1994 ACURA INTEGRA Clutch replace

Glutch Overhaul
l. Remove the center bolt while holding the pressure
ptate.
A/C CLUTCH HOLDERcommorcially availsbleRobinair: P/N 10204Kont.Moore: P/N J37872
CENTER BOLT13.2 N.m (1.35 kgt.m,9.76 lbf.ftl
Remove the pressure plate and shim(s), taking care
not to lose the shims.
sHrM{s)
Remove the snap ring B with a snap ring pliers,
then remove the pulley.
NOTE:
. Be careful not to damage the pulley and com-presso. during removal/installation.
a Once the snap ring B is removed, replace it with
a new one,
SNAP RING BReplace.
(cont'd)
22-33

and com
it with a
a
a
a
a
4t l\-N
r-

-l/
Compressor
Clutch Overhaul (cont'dl
Remove the screw from the field coil ground terma-
nal. Remove snap ring A with snap rjng pliers, then
remove the field coil.
NOTE:
. Be careful not to damage the field coil
pressor during removal/installation.
. Once snap ring A is removed, replace
new one.
SNAP RING AReplace.
FIELDcorL
5. lnstall in the reverse order of removal, and:
install the field coil with the wire side facing
down (see above).
clean the pulley and compressor sliding surfaces
with 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.
1. Remove the relief valve and the O-ring.
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 kgtm,9.76lbtftl
2. lnstall and tighten the relief valve.
Clean the mating surfaces.
Replace the O-ring with a new one at the relief
valve, and apply a thin coat of refrigerant oal
(ND-OIL 8: P/N 38899 - PR7 - A01) before install-
ing it.
NOTE:
. To avoid contamination, do not return the oil
to the container once dispensed, and never
mix it with other refrigerant oils.
. lmmediately after using the oil, replace the
cap on the container, and seal it to avoid
moisture absorption.
. Do not spill the refrigerant oil on the car; lt
may damage the painu if the refrigerant oil
contacts the paint, wash it off immediately.
Check for leaks, and insert the cap in the top of
the valve.
22-34

Starting System
Gomponent Location Index
A/T GEAR POSITION SWITCHTest, page 23-136Replacement, page 23-137
BATest, page 23-66
STARTER CUT RELAY {M/T}Test, page 23,68
CLUTCH INTERLOCK SWITCH (M/T}Test, page 23-78Switch Adiustment. section 12
Test, page 23-76Solenoid Test, page 23 78Repfacement, page 23 79Overhaul, pages 23-8OReassembly, page 23,85
23-73

Starting System
Startel Test
NOTE: The air temDerature must be between 59 8nd
10OoF (15 and 38oC) before testing.
Recommendsd Procodure:
a Use a staner svstem tester.
a Connect and operate the equipment in accordance
with the manutacturer's instructions.
a Test and troubleshoot as described.
Altohato Procedure:
a Use the following equipment:- Ammeter. 0-4OO A- Voltmeter, O- 20 V {accurate within 0.1 volt)
- Tachometer, O- 120O rpm
a Hook up voltmeter and ammeter as shown'
NEGATIVE TERMINAL
NOTE: After this test, or any subsequent repair,
reset the ECM to clear any codes (see section 1 1)
23-76
2.
Chock Stan€r Engag6ment:
1. Disconnect the 2-P connector (ignition coil primary
lead) from the distributor.
Press the clutch pedal allthe way in (M/T), and turn
the ignition switch to "Start". The starter should
crank the engine.
NOTE: On cars equipped with manual transmission,
the engine will not crank unless the clutch pedal is
fully depressed.
lf the staner does not crank the engine go to step 3.
Check the baftery, battery positive cable, ground,
and the wire connections for looseness and cor-
rosion,
Test again. lf the starter still does not crank the en-
gine, go to step 4.
Bvpass the ignition switch citcuit as follows {make
sure the transmission is in neutral):
Unplug the connector (BLK/WHT wire and solenoid
terminsl) trom the starter. Then connect a jumper
wire from the battery positive ( + ) terminal to the
solenoid terminal. The starter should crank the
engrne.
a lf the starter still does not crank the engine,
replace it and diagnose its internal problems.
a lf the starter cranks the engine, go to step 5.
J.
4.

