clutch HONDA INTEGRA 1998 4.G Workshop Manual

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

Compressor
Clutch Inspection
Check the plated parts of the pressure plate for color
changes, peeling or other damage. lf there is dam-
age, replace the clutch set.
Check the pulley bearing play and drag by rotating
the pulley by hand. Replace the clutch set with a new
one if it is noisy or has excessive play/drag.
Measure the clearance between the Dullev and thepressure plate all the way around. lf the clearance is
not within specified limits, the pressure plate must beremoved and shims added or removed as required,following the procedure on page 22-33.
Clearanca: 0.50 t 0.15 mm (0.020 r 0.006 in)
NOTE; The shims are available in three thicknesses:
0.1 mm, 0.3 mm and 0.5 mm.
22-32
Check resistance of the field coil.
Field Coil Resistance: 3.6 1 0.2 ohm at 68'F {20'C)
lf resistance is not within specifications, replace the
field coil.

J
Glutch Overhaul
1. Remove the center bolt while holding the pressure
plate,
A/C CLUTCH HOLDER
lCommorcially available)Robinair: P/N 1020,1
Kent-Moor6: P/N J37872
2.
CENTER BOLT13.2 N.m {1.35 kgf m,9 76lbtft)
IRemove the pressure plate and shim(s) taking
not to lose the shim(s).
sHtM(sl
[4
3. Remove the snap ring B with a snap ring pliers,
then remove the pulley.
NOTE:
o Be careful not to damage the pulley and com-
pressor during removal/installation.
. Once the snap ring B is removed, replace it with
a new one.
(cont'd)
I
/ T-\vr= ...--.-
-ffitll---.\lr l,
\-l I .v
22-33

Compressor
a
a
Clutch Overhaul (cont'dl
Remove the screw from the field coil ground termi,
nal. Remove snap ring A with snap ring pliers, then
remove the field coil.
. Be careful not to damage the field coil and com-presso. during removal/installation.
. Once snap ring A is removed, replace it with a
SNAP RING AReplace.
5. Install in the reverse order of removal, andl
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaceswith non-petroleum solvent.
check the pulley bearings for excessive play.
make sure the snap rings are in the groove prop-
efly.
apply locking agent to the threads of the center
bolt, and tighten it securely.
make sure that the pulley turns smoothly after
it's reassembled.
Relief Valve Replacement
Recover the refrigerant with Recovery/Recycling/
Charging System lsee page 22-221.
Remove the relief valve and the O-ring. Plug the
opening to keep foreign matter from entering the
system and the compressor oil from running out,
NOTE:
. Do not let the compressor oil run out.
. Make sure there is no foreign matter in the sys-
tem.
RELIEF VALVE13.2 N.m (1.35 kgf.m,9.76lbtft)
3. Clean the mating surfaces.
4. Replace the O-ring with a new one at the relief
valve, and apply a thin coat of refrigerant oil (ND-
OIL 8: P/N 38897-PR7-A01AH or 38899-PR7-A01)
before installing it.
5. Charge the system (see page 22-39), and test itsperformance (see page 22-241.
6. Check for leaks, and insert the cap in the top of the
FIELD
t\I lu
B _t_:---\-lr
\,/
22-34

Relay and Control Unit Locations
Engine Compartment
ABS PUMP MOTORRELAY
FAN RELAY
UNDER.HOOD AB{iFUSE/RELAY BOXIKG mod.ll
A/C COMPRESSORCLUTCH RELAYRADIATORFAN BELAY
UNDER.H(X)DFUSE/RELAY BOX
A&S MODULAUNIT
UNDER.HOOD ABII FUSE,/RELAY BOX {KE modoll
----ar:l
--r: u
D
tr
L]
ABS PUMP MOTOR
23-7

Connector ldentification and Wire Harness Routing
Starter Cables
Connectol ot
Terminal
Numbel of
CavitiesLocationConnects toNotes
Tl
r2
Right side of engine compartment
Right side oI engine compartment
Under-hood Iuse/relay box
Starter motor
oBatteryBattery positive terminal
Battely Ground Cable
Connector ol
Terminal
Numbel of
CavitiesLocationConnects toNotes
Right lront shock towerBody ground, via battery ground
caore
oBatteryBattery negative terminal
Engine Ground Cable A
Connector ol
Terminal
Number ol
CavitiesLocationConnects toNotes
T3Left side of engineValve cover
c2Left side oI engine compartmentBody ground. via engine ground
Engine Ground Cable B
Connector ol
Terminal
Numbel of
CavitiesLocationConnects toNot€s
r4Right side of engine compartmentTransmission housing
Right side of front frameBody ground, via engine ground
wire B
A/C Wire Harness
Connector or
Terminal
Number of
CavitiesLocationConnects toNotos
c 151
cl54
c156
8
2,l
Righr side of engine compartment
Left side of engine companment
Left side of engine compartment
Left side of engine compartment
Main wire harness (C207)
A,/C pressure switch
Condenser fan motor
ly'C compressor clutch
Right side of front frame
Under-hood ABS Fuse/Relav Box Cable
Connector or
Telminal
Number of
CavitiesLocationConnects toNotes
T5Right side o'f engine compartmentUnderhood ABS fuse/relay box
@Right side oI engine compaftmentBattery positive terminal
23-14

