1994 HONDA INTEGRA Valve cover install

Fuel Supply System
Fuel Tank
Replacement
@ oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.
1. Relieve the fuel pressure {see page 11-1OO).
2. Jack up the car and support with jackstands.
3. Remove the drsin bolt and drain the fuel into an approved container.
4. Remove the rear seat, access Danels and disconnect the 2P and 3P connectors.
5- Remove the EVAP two way valve cover and tuel hose protector.
6. Disconnect the hoses.
CAUTION:
a Whan disconnacling tho hosos, slide back tho clampr, th6n twist horos as you pull, to lvold drmlglng thcm.
a Clean the tlarod roint ot high plossulo hosos thoroughly brforc roconnccling thsm.
7. Place a jack. or other support, under the tank.
8. Remove the strao nuts and let the straDs tall free.
9. Remove the Juel tank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, caretully pry it off tho mount,
1O. Install a new washer on the dlain bolt, then install psns in the raverse ordgr ot rsmoval.
FUELPUMP
EVAPTWO WAY VALVE
38 l{.m(3.9 kgt'm,28 rbl.ftl
FUELTANK
EVAPTWO WAYVALVECOVER
FUEL TAI{KSTRAPS
tO t{.mll.O kgt'm,7 lbl.frl
11-114

NOTES
A.See flushing procedure, page l4-168 and 169.
B.Set idle rpm in gear to specitied idle speed. lf still no good, adiust motor mounts as outlined in engine
section of service manual.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining.
lf the clutch pack is seized or is excessively worn, inspect the other clutches Jor wear, and check the
orifice control valves and throttle valves for free movement.
E.It throttle valve B is stuck, inspect the clutches for wear.
lf the 1-2 shift valve is stuck closed, the transmission will not upshift. lI stuck open, the transmission
has no lst gear.
H.lf the 2-3 orifice control valve is stuck, inspect the 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressure control valve is stuck closed, the transmission will not shilt out of 1st gear.
K.improper alignment or main valve body and torque converter housing may cause oil pump seizure. The
symptoms ale mostly an rpm-related ticking noise or a high-pitched squeak.
L.ll the ATF strainer is ctogged with panicles of steel or aluminum, inspect the oil pump and ditferential
pinion shaft. lt both are OK and no cause lor the contamination is found, replace the torque converter.
M.lf the 1st clutch feedpipe guide in the right side cover is scored by the mainshaft, inspect the ball bear-
ing for excessive movement in the transmission housing. lf OK. replace the right side cover as it is dent-
ed. The O-ring under the guide is probably worn.
N.ReDlace the mainshstt if the bushing for the 4th feedpipe is loose or damaged.
It the 4th feedpipe is damaged or out ot tound, replace the right side cover'
Replace the subjshaft it thtbushing for the 1st-hold Jeedpipe is loose or damaged.
lf the 1st-hold feedpipe is damaged or out of round, replace it.
Replace the mainshaft if the bushing lor the 1st feedpipe is loose or damaged.
lf the lst feedpipe is damaged or out ot round, replace it.
o.A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse, such as rocking the car in snow.
P.InsDect the frame for collision damage.
o.Inspect for damage or wear:
1. Reverse selector gear teeth chamfers.
2. Engagement teeth chamters of countershaft 4th and reverse gear.
3. Shift fork for scutt marks in center.
4. Differential Dinion shaJt for wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replace items 1 , 2, 3 and 4 it worn or damaged. lf transmission makes clicking, grinding or.whirring
noise, atso replace mainshaft 4th gear and reverse idler gear and countershaft 4th gear in addition to
1,2,3ot4.lf ditiersntial Dinion shaft is worn, overhaul differential assembly, and replace ATF strainel, and thoroughly
clean transmission, tlush torque convertet, cooler and lines.
lf bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershaft and tinal
driven gear.
R.Be wry careful not to dsmage the torque converter housing when replacing the main ballbearing. You
may al;o damage the oil pump when you torque down the main valve body. This will result in oil pump
seizure it not detected. Use proper tools.
qInstall the main seal tlush with the torque converter housing, lf you push it into the torque converter
housing until it bottoms out. it will block the oil return passage and result in damage.
T,Harsh do\/vnshiJt"\./l,'hen coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
retainer/cam stopper. Throttle cable adjustment may clear this problem.
ifuitle cable adjustment is essential for proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cable adjusted too long will result in throttle pressure being too low for the amount of engine torque
input into ihe trsnsmission and may cause clutch slippage. A cable adjusted too short will result in too
hi;h throttle pressure which may cause harsh shitts, erratic shrfts and torque con
14-89