5. Check lor 8n op€n in the BLKMHT wire circuit be-
tween the staner and ignition switch, and con-
nectors.
6. Check the ignition switch (see page 23-70).
7, On cars with automatic transmission, check the A/Tgear position switch (neutral position switchl and
connector. On cars with manualtransmission, check
the staner cut relay, clutch interlock switch, and
connectors.
NOTE: Check the No. 39 (5O A) fuse in the under-hood
fuse/relay box for the starter cut relay.
Check tor Woar and Damago:
The starter should crank the engine smoothly and stead-
ily. lf th€ startsr engages, but cranks the engine errati-
cally, remove it. Inspect the starter, drive gear, and
flywheel ring gesr for damage.
a Check the drive gear overunning clutch for binding
or slipping when the armature is rotated with the drivegear held. Replace the gesrs if damaged.
Check Cranking Voltago 8nd Current Draw:
Cranking voltage should be no less than 8.O volts.
Current draw should be no more than 360 amperes.
lf cranking voltag€ is too low, or current draw too high,
check for:
a Fully charged battery
a Open circuit in starter armature commutatot segments
a Starter armature dragging
a Shoned armature winding
a Excessive drag in engine
Chack Cranking rpm:
Engine spsod during cranking should be above 1O0 rpm.
lf spe6d is too low, ch€ck for:
a Loose battsry or starter teminals
a Excessively worn starter brushes
a Open circuit in commutator segments
a Dirty or damaged helical spline or drive gear
a Defective drive gear overrunning clutch
Chock StErtor Disongagomoni:
Press the clutch pedal allth€ way in (M/T), turn the ioni-
tion switch to "lll" and rolease to "11".
The starter drive gear should disengage from the tlywheel
ring gear. When you rolease the key.
lf the drive gear hangs up on th€ flywheel ring gear, check
for:
a Solenoid plunger and switch malfunction
a Dirty drive gear assembly or damaged overrunning
clutch
23-77

Starting System
Clutch Interlock Switch Test
1 . Remove the dashboard lower cover and knee bolster
(see page 23-70), then disconnect the 2-P connec-
tor from the switch.
2. Check tor continuity between the terminals accord-
ing to the table.
lf necessary. replace the switch or adjust the switch
oosition (see section 12).
Starter Solenoid Test
1. Check for continuitv between the tetminals accotd-
ing to the table.
HOLD - |l{ COIL
23-78
Tsrminal
CoilMDHousing
HOLD- INo----c
PULL- INo----.oClutch Pedal
T€rminalAB
RELEASED
PUSHEDoo
Pt LL- tt{ coll

BRUSHES
Starting System
Starter Field Winding Test
1. Check for continuity between the brushes. lf there's
no continuity, replace the armature housing.
2. Check for continuity between each brush and the ar-
mature housing {ground) lf continuity exists, replace
the armatule housing.
Overrunning Clutch InsPection
Slide the overrunning clutch slong the shatt.
Does it move treely? ll not, replace it.
Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
DRIVE G€AR
ll the starter drive gear is worn or damaged, replsce
the ovsrrunning clutch assembly; the gea. is not
available separately.
Check the condition of the flywheel or torque con-
verter ring gear if the starter drive gear teeth ale
damaged.
4.
23-8,4
CLUTCH GEAR

Switch Test
1, Remove the dashboard lower cover.
2. Carefully pry the switch out of the left side air vent
Danel, then disconnect the 4-P connector and re-
move the switch.
3. Check lor continuity between the terminals in each
switch position sccording to the table,
MOONROOF SWITCH
Motor Test
Remove the headliner (see section 20).
Disconnect the 2-P connector from the moonroot
moror.
Check the motor by connecting power and ground
according to the table.
NOTE: Motor clutch test is in section 20.
lHatchblckl (Scd!n)
View from terminal side
It the motor fails to run or doesn't run smoothly.
replace it.
4.
Torminal
P"ri i-
---__\AID
OFFG---o
OP€No---oG-
CLOSE
o---o
Te.minal
Condition -- ---------lAB
OPENo
CLOSE@
,l
rd\./ cLos€
Y
IOPEiIIOFF
23-215