fuel HONDA INTEGRA 1994 4.G Workshop Manual

INTRODUCTION
How to Use This Manual
This manual is divided into 23 sections. The first page of each sec-
tion is marked with a black tab that lines up with its corresponding
thumb index tab on this page and the back cover. You can quickly
tind the tirst page of each section without looking through a full ta-
ble of contents. The svmbols printed at the top corner of each page
can also be used as a quick reference system.
Each section includes:
1. A table of contents. or an exploded view index showing:
a Parts disassemblv sequence.
a Bolt toroues and thread sizes.
a Page references to descriptions in text.
2. Disassemblv/assembly procedures and tools.
3. InsDection.
4. Testing/troubleshooting.
5. Repair.
6. Adiustments.
Special Information
@ lnai""tes a strong possibility of sevor€ pelsonal iniury
01 loss of life it instructions al€ not tollowed.
CAUTION: Indicates a possibility ot personal inlury or oquipmont
damage if instructions ale not followed.
NOTE: Gives helpful information.
CAUTfON: Detaifed doscriptions ot standad workshop procedures,
salety principlos and servica opelations are not included Pleaso note
that this manual conlains warnings and cautions against somo spocif-
ic sgrvice methods which could cause PERSONAL INJURY, damage
a vehicle or make it unsafe. Pleaso understand that those warnings
cannot cover all conceivablc waYs in which service, whethea or not
recommended bv HONDA, might be done, or of the possibla
hazardous consequences of svery conceivable way, nor could
HONDA investigate all such ways. Anyone using seryice plocedures
or toofa, whethor 01 not recomonded by HONDA, ,nust sttisfY him-
sett thoroughly that neither personal saf€ty nor v€hicle safety will
be jaopaldized.
All information contained in this manual is based on the latest product
information available at the time of printing. We reserve the right
to make changes at any time without notice. No part of this publica-
tion mav be reproduced, stored in retrieval system, or transmitted,
in any Jorm by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of the
publisher. This includes test. figures and tables.
Specificationstrtl:{lt'
Maintenance4Pi
Engine
H
I-""
Fuel and Emissions Za
*Transaxle
*Steeringr-\
lDl\.t/
* Brakes
(lncludins !TEg)o
*Electrical J--*
(lncludins ISBE)
First Edition 7/93 1448 pages
All Rights Reserved
Specifications Apply to U.S.A. and Canada
HONDA MOTOR CO.,LTD,
Service Publication ottice
As sections with r includ€ SRS components.
special precautions are lequiled when servicing.

Chassis and Paint Codes
U.S.Model
Vehicle ldentification Number
Manutactulol, Make and
Typ€ of Vshicle
JH4: HONDA MOTOR CO., LTD.
ACURA Psssenger car
Line, Body and Engino Type
DB7: INTEGRA 4-door/B1 881
DB8: INTEGRA 4-door/81 8Cl
DC2: INTEGRA 3-door/B18C 1
DC4: INTEGRA 3-door/B1 8B j
Body Type and Trsnsmission Type
3: 2-door Hatchback S-speed Manual
4: 2-doot Hatchback 4-speed
Automatic
5; 4-door Sedan s-speed Manual
6: 4-door Sedan 4-speed Automatic
Vehicle Glado (Seriesl
4: RS
5: LS
8; GS-R
Check Digit
Model Yaal
R: 1994
Factory Code
S: Suzuka Factory in Japan
Serial Numb€l
Vehicle ld€ntification Number and
JH4DB754* RSOOOOO 1
I
Engine Number
8l8Br-r300@l-----T-----
Engine Typ6
81881: 1.8 f DOHC Sequentiat Muhi-pori
Fuel-injected engine
B l8Cl : 1.8 | DOHC VTEC Sequ€nrial
Multi-port Fu€l-iniected €ngin€
Se al Numbel
Paint Code
COLOR
BG.33P
Federal Motor Vehicle Safety Standard Certification
Transmission Numbsr
Y80- 1 000@ I
Transmission Type
Y80: Manual
MPTA: Automatic
Serial Numbel
Paint Code
Paint CodeColor
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-7 2P
R-81
RP.24P
YR.5O3M
Paradise Blue-g.€en PeErl
Lausanne Gr6en Pead
Grsnada Black Pea.l
Frost White
Thunder Grav Metallic
Torino Red Pearl
Milano Red
Stealth Gray Pearl
Rosewood Brown M€tallic
1-2
3DOOR4DOOR

