catalytic converter HONDA INTEGRA 1998 4.G Workshop Manual

Exhaust Pipe and Muffler
EXHAUST
b
'+l\v
rl
IIrl
NOTE: Use new gaskets and self-locking nuts when reassembling.
818C1 engine:
6 x 1.O mm9.8 N.m (1.0 kgf.m, 7.2 lbf.ft)
HEAT SHIELD
EXHAUST PIPE 8
Replacement (cont'd)
SELF,LOCKING NUT10 x 'l .25 mm33 N.m {3.4 kgt.m,25 tbf.ft)Replace.
PIPE TIP
BRACKET
10 x 1.25 mm38 N.m (3.9 kgl.m,28 tbt.fr)
8 x 1.25 mm22 N.m 12.2 kgt.m, '16 lbI.ft)Replace.Tighren the bolts in steps,alternating side-to-side.
SECONDARY HO2S44 N.m (4.5 kgI.m,33 rbf.fr)
COVER
THREE WAYCATALYTICCONVERTER(TWCI
Inspection page 9 7
EXHAUST PIPE A
SELF-LOCKING NUTS10 x 1.25 mm54 N.m 15.5 kgf.m,40 tbfdr)Replace-
8 x 1.25 mm22 N.rn 12.2 kgf.m, 16 lbf.ft)Replace.Tighten the flange nuts in steps,ahernating side-to-side.
10 x 1.25 mm3a N.m {3.9 kgf.m,28 tbf.fr)Replace.
HEAT SHIELDSMUFFLER
9-8
9.8 N.m {'1.0 kgf'm,7.2 lbf'ft)

818C5 engine:
6x1.0mm9.8 N.m {1.0 kgf.m.7.2lbtft)
EXHAUST PIPE B
8 x 1.25 mm22 N.rn {2.2 kgt.m, 16 lbtftlReplace.Tighten the bolts in steps,alternating side to'side.
SELF.LOCKING NUT10 x 1.25 mrn33 N.m {3.4 kgl.m,2s rbf.ftJReplace.
PRIMARY HEATEDSENSOFIPRIMARY H02S)4,1 N.m (4.5 kgt.m.33 tbf.ftt
SECONDARY HEATEOSENSOR
J
{SECONDARY H02S)4,0 N.m (4.5 kgf.m,33 tbf.ft)10 x 1.25 mm3&t!.m t3.9 kgt.n.28 lbf.ftl. \
ElacKEr -*_____GASKETReplace-
GASKETSReplace.
Replace.
THREE WAYCATALYTICCONVERTERtTwc)Inspection page 9 7
SELF.LOCKING10 x 1.25 mm5a N.m {5.5 kgt m.40 tbf.ftlReplace.
6x1.0mm9.8 N.m (1.0 kgf.m, ?.2 lbt.ftl
10 x 1.25 mm38 N.m 13.9 kgt m,28 lbt.ftlReplace.
8 x 1.25 mm22 N.m 12.2 kgtm, 16lbf.h)Replace.Tighten the flange nuts in steps,alternating side to side.
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81881 engine:
O PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2S}{SENSOR 1}(' SECoNDARY HEATED oxYGEN sENsoR (sEcoNDARYHO2S) (SENSOR 2l€) MANIFoLD ABSoLUTE PRESSURE IMAP} sENsoRq] ENGINE COOLANT TEMPERATURE {ECT} SENSORO INTAKE AIN TEMPERATURE {IAT} SENSOB.O CRANKSHAFT SPEED FLUCTUATION {CKFI SENSOR€) IDLE AIR CONTROL IIAC) VALVE@ FAST IDLE THERMo vALvEO FUEL INJEcToR@ FUEL FTLTERO FUEL PRESSURE REGULAToR@ FUEL PUMP {FPl@ FUEL TANK
FUEL TANK EVAPORATIVE EMISSION IEVAP} VALVEFUEL PUI-SATION DAMPERAIR CLEANERRESONATORTHREE WAY CATALYTIC CONVERTER (TWC}POSITIVE CRANKCASE VENTILATION IPCV} VALVEEVAPOMTIVE EMISSON IEVAPI OONTROL CANTSTEREVAPORATIVE EMISSION IEVAP) PURGE CONTROLSOLENOID VALVEEVAPORATIVE EMISSION {EVAP} TWO WAY VALVEEVAPOBATIVE EMISSION IEVAP} BYPASS SOLENOID VALVEEVAPOMTIVE EMISSION {EVAP) OONTROL CANISTER VENTSHUT VALVEFUEL TANK PRESSURE SENSOREVAPORATIVE EMISSION {EVAP) THREE WAY VALVE
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(cont'd)
11-11

