Thermostat HONDA INTEGRA 1994 4.G Workshop Manual

Cooling
lllustrated Index
Radiator
Replacement ............................... 1 O-4
Engine Goolant Refilling and
Bleeding10-5
Cap Testing ............... 10-6
Pressure Testing ......... 10-6
Thermostat
Rep|acement ............................... 1 O-7
Testing .....1O'7
Water Pump
lllustrated Index ......... . 10-8
Inspection .10-9
Replacement ............................... 1 O-9
10-2

ENGINE COMPARTMENT HOSE CONNECTIONS:
Bl88l engine:FAST IDLETHERMOVALVE
THERMOSTATHOUSIITGIDLE AIR CONTROLIIAC} VALVE
O'RINGReplace.
BREATHER PIPE
O-RINGReplace.
HEATER HOSES
818C1 engine:
ENGINE OILCOOLER
IAC VALVE
HEATER BYPASSPIPE
FAST IDLETHERMOVALVE
THERMOSTATHOUSING
BREATHER PIPE
HEATEB HOSES
10-3

NOTE: Use
sembling,
new gaskets and O-rings when reas-
6 x 1.O mm11 N.m 11.1 kgt.m,8.O lbt.ftl
THERMOSTATMOUIITING RUBBERReplace.22-25 N.m 12.2-2.6 ksl.m, 'l6-'19 lbl.ttlECT SWITCH
Thermostat
Replacement
Testing
Replace thermostat if it is open at room temperature.
To test a closed th€rmostat:
SusDend the thermostat in a container of water as
shown.
Heat the water and check the temperature with a
thermometer. Check the temperature at which the
thermostat first opens and at full lift.
CAUTION: Do not let the thelmometer touch the
bottom of the hot container.
Measure the lift height of the thermostat when it's
fullv oDen.
STANDARD THERMOSTAT
Lift height: above 8.O mm (O.31 inl
Starts opening: 169 - 176"F {76-8OoCl
Fully open: 194oF (90oCl
l
THERMOMETER
THERMOSTAT
10-7

Troubleshooting
Symptom Chart
NOTE: Check the engine coolant level and allow the engine to warm up before troubleshooting.
SYMPTOMREMEDY
Hot air flow is low.Blower motor runs, but one ol more
speeds are inoperative.
Follow the tlowchart (see page 21-9).
Blower runs properly.Check for the following:. Clogged heater duct. Clogged heater outlet. Incorrect door position
No hot air JlowBlowel motor does not run at all.Follow the flowchart (see page 2l-l1l
Blower motor runs.Check for the following:. clogged heatet duct. Clogged blower outlet. Clogged heater valve. Faultv air mix door. Heater valve cable sdjustment lsee page 2'l-271
. Air mix control cable adjustment (see page 21-27)
. Faulty thermostat (see section lO)
. Clogged evaporator (with air conditioning). Frozen evaporator (with air conditioning)
Mode control motor does not run, or one or more modes are
inooerative.
Follow the flowchart (see page 21-14).
Recirculation control door does not change between FRESH
and RECIRCULATE.
Follow the flowchart (see page 21- 17).
21-A

Heater Control Panel Input/Output Signals
No.Wire ColorSignslNo.Wire ColorSi9n8l
IBLU/WHTHEATINPUT8GRN/YELHEATA/ENTINPUT
2YELI{EAT/DEFINPUTqRED/BLKCOMBINATION LIGHT SWITCHINPUT
YEL/BLUDEFINPUT10REDBRIGHTNESS CONTROLLEROUTPUT
4BLKGROUNDOUTPUT11BLU/REDA/C THERMOSTATINPUT
5GRN/REDRECIRCULATEINPUT12GRNHEATER FAN SWITCHOUTPUT
oGRN/WHTFRESHINPUT1?
YEL/REDVENTINPUT't4BLK/YELtG2INPUT
21-19