2.
1.Install the ATF magnet and suction pipe collar in the
torque converter nousrng.
Install the main separator plate with two dowel pins
on the torque converter housing. Then install the oil
pump drive gear, driven gear and driven gear shalt.
NOTE| Install the oil pump driven gear with its
grooved and chamtered side facing down.
OIL PUMPDRIVE GEAR
OIL PUMPORIVEN GEAR
Grooved and chamferedside faces separatorplate.
J.Loosely install the main valve body with Iour bolts.
Make sure the oil pump drive gear rotates smoothly
in the normal operating direction and the oil pump
driven gear shaft moves smoothly in the axial and
normal operating directaons.
Install the secondary valve body, separator plate and
two dowel pins on the main valve body.
Installthe control shaft in the housing, with the con-
trol shatt and manual valve togelher.
Install the detent arm and arm shatt in the main valve
body, then hook the detent spring to the detent arm.
SERVO SEPARATOR PLATE
--- 8ixli"'
6.
36
DETENTSHAFT
DETENT ARM
MANUAL VALVE
DETENI SPRING
17. Install the oil feed pipes.
14-157
E'.:
7. Install the servo body and separator plate with six
bolts.
8. lnstall the accumulator cover with three bolts
9. lnstall the servo detent base and ATF strainer with
three bolts and new lock washers.
10. Tighten the four bolts to 12 N.m (1.2 kgf'm, 8.7
lbf.ft) on the main valve body.
Make sure the oil pump drive gear and oil pump
driven gear shaft move smoothly same as in the step
11. lf the oil pump drive gear and oil pump driven gear
shaft do not move freelY. loosen the four bolts on
the main valve body and disassemble the valve
bodies.
Realign the oil pump driven gear shaft and reassem-
ble the valve bodies, then retighten the bolts to the
specified torque,
CAUTION: Failure to align the oil pump d1iv6n gear
shaft corroctly will result in a seized oil pump drivo
geal of oil pump drivon gear shatt.
l\
(...l
=..N
L,1ffi#
j-*/:
OIL PUMPDRIVE GEABOIL PUMP OIL PUMPDRIVEN GEAR DRIVEN GEARSHAFT
12. Install the stator shaft and stopper shatt.
13. Install the stopper shatt stay on the secondary valve
body with the bolt.
14. Install the regulator valve body with the bolt.
1 5. Install the torque converter check valve, cooler check
valve and valve springs in the requlator valve body.
16. Install the lock-up valve body, separator plate, two
dowel pins and lubricator plate with the eight bolts.
(cont'dl

7.Submerge the valve in a container of power steer-
ing fluid or solvent, and blow in the hose. lf air bub-
bles leak through the valve at less than 100 kPa
11.0 kgf/cm,, 14.2 psi), replace or repair it as follows.
AIR PRESSURE
i- POWER STEEBINGFLUID or SOLVENT
8, Hold the bottom end of th€ valve with a oDen end
wrencn.
9. Unscrew the seat in the top end of the valve, and
remove any shims, the relief check ball, relief valve
and relief valve spring,
REUEF VALVERELIEF CHECK BALL
sHrM(sllf us€d.SEAT13 N.m11.3 ks[.m, I lbf.tt]
Clampthis end ina vise with sott iaws.
FLOW CONTROL VALVE REUEFvALvESPBING
10. Clean all the parts in solvent, dry them off, then
reassemble and retest the valve. Sge page 17-43 for
f low control valve installation.
NOTE: lf necessary, relief pressure is adiusted at
the facto.y by adding shims under the check ball
seat. lf you found shims in your valve, be sure you
reinstall as many as you took out,
')4.
nlll
Pump Rotor Removal
CAUTION: Tho pump components are made ot alu-
minum. B€ car6ful not to damage them when servicing.
1. Remove the inlet joint and O-rjng.
13 x 1.9 mmO.RINGReplac€.
2. Remove the pump cover and O-ring.
PUMP COVER
58.5 x 1.5 mmO.RINGFeplace.
(cont'd)
17-37

