Mount HONDA INTEGRA 1998 4.G Workshop Manual

Hatch
Replacement
NOTE:
a An assistant is helpful when removing the hatch.
a Take care not to damage the hatch and body.
a Take care not to scratch the hatch side trim and hatch
trim panel.
a Open the hatch.
a Remove the high mount brake Iight {see section 23).
'1. Remove the hatch side trim on each side.
: Clip locaiions,
_);(zZZ////1
r.-lf
2. Remove the hatch trim panel
A: Clip locations
AA : Clip, 11 8V : Clip, 3
Ar^{N
# fN#=l*l y /
lrl
HATCH TRIM PANEL
20-148
5. Remove the rear wiper motor (see section 23i
NOTE: Detach the clips by sliding the hatch trim panel
forward, then remove it.
Remove the hatch spoiler as described on page 20-161
(if so equipped).
Disconnect the connectors, then remove the wire
harnesses from the hatch.
4.
A : Special boltlocations,2
V I Clip locations
AV: Clip, 3 BA: Clip. 6
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A
A
w
+
..h [-
g)
bll
/\
NOTE: Betore pulling out the wire harness, tie a
string to the end of it so you can pull it back in when
the hatch is reinstalled.
WIRE HARNESSES
CONNECTORS
CONNECTOR
WIBEHABNESS

Adjustment
NOTE:
. Before adjusting the hatch, loosen each bolt and nut slightly.
. Do not installthe support struts.
1. Adjust the hatch hinges rightand left, aswell asforeand aft. byusing the elongated holes.
2. Turn the hatch edge cushions, as necessary, to make the hatch fit flush with the body at each side.
3. Adjust the hstch fit to the hatch opening by moving the striker.
4. Use shims. as necessary, to make the hatch fit flush with the body at the rear edge.
5. Adiust the hatch side stop so that there is no clearance between it and the body side stop, then tighten the mounting
bolt (Tvpe R).
HATCHEDGE CUSHION
STOP(Typ. R
Modoll
SIDESTOPlTyp. R
Modell
HATCHEDGECUSHION
stoE
STRIKER
HATCHEDGE CUSHION
Type R Model:
SIDE STOP(Hatch side)
SIDE STOP(Body side)
6xl,0mft9.8 N.m 11.0 kg{.m,7.2 tbf.ftl
6x1.0mm9.8 N.m (1.0 kgt m,?.2 tbf.ftl
SIDE STOP(Hatch side)
Adjust forno clearance,
SIDE STOP(Body side)
NOTE: Move the striker right or left until it's centered
in the hatch latch as shown.
STRIKER
HATCH
8 x 1.25 mm
SHIM
8 x 1.25 mm22 N.m 12.2 kgl.m,16 rbt.ft)
HATCH

Sub-frame Torque Sequence:
CAUTION: Atter loosening the lea. beam mounting bolts. be sure to replace them with new ones.
6 x 1,0 mm9.8 N m (1.0 kgf m,7.2 rbf.ft)REAB BEAM BRACE
REAR BEAMCOLLAR
'10 x 1.25 mm44 N.m (4.5 kgl.m.33 tbf.ft)
REAR BEAM
REAR BEAM14 x 1.5 mm89 N m {9.1 kgf m.66 tbt.frlReplace.
Sub-frame
20-169

Blower Unit
Replacement
NOTEr The blower motor, recirculation control motor
and blower resistor can be replaced without removjng
the blower unit (see page 21-21).
Remove the glove box {see section 20}.
Remove the four bolts and the glove box frame.
Without Air Conditioning
3-a. Remove the wire harness clips trom the heater duct.
Remove the tour self-tapping screws and the heat-
er duct.
1.
2.
HEATER DUCT
21-20
With Air Conditioning
3-b. Remove the evaporator (see page 22-26).
CLIPS
9.8 N.m 11.0 kgf.m,7.2 rbf.ftl
4. Disconnect the connectors from the blower motor,
the blower resistor and the recirculation control
motor,
5. Remove the wire harness clip from the recirculation
control motor, and release the wire harness from the
clamp on the blower unit.
Remove the two mounting bolts, the mounting nut
and the blower unit.
6 x 1.0 mm
6.
6 x 1.O mm9.8 N.m (1.0 kgf'm,7.2 rbr.ftl
Install in the reverse order of removal. and make sure
there are no air leaks.
9.8 N.m (1.0 kgl'm,