818C5 engine:
il] PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2SI{SENSOR 1)O SECONDARY HEATED OXYGEN SENSOR ISECONDARYHO2S) {SENSOR 2)O MANIFoLD ABSoLUTE PFESSURE (MAPI sENsoRi4] ENGINE COOLANT TEMPERATURE {ECT} SENSOR(9) INTAKE AIR TEMPERATURE IIAT} SENSORG) CRANKSHAFT SPEED FLUCTUATTON TCKFI SENSON[t KNOCK SENSOR tKSt@ IDLE AIR coNTRoL {IACI vALvEO FUEL INJECToR{D FUEL FILTERO FUEL PRESSURE REGULAToR(} FUEL PUMP {FP}(} FU€L TANK
FUEL TANK EVAPORATIVE EMISSION (EVAPI VALVEFUEL PULSATION DAMPERAIR CLEANERRESONATORTHREE WAY CATALYTIC CONVERTER {TWCIPOSITIVE CRANKCASE VENNLATION (PCV) VALVEEVAPOMTIVE EMISSION {EVAP} CONTNOL CANISTEREVAPONATIVE EMISSION {EVAP) PURGE CONTROLSOLENOID VALVEEVAPORATIVE EMISSION IEVAP} TWO WAY VALVEEVAPORATIVE EMISSION IEVAP) BYPASS SOLENOID VALVEEVAPORATIVE EMISSION IEVAP) CONTROL CANISTER VENTSHUT VALVEFUEL TANK PRESSURE SENSOREVAPORATIVE EMISSION IEVAP}THREE WAY VALVE
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11-13

DTC(MlL indicationlDeteciion ltemProbable CausoPage
P013s {41)
Primary Heated Oxygen Sensor
Heater
Circuit Malfunction {Sensor '1)
. Open or shon in Primary HO2S (Sensor 1) heater
circuit. ECM1't-74
P0137 (63)Secondary Heated Oxygen
Sensor
Circuit Low Voltage (Sensor 2)
Short in Secondary HO2S (Sensor 2) circuit
Secondary H02S {Sensor 2)
ECM11-7'l
P0138 {63)
Secondary Heated Oxygen
Sensor
Circuit High Voltage (Sensor 2)
Open in Secondary HO2S (Sensor 2) circuit
Secondary HO2S (Sensor 2)
ECM
P0139 (63)Secondary Heated Oxygen
Sensor
Slow Response (Sensor 2)
Secondary HO2S (Sensor 2)
P0141 (651Secondary Heated Oxygen
Sensor Heater
Circuit Malfunction (Sensor 2)
. Open or short in Secondary HO2S(Sensor 2) heater circuit. ECM11-'14
P0171 (45)
System Too LeanFuel supply system
Primary HO2S {Sensor I )MAP sensor
Contaminated fuel
Valve clearance
Exhaust leakage
11-76
P0172 t45l
System Too RichFuel supply system
Primary HO2S (Sensor 1)
MAP sensor
Contaminated fuel
Valve clearance
11.76
,...,{iil
174l
Random Misfirelgnition system
Fuel supply system
MAP sensor
IAC valve
Contaminated fuel
Lack offuel
't 1-78
P0301 (71)
P03Q2 l'121
P0303 (73)
P0304 (74)
- Cylinder 1- Cylinder 2- Cylinder 3- Cylinder 4
Misfire Detected
Fuel injector
Fuel injector circuit
lgnition system
Low compression
Valve clearance
11-79
P0325 {23)
Knock Sensor Circuit
MalfunctionOpen or short in Knock Sensor circuit
Knock Sensor
ECM11-82
P0335 (4)Crankshaft Position
Sensor Circuit
Malfunction
Crankshaft Position Sensor
Crankshaft Position Sensor circuit
ECM1 1-83
P0336 (4)Crankshaft Position
Sensor
Range/Performance
. Crankshaft Position Sensor. Timing belt skipped teethIl-83
P0420 (67)Catalyst System Efficiency
Below Threshold
. Three Way Catalytic converter. Secondary HO2S11-139
(cont'd)
11-43

t"iI
Emission Gontrol System
System Description
Three Way Catalytic Converter (TWCI
\
t
The emission control system includes a Three Way
Catalytic Converter (TWC), Positive Crankcase Ventilation
(PCV) system and Evaporative Emission (EVAP) Control
system. The emission control system is designed to meet
tederal and state emission standards.
InsDeciion
!@@ Do not smoke during this procedure. Keep
any open llame away from your work area.
1. Start the engine. Hold the engine at 3,000 rpm with
no load {in Park or neutral) until the radiator fan
comes on, then let it idle.
2. Connect a tachometer.
Check and adjust the idle speed, if necessary (see
page '11-11 ! ).
Warm up and calibrate the CO meter according to the
meter manufacturer's instructions.
Check idle CO with rhe headlights, heater blower,
rear window defogger, cooling fan, and air condition-
er off.
NOTE: {Canada) Pull the parking brake lever up.
Start the engine, then check that the headlights are
olf.
CO meter should indicste 0.17o maximum.
DescriDtion
The Three Way Catalytic Converter {TWC) is used to convert hydrocarbons (HC), carbon monoxide (CO), and oxides of
nitrogen (NOx) in the exhaust gas, to carbon dioxide (COr), dinitrogen {Nr) and water vapor.
Bl8Cl engine l818Bl, 818C5 engines is similar):
FRONT OFVEHICLE
PRIMAEYHEATEDOXYGEN SENSORIPRIMARY HO2S}
HOUSING
WAYCATALYSTS
SECONOARYHEATEDOXYGEN SENSOR{SECONDARYH02St
\