Canada Model
Vehicle ldentification Numbel
Manutacturer, Makeand
Type of v€hicle
JH4: HONDA MOTOR CO., LTD.
ACURA Passenger car
Lino. Body and Engine TYPo
D87: INTEGRA 4-doot/Bl 881
DC2: INTEGRA 3-dootBl 8C1
DC4: INTEGRA 3-doori B18B1
Body Type and Transmission TYPo
3: 2-door Hatchback 5-speed Manual
4'. 2-door Hatchback 4-speed
Automatic
5: 4-door Sedan s-speed Manual
6: 4-door Sedan 4-speed Automatic
Vehicle Grade {Sedes}
3: RS without passenger SRS airbag
4: RS with passenget SRS aitbag
8: GS-R
Check Digit
Model Yeat
R: 1994
Factory Code
S: Suzuka Factory in Japan
Serial Numbel
JH4DB753. RS800001
Engine Number
81881-1 700001
Engin€ Type
81881: 1.8 I DOHC Sequential Multi-port
Fuel-injected engine
B18C1: 1.8 I DOHC VTEC Sequential
Multi-Dort Fuel-iniected engrne
Serial Number
Paint Code
COLOR
BG.33P
Vehicle ldentification Number and
Canadian Motor Vehicle Safety Standard Certification
Transmission Number
Y80-1000001
Transmission Type
Y80: Manual
MPTA: Automatic
Serial Numbel
Paint Code
Paint CodeColor
Paradise Blue-green Pearl
Lausanne Green Pearl
Granada Elack Pearl
Frost White
Thunder Gray Metallic
Torino Red Pearl
Milano Red
Stealth Gray Pearl
Rosewood Brown Metallic
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-72P
R-81
RP-24P
YR-503M
3DOOR4DOOR
1-3

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

Design Specifications
]TEMMETRICENGLISHNOIES
:' vENSTONSOveralllength 3 DOOR
4 DOOR
Ov€rallWidth
Overall Height 3 DOOR
4 DOOR
Wheelbase 3 DOOR
4 DOOR
Track F/R
Ground Clearance
Seating Capacity
4.380 mm
4.525 mm
'1,710 mm
1,335 mm
1,370 mm
2,570 mm
2,620 mm
't,475/1,470 mm
150 mm
Four (3 DOOR)
172.1in
178.1 in
67.3 in
52.6 in
101.2 in
103.1 in
5|8.1/57.9 in
Five (4 DOOR)
,rerght (usA)cross V€hicle Weight Rating {GVWR)3,680lbs
'le,ght {CANADA)Gross Vehicls Weight Rating {GVWR)1,670 kg
:\GINEType81881 engine
818C1 engine
Cylinder Arrangement
Bore and Stroke
Displacement
Compression Ratio
81881
818C1
81881
B18C I
81881
B 18C1
81881
818C1
engrne
engane
engrne
engine
engine
engine
engine
engine
L!brication Systom
OilPump Displacement
Wster Pump Displacement
FuelRequired
81881
B18C 1
81881
B 18C1
91881
engrne
engrne
engine
engine
engine
818C1 engine
Water-cooled, 4-stroke DOHC
gasoline engine
Watercooled, 4-stroke DOHC
VTEC gasoline engine
Inline 4-cylinder, transverse
81.0 x 89.0 mm
81.0 x 87.2 mm
1,834 cm3 (mf )
1,797 cm3 (m{)
3.19 x 3.50 in
3.19 x 3.43 in
112 cu-in
110 cu-in
9.2:1
10.0 : 1
Eelt driven, OOHC 4 valve per cylinder
Belt driven, DOHC VTEC
4 valve per cylinder
Forced and wet sump, trochoid pump
50, {53 US qt, 44 lmp qt)/minute'l
71 f {75 US qt, 62 lmp qt)/minute"
140 f (148 US qt, 123 lmp qt)/minute*!
140 f (148 US qt. 123 lmp qt)/minute*'
UNLEADED gasoline with 86 Pump
Octane Numb€r or higher
Premium UNLEADED gasoline wilh
91 Pump Octane Number or higher
STARTERTypo
NormalOutput
NominalVoltage
Hour Rating
Direction of Rotation
Weight
Gear reduction
1.4 kW
12V
30 seconds
Clockwise as viewed lrom g6ar end
3.7 k9 | 8.3lbs
CLUTCHClutch Type
Clutch Facing Area
M/TSingle plate dry, diaphragm spring
Torq!e converter
203 cm' I 31 sq-in
TRANSMISSIONTransmission Type M/T
Primary Reduction
Synchronized 5-speed forward, 1 reverse
Electronically controlled
4-speed automatic. 1 rcverse
Diract 1 : 1
'1: At 6,000 engine
'2: At 7,600 engine
rpm
rpm
(cont'd)
3-17