Heater Unit
Replacement
SRS components are located in this area. Review the
SRS component locatio.s, precautions, and procedures
in the SRS section (23) before performing repairs or ser-
vtce.
1. When the engine is cool, drain the engine coolant
from the radiator (see section 1O).
@ oo not remove the radiator cap when
the engine is hot; the engine coolant is undol
prsssure and could sevdely scald you.
2. Ooen the clamD, then disconnect the heater valve
cable from the heater valve arm.
HEATER VALVE CABI-E
I
i
21-22
3. Disconnect the heater hoses lrom the heater unit.
CAUTION: Engine coolant will damaga paint. Ouick-
ly rinse any spilled engine coolant from painted
sudaces.
NOTE: Engine coolant will run out when the hoses
are disconnected, drain it into a clean drip pan.
4. Remove the mounting nut from the heater unit.
NOTE: When removing the mounting nut, take care
not to damage or bend the fuel pipes, brake pipes,
etc.
8 x 1.25 mm22 N'llt. 12.2 kgl'm, 16 lbl.tl)
CLAMPS
HEATER HOSES

.J
5.
6.
7.
8.
Remove the dashboard (see section 2O).
Remove the heater duct (see page 21 20) or the
evaporator lsee page 22-261.
Remove the two bolts, the nut and the passenger's
SRS beam.
PASSENGER'SSRS BEAM
Disconnect the mode control motor connector. and
remove the wire harness clip from the heater unit.
Remove the two mounting nuts and the heater unit.
6 x 1.0 mm9.8 N.m (1.0 kgf.m, 7.2 lbf.ftl
I r 1.25 mm22 N.m 12.2 kgf.m, 16 lbf'ft)
Il
I
I
lnstall in the reverse order of removal. Make note of
these items:
. Apply sealant to the grommets
. Do not interchange the inlet and outlet hoses.
Make sure that the hose clamps are secure.
. Loosen the bleed bolt on the engine and refill the
radiator and coolant reservoir with the proper
engine coolant minure (see section 10).
Tighten the bleed bolt when all the trapped air
has escaped and engine coolant begins to flow
from it (see section 10).
. Connect all cables and make sure they are prop-
erly adjusted (see page 2'l-271.
;!
i
21-23

A/C System Service
Recovery
Use only 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: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritale eyes. nose and
throat. Avoid breathing the air conditioner rclrigerant
and lubricant vapor o. mist.
lf accidental system discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be Dressure tested or leak tested with
compressed air.
@ some mixtures of air and R-134a have
been shown to be combustible at €levated pros3ures
and can result in lire or explosion causing iniury or
plop€rty damage. Never use comprossgd air to pressure
iest R-134a service equipment or vehicle air conditioner
sYstsms.
Additional health and safety information may be
obtained from the refrigerant and lubricant manufac-
tures,
Connect a R-134a refrigerant Recovery/Recycling/
Charging System to the vehicle. as shown, follow-
ing the equipment manufacturer's instructions.
Measure the amount of refrigerant oil removed
from the IVC system after the recovery process is
completed.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system before
charging.
Recov€ry/Recycling/Cha.ging Systom.
HIGH.PRESSURESIDE
't.
22-22