Three Way Catalytic Converter (TWC)
lT042O I Th" """n tool indicates Diagnostic Trouble Code (DTC) P0420: catatyst system efficiency below threshold.
Descriotion
This system evaluates the catalyst's capacity by means of the HO2S (Primary and Secondary) output during stable drivingconditions. lf deterioration has been detected during three consecutive driving cycles, the MIL comes on and DTC p0420 willbe stored.
NOTE: lf some of the DTCS listed below are stored at the same time as DTC PO42O. troubleshoot those DTCS tirst. thentroubleshoot DTC P0420.
P0136, P0139: Secondarv HO2S
P0141:Secondary HO2S Heater
Possible Cause
. TWC Deterioration
. Exhaust system leakage
Troubleshooting Flowchart
Problem verification:1. Do the ECM Reset Procedure.2. Start the engine. Hold theengine at 3,000 rpm with noload (in Park or neutral) untilthe radiator fan comes on,3. Connect the SCS service con,
4. Test drive 40 - 55 mph (64 -
88 km/h) for approx. two min-utes, Then decelerate Ior atleast 3 seconds with the throttle completely closed. Thenreduce the vehicle speed to35 mph (56 km/h), and try tohold it until the readinesscode comes on.
I
- The MIL has been report€d on.- OTC P0420 is stored.
Intermittent tailure, sFtem is OKat this time.ls DTC P0420 indicated?
Check the TWC {s6e 3ection 91.lf necessary, reolace the TWC.
11-139

I
T
Remove the three upper transmission mounting
bolts and the lower starter motor mountino bolt.
STARTERMOTOEMOUNTINGBOLT
Drain the transmission oil, then reinstall the drainplug with a new washer (see page 13-3).
Remove the engine splash shield.10.
11.
6tr!
/
SELF.LOC1(ING NUTReplace.
Disconnect the heated oxygen sensor (HO2S) con-
nectors, then remove the exhaust pipe A. and the
three way catalytic converter (B'18C1 and B18C5
engines).
Feplace. THREE WAYCATALYNCCONVERTENlg18C1 lnd 818C5 onginrsl
Remove the cotter pins and loosen the castle nuts,
then separate the ball joints from the lower arm(see sectiotr'l8).
LOWER ARM
DAMPER CASTLE NUTFORK
13. Remove the right damper FORK
(cont'd)
13-5

18.Install the exhaust pipe A. and the three way cat-
alytic converter {B18Cl and B18C5 engines), and
connect the heated oxygen sensor {HO2S) connec-
tors.
GASKETReplace.
HO2SCONNECTORSSELF-LOCKING NUTFeplace.10 x 1.25 mm33 N.m {3.4 kg{.m,jj25 rbr.ftl
GASKETReplace.SELF.LOCKING NUTReplace.8 x 1.25 mm'16 N.m (1.6 kgf.m,12 tbtfr)
SELF.LOCKING NUTReplace.10 x 1.25 mm54 N.m (5.5 kgt.m,40 tbt frlTHREE WAYCATALYTICCONVENTER{Bl8Cl and 8'18C5 engincsl
'19. Install the engine splash shield.
20. lnstall the slave cylinder, then instsll the clutch pipe
bracket.
NOTE: Use only Super High Temp Urea Grease(P/N 08798 - 9002).
6x1.0mm9.8 N.m 11.0 kgt m,7 lbI.ft)
SLAVECYLINDER
8 r 1.25 mm22 N.m 12,2 kotm_- 9(x)21 16 tbt.ftt
Connect the vehicle speed sensor (VSS) connestor
and the staner motor cables.
Install the wire harness clamps.
6x1.0mm9.8 N.m {1.0 kgf m, 7 lbt'ft)
VSS CONNECTOR8 x 1.25 mm8.8 N.m {0.9 kg{.m,6.s rbr.ft)
5{P/N 08798
21.
WIREHARNESSCLAMPS
(cont'd)
13-49

Power Steering Gearbox
Installation (cont'dl
11. Install the steering joint cover with the clamps and
clips.
lnstall the rear beam brace rod and return line
clamp on the rear beam.
NOTE: lnstall the rear beam brace toward the
return line clamp.
12.
CLIP
38 N.m 13.9 kgl'm,28 lbf tl)
17-60
13. Install the three way catalytic converter with the
new gaskets and new self-locking nuts, and connect
the secondary heated oxygen sensor (HO2S) con-
nector.
SECONOARYHEATED OXYGEN SENSOR CONNECTOR
22 N.m {2.2 kgf.m, 16lbIft)
Connect the shift linkage (M/T model: see section
13, A,,/T model; see section 14).
Thread the right and left tie-rod ends onto the rack
an equal number of turns.
14.