Lubrication Points
For the details ol lubrication points and type of lubricants to be spplied, reter to the illustrated index and various workprocedure (such as Assembly/Reassembly, Replacement, Overhaul, Instatlation, etc.) contained in each section.
No.LUBRICATION POII\ITSLUBRICAI\IT
IEngineAPI Service Grade: Use SG or SH "Energy Conserving
II" grade oil.
The oil container may also display the API Certifications€al shown below. Make sure it says'For GasolineEngines.'
SAE Viscosity; See chan below.
Transmission Manual
Automatic
API Service Grades: SF or SG
SAE Viscosity: 1O W-3O or 1O W-4O
Honda Premium Formula or DEXRON@ II
Automatic transmission fluid
3Brake line (lncludes Anti-lock brake linelBrake fluid DOT3 or DOT4
4Clutch lineBfake tluid DOT3 or DOT4
Power steering gearboxSteoring grease P/N 08733-BO7OE
Release fork (Manual transmission)Supe. High Temp Urea Grease (P/N O8798*9OO2)
8
Throttle wire end {Dashboard lower Danel holel
C.uise cont.ol actuatot wire end
{Dashboard lower Danel holel
Silicone grease
I
10'I 'l
12
13
14
15
to
17
18
Throttle cable end (Throttle linkl
Cruise control actuator cable end lActuator link)
Brake master cvlinder Dushrod
Clutch master cylinder pushrod
Engine hood hinges and engine hood latch
Batte.v terminals
Fuel fill lid
Hatch hinges or trunk hinges
Door hinges. upper and lowet
Door oDen detent
.Multi-purpose grease
19Rear brake calioersRust-p,eventive agant
20Power steering systemHonda power steering tluid-V
21Air conditioning compressorRetrigerant oit ND-otL8 |PlN 38899-pR7-A01)(For Relrigerant: HFC-134a (R-134a))
-20 0 20 r}() 60 ao loooF
-30 -20 -'to o 10 20 30 40"c
Recolnmendod engine oilEngine oil viscosity torambient tgmpelalure rangos
API CERTIFICATION SEAL

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

Insrall the left front mount, then tighten the bolts in
the numbered sequence as shown (O-@),
O 12 x 1.25 ]n]n83 N.m 18.5 kst.m,61 lbt.ftlReplace.
@ 12 r 1.25 mm59 N.m {6.0 kgl.n,43 tb{.ftlReplace.
@ 10 r 1.25 mm44 N.m (4.5 kgf.m, 33 lbt.ftl
k-
5-15
a Check that the sp.ing clip on the end of each
driveshaft clicks into place.
GAUTION: Uso oow spring clips.
a Bleed air trom the cooling system at the bleed bolt
with the heater valve open (see page 10-5).
a Adjust the th.ottle cable (see section 1 1).
a Check the clutch pedal tree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
Alternator belt {s€e section 23).
P/S pump belt {see section 17).
A/C comoressor belt (see section 22).
a Inspect tor fuel leakage (see section 1 1).
. After assembling fuel line parts, turn on the ig-
nition switch (do not operate th€ starter) so
that the Juel pump operates for approximat€-
lV two seconds and the tuel line pressurizes.
Repeat this operation two or three times and
check for fuel leakage at any point in the fuel
line.
(cont'd)