1994 HONDA INTEGRA Workshop Manual

1.
2.
Starter Replacement
Disconnect the negative cable from the batterv.
Remove the intake air duct.
AIR CIEANERHOUS|L
Remove the engine wire harness and startef cablesfrom their brackets.
ENGINE WIRE HARI{ESS
CAALES
4.Disconnect the staner csble from the B terminal onthe solenoid, then the BLK/WHT wire from the Sterminal.
Remove the two bolts holding the staner, then re-move the startef.
UPPER MOUI{TII{G BOLT44 N..h (4.5 kgl.m, 33 lbt,ftl
8 TERMII{AL MOUIITTI{G NUT9 .ln (0.9 kgf.m, 6.5 tbf.ttl
TERMINAL
BLI(AA/HT WIRE
6. Install in the reverse order of removal,
23-79

Starting
Startel
System
Overhaul
from clutch side.
-s@]
MOLYBDENUMDISULFIDE
CAUTION: Disconnecl th€ battery n€gative cable befole
lomoving the startet.
NOTE: The original radio has a coded theft protection
citcuit. Be sure to get the customer's code number before
- disconnecting the batterY.- removing the No.3 2 (7.5 A) fuse from the under-hood
fuse/relay box.- removing the tadio.
Atter service, reconnect power to the radio and turn at
on. When the word "CODE" is displayed, enter the cus-
tomer's 5-digit code to restore radio operation.
tr./.' BRUSH HOLDERTest, page 23-8'l
ERUSH
COVER
I
6
OVERRUNNING CLUTCH ASSEMBLYInspection, page 23_84
SOLENOIDPLUNGERInspection, page 23-85
BRUSH HOLOER
ARMATURE
STARTERSOLENOIDTest, page 23-78
PINION GEAR IDLER GEAR
Inspection, page 23-11
IDLER GEAR
I
@*
SOLENOID HOUSING
HARNESS BRACKET
STEEL BALL
install steel ball
lnspection and Test,page 23-82
ROLLER BEARINGSand CAGEPrevenl rollers trom being scattered and lost.
MOLYBDENUM DISULFIDE
_R1
MOLYADENUMDISULFIDE
23-80
ENO COVER
ARMATURE
GEAR HOUSING

Starter Brush Holder Test
1 . Check that there is no continuity between the O and
O brush holders. lf continuity exists. replace theb,ush holder assembly,
G) BRUSH HOLDER E BRUSH HOLOER
O BRUSH I{OLDERO BRUSH HOLDER
Insert the brush into the brush holder, and bring thebrush into contact with the commutator, then attacha spring scale to the spring, Measure the spring ten-sion at the moment the spring lifts off the brush.
Spring Tension: 17.7 -23.5 N {1.8-2.4 kgf,4.O_5.3 tbfl
SPRING SCLAE
Starter Brush Inspection
Measure the brush length. lf it is less than the servicelimit, replace the armature housing and brush holder as-sembly.
Brush L€ngth
Standard {Now): 15.O- 15.5 mm (0.59-0.61 inlSe.vice Limit: 10.0 mm (0.39 inl
NOTE: To seat new brushes after installing them in their
holders, slip a strip of # 5OO or # 600 sandpaper, with
the grit side up. over the commutator and smoothly ro-
tate the armature. The contact surface of the brushes
will be sanded to the same contour as the commutato..
23-81

Starting System
Armature Inspection and Test
1 . Inspect the armature for wear or damage due to con-
tact with the field coil magnets.
Inspect tor damage
A dirtv or burnt commutator surface may be l€sul-
faced with emery cloth or a lathe within the follow-
ing specilications.
Commutator Diamet€r
Stsndald (N6w): 29.9-3O.O mm (1.17-1.18Inl
Selvico Limit: 29 mm (1.14 lnl
VERNIEB CALIPER
23-82
3.
4.
Commutrtor Runout
Standard (Naw): 0-O.O2 mm (0-O.OO08 inl
Sowico Limit: 0.O5 mm (O.O02 inl
lf the commutator runout and diamete. are within
limits, check the commutator tor damage or for car-
bon dust or brass chips between the segments.
lf the surf6c6 is dirty, recondition it with # 50O or
# 600 sandpsper.
COMMUTATOR

Check for mica depth. It necessary, undercut micawith a hacksaw blade to achieve proper depth.
ITOT GOOO
MICA DEPTH
Commutator Mica D6pth
Stsndard {Nsw):0.5-0.8 mm (O.O2-0.03 in}Sslvice Limit: 0.2 mm (O.OO8 inl
Check tor continuity between the segments of thecommutator. lf an open circuit exists between anvsegments, replace the armatute.
M
ARMATURE TESTER
ARMATUFE
Place the armatute on an armature tester. Hold ahacksaw blade on the armature core,
HACKSAW BLADE
It the blade is attracted to the core or vibrstes whilethe core is turned, the armature is shorted. Reolacethe armature.
Check with an ohmmeter that no continuity existsbetween the commutator and armatute coilcore. andbetween the commutator and armature shaft. lf con_tinuity exists, replace the armature
COMMUTATOR
8.
SHAFT
23-83

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

Solenoid Plunger Inspection
Check the contact points and the face of the staner sole-noid plunger for burning, pitting or any other defects. lfsurfacas are rough, recondition them with a strio of# 500 or #600 sandpaper.
soLEr{otDPIUNGER
Starter Reassembly
R€assemble the starter in the reverse order of disas-sembly.
1. Pry back each brush spring with a screwdriver, thonposition the brush about halfway out of its holder,
and release the spring to hold it there.
2. Instsll the armature in the housing. Next pry back
each brush spring again and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
a&T&'
s..
V BRUSH
3. Install the end cover on the brush holder.
23-85

Starting System
Performance Test
NOTE: Before staning the tollowing checks. disconnect
the wire Jrom te.minal M, and make a connection as
described below using as heavy a wire as possible {prefer-
ably equivalent to the wire used for the car).
Pull-in Coil Tasl:
Connect the batterv as shown. It the starter pinion pops
out, it is working properly.
GAUTION: Do not leavo the battery connectod for mora
than 10 seconds.
Hold-in Coil Tost:
Disconnect the battetv from the M terminal. lf the pin-
ion does not retract, the hold-in coilis working properly.
CAUTION: Do not l6ave tho battory Gonnected for moro
than 10 soconds.
23-86
Rotracting Test:
Disconnect the battery negative cable. ll the pinion
retracts immediately, it is working properly.
NOTE: Do not leave the battery connected tor more than
1O seconds.
Startoi Noioad Test:
1, Clamp the starte. firmly in a vise.
2, Connect the starter to the battery as shown and con-
tirm that the motor starts 8nd keeps rotating.
It the electric current and motor speed meet the
sDecifications when the battery voltage is at 11 V,
the staner is working properly.
Spacifications: 90 A or less {Eleciric curentl.
3OO0 rpm or more (Motor speodl