Flow Gontrol Valve Installation
1. Apply steering grease (Honda P/N 08733 - B070E) to
new O-rings.
2. Coat the flow control valve with clean power steer-
ing fluid.
3. Install the flow control valve, spring and control
valve cover on the pump housing.
4. Tighten the three control cover bolts.
FLOW CONTROLVALVE
SPRING
E;W
11 N.m {1.1 kgl.m,8lbtftl
2
Pulley Installation
1. Hold the steering pump in a vise with soft jaws.
CAUTION: Be careful not to damago the pump
hou3ing with the laws ol th€ vise.
2. Install the pump pulley as shown. Then install the
pulley nut.
Hold the pulley with the special tool and tighten the
pulley nut.
PULLEY NUT6ir N.m (6.5 kgt.m,47 lbt tt)
Check that the pump turns smoothly by turning the
pulrey.
PULLEY NUT
PULLEY
17-43

lnstallation
CAUTION; BG Glrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1. Before installing the gearbox, slide the rack all the
way to right.
2. Pass the right side of the steering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack all the
wav to the left.
4. Raise the left side of the steering gearbox above
and through the left side of the rear beam.
5. Install the pinion shaft grommet and insert the pin-
ion shaft up through the bulkhead.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodv.
6. Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
hose connactions for interference with adjacent
pans.
58 N.m 15.9 kg[.m, $ lbl.ftl
TAA
38 N m 13.9 kgl.m, 28 lbt.ftl
17-63
YELLOW GEAR TOOTH
7.Center the steering rack within its stroke.
Make sure that the cable reel of the SRS is centered
as follows:
. Turn the steering wheel left approx. 150 degrees,
to check the cable reel position with indicator.
. lfthe cable reel is centered. the yellow gear tooth
lines up with the alignment mark on the cover.
. Return the steering wheel right approx. 150
degrees to position the steering wheel in the
straight ahead position.
ALIGNMEi'IT MARK
Slip the lower end of the steering joint onto the pin-
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.
. Be sure that the lower steering ioint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
. lf the steering wheel and rack are not centeted,
reposition the serralions at lower end of the
steering joint.
(cont'dl
22 N.m 12.2 kgi.m, 16lbf.ftlLOWER BOLT

Steering Gearbox
Installation (cont'd)
10. Install the steering joint cover with the clamps andcliDs.
STEERING JOINT COVER
11. Connect the fluid lines to the valve bodv unit.
CLIP
RETURN HOSE
17-64
38 N.m 13.9 kg{.m, 28 lbf.ft)
12. Install the rear beam brace rod and return pipe
clamp on the rear beam.
NOTE: Install the rear beam brace toward thereturn pipe clamp.
13. Install the three way catalytic converter with thenew gaskets and new self-locking nuts, and connectthe heated oxygen sensor (H02S) connector,
HEATED OXYGEN SENSOR CONNECTOF
SELF.LOCKING NUT33 N.m 13.4
SELF.LOCKING NUT22 N.m (2.2 kgt m, 16 lbt.ftl
14. Connect the shift linkage (M/T model: see section
13, A/T model: see section 14).

A/C System Service
Leak Test
Only use 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: Exposura to air condition ratrigerant and
lubaicant vapor or mist can irritato oyes. nose and
throat. Avoid br€athing tho sir conditionsr reftigolant
and lubricant vapor or mist.
lf accidental svstem discharge occurs, ventilate work
area before resuming service.
R-134a service equipment or vehicle air conditioner sys-
tems should not be pressure tested or leak tested with
comoressed air.
@ some mixturos ot air and R'13'la have
b.6n shown to b€ combustible at glsvated pressur€s
and can result in firo or sxplo3ion causing iniury or
proporty damage. Ngvar uso compress€d tir to pro33ure
tost R-134a $rvics oquipmont or vohicl€ air Gonditionsr
systcms.
Additional health and satetY information may be ob-
tained from the refrigerant and lubricant manufactures'
1. Connect a R-134a retrigerant Recovery/Recycling/
Charging System to the car. as shown, following
the equipment manufacturer's instructions.
NOTE: Be sure to install the same amount of new
refrigerant oil back into the A/C system before
chargtng.
2. Open high pressure valve to charge the system to
about 98 kPa (1.0 kgf/cm', 14 psi), then close the
supply valve.
3. Check the system for leaks using a R-134a refriger-
ant leak detector with an accuracy of '!4 g {0.5 oz)
per year or better.
4. lf you find leaks that require the system to be
opened (to repair or replace houses, fittings, etc.),
recover the system according to the Recover
Procedure on page 22-22.
5. Aiter checking and repairing leaks, the system must
be evacuated (see System Evacuation gn page 22-
38).
Rocov.ry/R.cycling/Ch.tging Sy3tcm
LOW PRESSURESIDE
HIGHSIDE
22-40