Connector ldentification and Wire Harness Routing
Main Wire Hsfness {Left branch}
Connector ol
TerminalNumber ol
CavitiesLocationConneqts toNot6s
c406
c41 1
c4't2
c413
c414
c415
c416
c417
c4l8
c419
c420
c421
c422
c423
c424
c424
c425
c426
c427
c428
c429
c430
c431
c43'rc432
c433
c434
c435
c436
c431
c438
c439c440
c441
c442
c443
c444
c445
c446
c447
c44ac449
c450
c451
c452
c452
c453
c454c455
16
2
2
14
4
8
14
20
22
26
Center floor
Center floorCenter flodrCenter floorUnder left side of dashBehind Ieft kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Behind left kick panel
Under left side of dash
Under left side of dash
Under left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dash
Under left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashBehind dashboard lower coverBehind dashboard lower coverBehind dashboard lower coverBehind dashboard lower coverBehind dashboard lower coverBehind dashboard lower coverUnder leit side of dashUnder left side of dashUnder left side of dashUnder left side of dashUnder left side of dashBehind under-dash fuse/relay boxUnder left side of dashBehind dashboard lower coverBehind dashboard lower coverBehind dashboard lower coverCenter floorUnder middle of dashUnder left side of dash
Data Iink connector (DLC)
A,/T gear position console lightShift lock solenoidAy'T gear position switchInterlock control unitDaytime running lights controlOaytime running lights controlCruise control unitJunction connectorTransmission control module(rcM)
Transmission control module
{TCM)Rear wire harness (C501)
Rear wire harness (C502)
Engine compartment wire harness(c301)
Engine companment wire harness I *1
(c3021 IEngine compartment wire harness(c302) lRoof wire harness {C663} |Security system {Option) | CanaAaSRS main harness (C802) |Clutch interlock switch I VnClutch switch (With cruise control) M/TDashboard wire harness (C552) AlTBrake switch lwithout cruise Icontrol) |Brake switch (With cruise control)lgnition switch ISecurity system {Option) CanadaCombination light switch /Combination light switch ICombination light switchCombination light switchUnder-dash fuse/relay box (C913)
Under-dash fuse/relay box (C916)
Underdash fuse/relay box (C917)
Under-dash fuse/relay box (C923)
Under-dash fuse/relay box (C924) |Under-dash fuse/relay box {C918) I OptionalSecurity system (Option) CanadaSecurity system (Optionl CanadaPGM-Fl main relayStarter cut relay ] M,.fRear window defogger relay IIntegrated control unitSecurity system (Option) CanadaHorn relay
Dashboard wire harness (C553)
Dashboard wire harness {C553) | -2
Parking pin switch I A,"ISecondary HO2S
Cable reel
Afi
I Atr
lf[
unit ] Canadaunit I Canada
16
14
20
't2
ti
I'
li
ll
li
+4
3
G401 Behind teft kick panelBody ground, via main wire harness*1: RS+2: Except RS
23-26

Fuses
Under-hood Fuse/Relay Box
AITEFNATOR[To .ngine wiro hrrn83 1T101)l
BATTERYlTo stano. csblca lTlll
C!104 [To condenso] fan relayl
*: Not u6edclutch l.hyl
NOTE: View from the backside of the under-hood fuse/relav box.
ClOg [To main wiro ha]ne3s {C215ll
C!107 [To blow.r motor r.l.yl
C908 [To m.in wiro h.rn.$ (C2l7ll
rr17
LI
Fl51
LI
rl56
lJ
rr51
IJ
C905 [To A/C compr.ssor C9O6 [To radirto] fan
23-52
Cltl1 lTo main wire harness lc218ll: USA
C€10 [To mrin wir. hlrnoit lC216ll

J
)1 -
Fuso NumborAmpsWir€ ColorComponent(s) or Circuh(rl Protastcd
41100 ABattery. power distribution
4240AWHT/BLKlgnition switch (BAT)
437.5 AWHT/REDCeiling light, cargo area light, data link connector (DLCl, power
antenna connector
44't5 AYEL/WHTPGM-Fl main relay
45Not used
4640AWHT/8LU
No. 7 (20 A) fuse (Via power window relay), No. 8 (20 A) tuse (Via
power window relay)
No. 10 (20 A) fuse (Via power window relay), No. 11 (20 A) fuse (Via
power window relay)
417.5 AWHT/BLUClock,8udio unit connector, ECM, TCM, Maint€nance reminder unit
4840AWHTCombination light switch (Headlight)
4930AWHT/BLUMoonroof relay
5040AWHT/GRNRear window defogger {Via rear window defogger relay)
51154WHTCombination light switch (Dash lights)
20AWHT/GRNHorn, horn relay, brake lights, AgS control unit, ECM, TCM
10AWHT/GRNTurn signal/hazard relay, hazard warning light
5440AWHT/flEDNo. 1 (20 A) fuse
40ABLU/WHTBlower motor (Via blower motor relsy)
56204BLU/BLKCondenser fan motor (Via condenser {an motor relay)
REDA,/C compressor clutch (via Ay'c comp.essor clutch relay)
57204BLVREDRadiator f8n motor (Via radiator fan relay)
23-53

1
I
PowerRelays
RelayTest
JNOTE: See page 23-194 for turn signal/hazard relay
input test.
Normally.open type:
fWC2i
1. Check for continuitv between the terminals.
. There should be continuity between the A and B
terminals when power and ground are connect-
ed to the C and D terminals.
. There should be no continuity between the A
and B terminals when power is disconnected.
<2
F;Z
,,A
/ l'El--E \
ey
Normally-opon type:
'1. Check continuity between relay terminals.
. There should be continuity between the A and C
terminals when power and ground are connect-
ed to the B and D terminals.
o There should be no continuitv when oower is
disconnacted,
o Power window relay
. Radiator fan relay
. Condenser fan relay
. AVC compressor clutch relay
Typel:
c
I Blower motor relay
. Rear window defogger relay
Typel:
Terminal
P";(c5t--__\B
Disconnected
Connectedoo
Terminal
P"*"r(B5-lc
Connectedoo
Disconnected