteen guides
to do, Vou may have to reheat the head one or twomore times.
Valve Guide Installed Height:
Intake: 12.55 - 13.05 mm {0.49it - 0.51it inl
Exhaust 12.55 - 13.05 mm {0.494 - 0.514 inl
VALVE GUIDE
Reaming
NOTE: For new valve guides only.
1. Coat both reamer and valve guide with cutting oil.
2, Rotate the reamer clockwise the full length of thevalve guide bore.
3. Continue to rotate the reamer clockwise whileremoving it from the bore.
4. Thoroughly wash the guide in detergent and waterto remove any cutting residue.
5. Check clearance with a valve (see page 6-70).
. Verify that the valve slides in the intake and ex-haust valve guides without exerting pressure.
REAMER HANDLE
Turn reamer inclockwise directiononry.
C'
o
a
-'{)
6-72

Fuel and Emissions
Spocial Tools ................ 1 1-2
Compon€nt Location
lndex ................. ...... 11-3
System Description
Vacuum Connectiona .......,.................... 1 1 -8
Efectrical Connections ....,.,.,......,...,,.....,'11-12
Syst€m Connectors ...,...,.................-.--. 11-2O
T.oubloshooting
Troubleshooting Guido .......................... 1 1-32
Self -diagnostic Procedures .,..,............... 1 1 -34
How to Road Flowcharts ...................,... 11-39
PGM-Fl System
Systom Description .............................. 1 l-4O
Troubleshooting Flowcharts
Engine Control Moduls ............... ........... 1 1 -42
Heated Oxygon Sensor ......,.................. 1 1-46
Heated Oxyg€n Sonsol Heatel .....,......... 1 1 -47
Fuel Supply System ..............-............... 1 1-50
Manitold Absolute Pressure
Ssnsor ............................................ 1 1-52
Top D6ad Cente./Crankshatr
Position/Cylindor Position sonsor ........ 1 1 -56
Engine Coolant Tempsrature Sonsor ....... 11-58
Throttlo Position Sonsor ........,..,,........... 1 1-60
Intake Air Temperaturs Sensor ............... 11-62
Baromet c Prsssuro Sensor ......,...,...,..,. 11-64
lgnition Output Signal ........................... 1 1 -66
Vehicle Spe€d Sensor ........................... 1 1 -68
Electdcal Load Dotector ....,...,..........,.... 1 1 -7O
Knock Sensor [818C1 engine] ............... 11-74
A/T Fl Signal A/B ................................. 1 1-76
ldle Contlol System
System Troubleshooting Guide .................. 1 1 -78
Systom Description ........ 11-79
Troubloshooting Flowchans
ldl€ Ail Control Valve ........................... 1 1 -82
Ail Conditioning Signal ......................... 1 1 -84
Altemator FR Signal ............................. 1 1 -86
Automatic Transaxle (A/T) Gear
Position Signal ......... 11-88
Brake Switch Signal ............................. 1 1 -9O
Startel Switch Signal ............................ 11-92
Power Steering Pressure Switch Signal ... 11-93
Fast ldle Thermo Valve ...................,......... 1 1 -94
ldls Speed S€tting .................................... 1 1 -95
Fuel Supply System
Systam Tloubloshooting Guid. .................. 1 1 -97
Fuol Linos ...................... 1'l -98
System Description ........ 11-100
Fuol Prassure ................. 11-100
Fu6l Ini6ctors ................. 11-102
Fuel Pressure Ragulato. .,. 11-106
Fuel Filter ...................... 11-108
Fual Pump ..................... 11-109
PGM-Fl Main F6lay ................................... 1 1"1 1 1
Fuel Tank ...................... t 1-114
Intake Air System
System Troubloshooting Guido .................. 1 1 -1 1 5
Systom Dascription ........ 11-116
Air Clean€r .................... 11-117
Throttls Cable ................'11-118
Throttl8 Body ................ 11-120
lntake Air Bypass Cont.ol Systsm
[B18Cl enginal .,......... 11-123
Intake Manilold [B1881 onginol ................. 11-128
Emission Control System
Systsm Troubleshooting Guido .................. 1 1 -1 29
Systam Doscription ........ 11-130
Tailpips Emission ........... 11-130
Thrae Way Catalytic Convortor ...,...,........., 11-131
Positiva CrankcaEo V6ntilation Systcm .,....., 11-134
Evaporativo Emission Contro|,..,..,.,.,,.,,..,.., 1 1-135

Component Locations
lndex
81881 sngin6:
IOLE AIR CONTROL OACI VALVEpage '11-82T
MANIFOLD ABSOLUTEPRESSURE {MAP} SENSOREVAP
THROTTLE POSITIOIII {TP) SENSORTroubleshooting, page 1 1-60
Troubleshooting,
(ECTI SENSOR HEATEO
PURGE CONTROLSOLENOID VALVETroubleshooting,11-137
THROTTLE CABLEInspection/Adiustment, page 1 1-1 18
Installation, page 11- 1 18
SENSOR lHO2S}
TOP DEAD CENTER/CRATIIKSHAFTPOSITIOf{/CYLINDER POSITION(TDC/CKP/CYP} SENSORTroubleshooting, page 1 1-56
INTAKE AIR TEMP€RATURE IIAT) SEI{SORTroubl€shooting, page 1 1 -62
POWER STEERING PRESSURE (PSP)
swtTcHTroubleshooting. page 11-93
sq
IDLE THERMO VALVEInspection, page 11-94
ELECTRICALLOADOETECTORIELD}Troubleshooting.page,l l-70
IGNITIONMODULE {ICMI
Troubleshooting, page 1 1-66
ENGINE COOLANT TEMPERATroubleshooting, page I 1-58Troubleshooting. pages 11-46, 47
11-3

ENGINECOOLANT
@ FUEL TAI{K EVAPORATIVE EMISSION (EVAP} VALVE
G) FUEL PULSATION DAMPER
@ AIR CLEANER
@) RESONATOR
@ THREE WAY CATALYTIC CONVEnTER (TWC)
o POS|TIVE CRANKCASE VEITITILAT|ON IPCV) VALVE
@ EVAPOBATIVE EMISSION IEVAP) COI{TROL CANISIER
@ EvApoRATrvE EMrssroN IEVAP) PURGE coNTRoL
SOLENOID VALVE
@ EVAPORATTVE EMISSION (EVAP) PURGE CONTROL
DIAPHRAGM VALVE(iD EVAPORATIVE EMISSION (EVAPI TWO WAY VALVE
|l
U]
HEATED OXYGEI{ SEI{SOF (HO2S}
MANIFOI.D ABSOLUTE PRESSURE (MAP) SEI{SONENGINE COOLANT TEMPERATURE IECT} SENSORINTAKE AIR TEMPERATURE IIAT} SEI'ISORIDLE AIR CONTROL IIAC) VALVEFAST IDLE THERMO VALVEFUEL II{JECTORFUEL FILTERFUEL PRESSURE REGULATONFUEL PUMP IFP)FUEL TAI{K
11-9