J
Pressure Test Chart
Performance Test on page 22.24.
TEST RESULTSRELATED SYMPTOMSPROBABLE CAUSEREMEDY
Discharge (highlpressure
abnormally high
After stopping compressor, pressure
drops about 200 kPa (2.0 kgflcm',28psi) quickly, and then falls gradually.
Air in systemRecover, evacuate and rechargewith specified amount.Evacuation: see pag€ 22-38Charging: see page 22-39
Reduced or no air tlow throughconoenser.
. Clogged condenser orradiator fins. Condenser or radialor fannot working proPerly
CleanCheck voltage and fan rpmCheck fan direction
Line lo condenser is excessively hot.Restricted flow of felrigerantin systemRestricted lines
Dischargepressureabnormally low
High and low pressures are balancedsoon after stopping compressor. Lowside is higherthan normal.
. Faulty compressordischarge valve. Faulty compressor seal
Replace the compressor.
Outlet of expansion valve is notfrosted, low pressure gauge
indicates vacuum.
. Faulty expansion valve. lvloisture in system
. Replace. Recover, evacuate and rechargewith specified amount.
Suction (low)pressure
abnormally low
Expansion valve is not frosted andlow-pressure line is not cold. Lowpressure gauge indicates vacuum.
Frozen expansion valveFaulty expansion valveReplace the expansion valve.
Discharge temperature is low and theairflow from vents is restricted.Frozen evaporatorRun the fan with compressor off,then check A,/C thermostat.
Expansion valve is frosted.Clogged expansion valveClean or replace.
Receiver/dryer outlet is cool and inletis warm (should be warm duringoperal|onJ.
Clogged receiver/dryerReplace
Suctionpressureabnormally high
Low-pressure hose and seryicevalve are cooler than the temPera-ture around evaporator.
Expansion valve open toolongLoose expansion capillarytube
Repair or replace.
Suction pressure is lowered whencondenser is cooled by water.Excessive refrigerant insystemRecover. evacuate and rechargewith specified amount.
High and low pressure are equalizedas soon asthe compressor asstopped, and both gauges fluctuatewhile running.
Faulty gasket
Faulty high-pressure valveForeign panicle stuck in highpressure valve
Reolace the comDressor.
Suction and dis-charge pr€ssuresabnormally high
Reduced air flow throughcondenser.
. Clogged condenser orradiator fins. Condenser or radiator lannot working properly.
Clean condenser and radiatorCheck voltage and fan rpmCheck fan direction
No bubbles in sight glass whencondenser is cooled bv water.Excessive refrigerant in systemRecover. evacuate and rechargewith specified amount.
Suction anddischargepfessure
abnormally low
Low-pressure hose and metal endareas are cooler than evaDorator.Clogged or kinked lowpressure hose partsRepair or replace.
TemP€rature around expansionvalve is too low compared with thataround receiv€r/dryer.
Clogged high-pressure lineRepair or replace.
RetrigerantleaksCompressor clutch is dirty.Compressor shaft seal leakingReplace the compressor.
Comoressor bolt(s) are dirty.Leaking around bolt(s)Tighten bolt{s) or replacecompressor.
Compressor gasket is wet with oil.Gasket leakingReolace the comoressor.
22-23

Evaporator
Replacement
Cut the dashboard insulato. at the areas shown.
Disconnect the connector from the A,,/C thermostat.
and remove the wire harness clips from the evapo-
rator.
6 x 1.0 rnm9.8 N.m 11.0 kgf.m,7.2 tbl.ft)
EVAPOBATOB
7. Remove the four self-tapping screws. the mounting
bolt and the mounting nut.
8. Disconnect the drain hose, and remove the evapo-
rator.
9, Install in the reverse order of removal, and:
. if you're installing a new evaporator, add refrig-
erant oil (ND-OlL 8: PiN 38897 - PR7 - A0IAH or
38899 - PR7 - A0 I I lsee page 22-21) .. replace the O-rings with new ones at each fitting,
and apply a thin coat of refrigerant oil before
installing them.
NOTE: Be sure to use the right O-rings tor 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 itsperformance {see page 22-24l.
CLIPS
SRS components are located in this area. Review the
SRS component locations, precautions, and procedures
in the SRS section {23) before performing repairs or ser-
vice.
1. Recover the retrigerant with a Recovery/Recycling/
Charging System \see page 22-221.
2. Remove 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-
UOn.
6x1.0mm9.8 N.m 11.0 kgf.m,1.2 tbi.ft)
Remove the glove box (see section 20).
Remove the four bolts and the glove box frame.4.
SUCTION LINE
RECEIVER LINE
22-26

Compressor
Replacement
lf the compressor is marginally operable, run the
engine at idle speed, and let the air conditioner
work a few minutes. Then shut the engine off.
Recover the refrigerant with a Recovery/Recycling/
Charging System \see page 22-22).
Remove the power steering pump (see section 17).
NOTE: Do not disconnect the hoses from the power
steering pump.
Disconnect the condenser fan connector.
Disconnect the compressor clutch connector, then
remove the compressor clutch connector and the
clips from the condenser fan shroud
Remove the two mounting bolts and the condenser
fan shroud.
NOTE: Be careful not to damage the radiator fins
when removing the condenser fan shroud.
1.0 mmN.m (1.0 kgt.m,rbf.ftt
CONDENSER FAN SHROUD
COMPRESSOR CLUTCH CONNECTOR
5. Remove the bolts, then disconnect the suction line
and the discharge line from the compressor.
NOTE: Plug or cap the lines immediately aiter dis-
connecting to avoid moisture and dust contamina-
tio n.
6x1.0mm9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
22-30
6. Loosen the adjusl pulley bracket pivot bolt and the
adjusting bolt, then remove the A/C compressor
belt from the Dullev as shown.
ADJUSTING BOLT
A/C COMPRESSOR BELT
Remove the four mounting bolts and the compres-
sor.
NOTE: Be careful not to damage the radiator fins
when removing the compressor.
7.
./.,
COMPRESSOR