Vacuum HONDA INTEGRA 1994 4.G Workshop Manual

Fuel and EmissionsSection 11
ClutchSection 12
Unit ot length: mm {in)
MEASUREMENTsTAt{ItAno (NewlSERVICE UMIT
.u.l pumpDisolacoment in l2 V, 10 seconds 81881 engine
m, (fl oz, lmp oz) 818C1 engins222 17 .5,7 -81 min. | 12011.1' 1'21
364 (12.3, 12.8) min. I too (:.1, g.st
F aa3uro rggulatorPressure with regulator vacuum hose disconnected
kPa (kgflcm', psi) Bl8Bl engineBl8Cl engin€275 - 32a 12.8 -3.9,39.6 - 46.9)329 - 378 (3.35 - 3.85, 47.6- 5.47)
tualt6nkCaprcity, {US gal, lmp gal)50 (13.2, 11.01
En9in6ldle sDeed with headlight and cooling fan ofi rpm7501 50 (M/T: neut..ll750I 50 {A/T: E or E position}
Fast idle rpm1,600 i 2(x' lM/T: nsurr6l)l,eoo I 200 (A/T: E or E po6itioo)
ldl6 CO %0.1 max.
MEASUREMENTSTAM'Ad' IiEWISERVICE UMIT
clutch padslP6d6l height to lloor
SirokePedal play
Disengagement height to floor
164 (6.46)
130 - 140 (5.12 - 5.51)12 - 21 (0.47 - 0.83)83 (3.27) min.
Clutch sudace runout0.05 10.002) max,0.'15 (0.006t
clutch discRiv€t h€ad depthThickness
1.3 (0.05) min.8.4- 9.1 (0.3 - 0.36)0.2 (0.011
6.0 (0.24)
Pr6sur6 plat€WarpageOiaphragm spring linger alignment0.03 (0.001) mrx.0-6 (0.02) ma*0.15 (0.006)
0.8 (0.03)
{n+
3-7

Engine Removal/lnstallation
m
(cont'd)
Remove the intake air duct, air cleaner housing as-semblv and the bracket.
6 x 1.O mm9.4 N.m {l.O ksf.m, 7.2 tbf,ftl
Remove the evaporative emission (EVAp) controlcanister hose and vacuum hose.
VACUUM HOSE
THROTTI.E BODY
7. Remove the engine wire harness connectoE on theright side of engine compartment.
8. Relieve fuel pressure by loosening the service bolton the tuel filter about one turn {see section 1 1).
@ oo not amoke whito working on thofuel system. Keep open flame away trom wo.k arsa.Drain fuel only into an approved container.CAUTION:
a Before disconnocting any fu€l line. reliovo the tuolpressule as doscribed above.a Place a shop towel ov61 the fu6l filter to prevontprossurized tuel from spraying ovel tho aogine.
9. Remove the fuel feed hose.
SERVICE BOLT15 N.m (1.5 kgt.m, 11 tbt.ftl
BAITJO EOLT33 N.m 13.4 kgt.m,25 tbt.ftt
6 x'l.O mm9.8 N-m ll.0 kgt.m.

1O. Remove the brake booster vacuum hose and fuel
return hose.
6 x 1.O mm11 N.m {1.1 kgl'm,8.O rbt.ltl
BRAKE BOOSTERVACUUM HOSE
't 1.
BETURN HOSE
Remove the throttle cable by loosening the locknut.
then slip the cable end out of the accelerator linkage.
NOTE:
a Take care not to bend the cable when removing
it. Always replace any kinked cable with a new
one,
a Adjust the throttle cable when installing (see sec-
tion 1 1).
LOCKNUT
AOJUSTING NUT
5-5
't2.Remove the engine wire harness connectors, termi-
nal and clamps on the left side ot engine com-
oartment.
6 x 1.0 mm9.8 N.m {1 .O kgf.m,7.2 tbt.ftl
ENGINE WIREHABNESS
13. Remove the cruise control actualor.
CRUISE CONTROLACTUATOR
8 x 1.25 mm24 N.m (2,4 kgl.m,17 lbf.Irl