Wiring/Connector Locations
A/C DIODECONNECTOR(Loc.ted .bovo tho.ight kick p.n.ll
RADIA'OR FAN RELAY{Localed in the undel-hood fu3o/reltY box)
A/CTHERMOSTAT CONDENSERFANCONNECTOR CONNECTOR
MAIN WIRE HARNESS
A/C WIRE HARNESSCONNECTOR
RADIATOR FANCONNECTOR
A/C WIRE HARNESS
COMPRESSOR CLUTCHCONNECTORA/C PR€SSURE SWTTCHCONNECTOR
22-4

From page 22-15
Turn the ignition switch ON (IIl.
Measure tho voltage betweon theBLK/YEL wire terminal (+) andbody ground (-).
R.p.i. op.n ir th. BLX/YEL wirobatwc.n tha unda.-darh fuao/r.l.y box .rd rh. A/C th.rmo.t!r.
Measure th€ voltage between theYEL/WHT wire terminal {+} andbody ground (-).
R.prir op.n in th. YEL/WHTwiro bctwaan tha A/C praaau.crwhch .nd th. A/C th..mo.ht.
ls there battory voltage?
T!rn the ignition switch OFF.
R€connect the Ay'C thermostat 3Pconn€ctor and connect the BLU/RED wire terminal to ground witha l!mper wire,
Do the radiator and con-donser fans run and thecompressor clutch engage?
Turn the ignition switch OFF anddisconn6ct the jumper wire.
YEL/WHT l+l
View from wir€ side
To page 22-18
(cont'd)
22-17

A/C Thermostat
Test
Connect battery power to terminal C and ground termi-
nal B, and connect a test light between terminals A and
NOTE: Use a 12 V, 3W- 18Wtest light.
Dip the A-/C thermostat into a cup filled with ice water,
and check the test light.
The light should go off at 37"F (3"C) or less. and should
come on at 39"F (4"C1 or more.
lf the light doesn't come on and go off as specified,
replace the Ay'C thermostat.
There should be continuity between the A and C term!nals when power and ground are connected to the Band D terminals.
There should be no continuity when power is discon-nected.
. Radiator fan relay
Condenser fan relay
Compressor clutch relay
Relays
a
a
,I Ir-b
InP.I I
12V.3W-18W
ABC
22-19

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

Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnesses are coverod with
yollow in3ulation.
. B€tore disconnocting 8ny part of tho SRS wire har-
nsss, conngqt th€ 3hort connestor{sl.
. Roplaca ths entire aftected SRS harness a$embly if
it has an op€n circuit or damaged wiring.
lcove.ed with yellow insulation)
Recover the refrigerant with a Recovery/Recycling/
Charging System lsee page 22-22]-.
Femove the bolts, and disconnect the receiver line
and the suction line from the evaporator.
NOTE: Plug or cap the lines immediately after dis-
connecting to avoid moisture and dust contamina-
tion into the svstem.
2.
L
6x1.0mm9.8 N.m {1.019f.m,1.2 tbl.ttl
SUCTION LINE
RECEIVEB LINE
3.Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.
Disconnect the connector from the Ay'C thermostat,
and remove the wire harness clips from the evapo-
rator.
Remove the four self-tapping screws, mounting bolt
and the mounting nut.
Disconnect the drain hose, and remove the evapo-
rator.
1.
6x1.0mmAPORATOR9.8Nm{1.0kg{.m,7.2 tbtft)
a
a
8. Install in the reverse order of removal. and:
it you're installing a new evaporator, add refrig-
erant oil (ND-OIL 8: P/N 38899 - PR7 - A01) (see
page 22-2'll.
replace the O-rings with new ones at each fitting.
and apply a thin coat of refrigerant oil (ND-OlL 8:
P/N 38899 - PR7 - A01l before installing them.
NOTE: Be sure to use the right o-rings for HFC-
134a {R-134a} to avoid leakage.
apply sealant to the grommets.
make sure that there is no air leakage.
charge the system (see page 22-39) and test its
performance (see page 22-241.
22-26