37, Remove the left and right front mounts and brackets.
MOUNT BOLT
LEFT FRONTMOUNT
12 t 1.25 nn59 N.m {6.0 kgt.m,43 lbf.trlReplace.
38. Remove the rear mount bracket,
12 r 1.25 mm59 N.m (6.0
Replace.43 rbf.ftl
REAR MOUNT12 r 1.25 m|n59 N.m {6.0 kgt.m,43 tbt.frlReplace.
14 x 1.5 mm118 t{.m (12.O kgt.m,86.8 lbl.ft}R6place.
MOUNT/BRACKET
39. Remove the side engine
10 r 1.25 mm
mounr.
WASHERSReplace.Replace.SIDE ENGIITE
40. Remove the transmission mount
TRA SM|SS|OI{MOUNT
41. Check that the engine is completely free of vacuum
hoses, fuel and engine coolant hoses, and electrical
wi.ing.
42. Slowly raise the engine approximately 150 mm (6
in), Check once again that all hoses and wires are
disconnected from the engine
43. Raise the engine all the w8y and remove it trom the
car.
(cont'dl
5-11

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

Cylinder Head
Removal (cont'd)
7. Remove the vacuum hose and €vaoorativs emis-
sion (EVAP) control canister hose.
EVAP CONTROLCANISTER HOSE
Remove the water bypass hose and positive
crankcase ventilation {PCV) hose.
WATER BYPAssHOS€PCV HOSE
9. Remove ths brake booster vacuum hose and fu€l
return hose,
BRAKE BOOSTERVACUUM HOSE
6x1.0mm12 N.m 11.2 kgf.n,8.t lbf.trl
10. R€mov6 tho thronlo cable.
NOTE:
o Taks care not to bsnd the cabl6 when removing
it. Always replace any kinked cable with a new
on6.
o Adiust the th.ottle cable when installing (see s6c-
tion 1l).
AD.'USTING THROTTI,"ENUT CABI.T

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

Special Tools
Ref. No I Tool Numb€rDescription I OtV I Page Reference.
o
@
@
@
@
A973X_041*XXXXX
oTJAZ -O010008
OTLAJ_PT3O1OA
oTPAZ-0010100
o7406-OO40001
Vacuum Pump/Gauge
Vacuum/Pressure Gauge 0-4 in. Hg
Test Harness
SCS Short Connector
Fuel Pressure Gauge
,l
1
1'l
1
1't -'t 20,
140
11-139,'t 1-37
I t -J.+
11-t01,
124,'137,
140
106

o
11-2

System Description
Vacuum Connections
81881 engin€:
EVAPORATIVE EMISSION(EVAP} PURGE CONTROLDIAPHRAGM VALVE
EVAPORATIVE EMISSIOT{(EVAPI
PURGE CONTROLSOLENOID VALVE
ToEVAPORATIVEEMtSSTON{EVAP}TWO WAYVALVE
EVAPORATIVE EMISSIONIEVAP) CONTROI- CANISTER
FRONT OFVEHICLE
11-8

System Description
Vacuum Connections
818C1 engine:
INTAKEAIRBYPASS IIAB}VACUUMTANK
INTAKE AIRSYPASS IIAB}CONTROL DIAPHRAGM VAI-VE
MANIFOLO ABSOLUTEPRESSURE {MAP) SENSOR
toEVAPORATIVEEMISStONIEVAPITWO WAYVALVE
EVAPORATIVE EMISSION{EVAP) PURGE CONTROLDIAPHRAGM VALVE
EVAPORATIVE EMISSIONIEVAPI CONTROL CANISTER
INTAKE AIRBYPASS IIABICONTROL SOLENOID VALVE
PURGE CONTROLSOLENOID VALVE
11-10