1994 HONDA INTEGRA cks

How to Read Flowcharts
A flowchrrt is dasigned to be us€d fiom start to final repair. lt's like a map showing you the shortest distanco. But be-
ware: if you go off tho "map" anywhere but a "stop" symbol, you can easily get lost
l6rffil Desclibas the conditions or situation to start a troubleshooting flowchart.(bold tyDo)
|TeTiONl Asks you to do something; pedorm a test, set up a condition etc'
<:6Eei6io-fr\> Asks you about the result of an action, then sends you in the appropriste troubleshooting direction.
I-SJTFI The snd of a series ot actions and decisions, describes I tinal repair action and aomotimea diracts
(bold typel you to 8n garlier part of the tlowchart to confirm your repair'
NOTE:
a Tha tarm ,,lntormittgnt Failure" is used in these chans. lt simply means a system may have had a failur6, but it chocks
out OK !t this time. lf th6 Msltunction Indicator Lamp (MlL) on ihe dash does not come on, check for poor connections
or loose wires at all connectors rolated to the cilcuit that you are troubleshooting (see illustration b6low).
a Most ot tho troublashooting flowchans have you reset the Engine Control Module (ECM) and try to duplicate the Disg-
nostic Troubls Cod6 (DTC). lf the problem is intermittent and you c8n't duplicat€ the cod6, do not continus through
the flowchart, To do so will only rosult in confusion and, possibly, a ne€dlessly replaced ECM
a ,,opon,'and ,,short,, are common electrical terms. An open is a break in a wir6 or at a conn€ction. A short is an
accidontal connaction ot a wir€ to ground or to another wire. In simple electronics, this usually means som€thing won't
work at all. In complex electronics (like ECM's), this can sometimes mean something wolks, but not the way it's sup-
poSad to,
a il th6 olectricsl readings are not as specified when using the test harness, check the test harness connoctions bsfore
procooding.
LOOSE
11-39

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

Emission Control System
Three Way Catalytic Converter (TWC) (cont'dl
Inspection
lf sxcessive oxhaust system back-pressure is suspected. remove the TWC trom the car and make a visual check for plug-
ging, melting or cracking of ths catalyst. Replace the TWC if any of the visible area is damaged or plugged.
81881 ongino:
TI{REE WAYCATALYTICCONVERTER {TWCIRemovsl/installation, see section 9
Inspect housing for cracks orother damage.Inspect element tor cloggingby looking through the inside.
HEAT SHIELD
11-132
T SHIELO

818Cl engine:
HEAT SHIELO
r{
THREE WAYCATALYTICCOI{VEBTEB {TWCIR€moval/installation. sso s€ction 9Inspoct housing tor cracks orothor damage.Inspect elemont for cloggingby looking through the inside.
HEAT SHIELD
11-133

Emission Control System
Positive Crankcase Ventilation (PCVI System
Description
The Positive Crankcase Ventilation (PCV) system is
designed to prevent blow-by gas {rom escaping to the
atmosphsre. The PCV valve contains a spring-loadsd
plunger. When the Bngine starts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into th€ intak€
manifold.
FCV VALVE
.F: ILOW-BY VAFORer FRESH AIR
11-134
Insp€cdon
1. Check th€ PCV hos6s and connections tor lsaks and
clogging.
At idle, mak6 sur€ th6fe is a clicking sound from th6
PCV valve when the hose between rcV valve and
intake manifold in lightly pinched with your fingors
or oli€rs.
a lf thera is no clicking sound, ch6ck the PCV valve
grommet for cracks or damage. ll the grommet
is OK, reolace the PCV valve and recheck.
2.
SREATHER
Gontly pinch hero.

Adjustment
NOTE:
a To check the clutch interlock switch and clutch
switch, see seclion 23.
a The clutch is selt-adjusting to compensate for wear.
CAUTION: It there is no clearanco between the mastel
cylinder piston and push lod. the releaso boaring is held
againsl the diaphragm spring, which can result in clutch
slippage 01 othel clutch problems.
Loosen locknut A, and back otf the clutch switch
{or adjusting bolt) until it no longer touches the clutch
pedal.
Loosen locknut C, and turn the push rod in or out
to get the specified stroke (@) and height (O) at the
clutch pedal.
Tighten locknut C.
Turn the clutch switch (or adjusting bolt) until it con-
tacts the clutch pedal.
Turn the clutch switch (or adjusting bolt) in 3/4 to
1 full turn further.
Tighten locknur A.
7. Loosen locknut B and the clutch interlock switch.
8. Measure the clearance between the tloor board and
clutch pedal with the clutch pedal tully depressed.
9. Release the clutch pedal 15-20 mm {O.59-O.79
in) from the fully depressed position and hold it there.
Adiust the position of the clutch interlock switch so
that the engine will start with the clutch pedal in this
oosition.
1 0. Turn clutch interlock switch 3/4 to 1 tull turn funher.
11. Tighten locknut B.
LOCKNUT B9.8 N.m (1.0 kgf.m, 7 lbf.ftl
CLUTCH INTERLOCKswtrcH
6.
1.
2.
ASSIST SPRING
-6ll
LOCKNUT Cl3 N.m l'l.3 kgf.m, 9
CLUTCH SWITCH{or AOJUSTING BOLTI
LOCKNUT A9.8 {N.ml (1.0 kgl.m, 7 lbt.ftl
(STROKE at PEDALI: 130-140 mm 15.12-5.51 in){TOTAL CLUTCH PEDAL FREE PLAY): 12-21 mm 10.47-0.83 inl including tho p.dal play I -lO mm 10.04-0.39 inl{CLUTCH PEDAL HEIGHTI: 164 mm (6.46 in} to tho lloot{CLUTCH PEDAL DISENGAGEMENT HEIGHTI: 83 mm 13.27 inl minimum to tho lloo.
PUSH ROD
CLUTCH MASTER CYLINDER
Clutch Pedalctutch Pedat I
[-],ll'"-"" f
| :;i:'":fff*tr#:?iff:".,*::,::". | .#::J:::
sb''''""
| |
| "orr,O", It there is no clearanco between the master | ,. aoo""n locknut B and the clutch intertoct switcl. | |cylinder piston and push lod. the releaso boaring is held | | Iagainst the diaphragm spring, which can result in clutch | 8. Measure tne clearance between the floor board and I Islippage 01 othel clutch problems.
I
clutch pedal with the clutch pedal tully deeressed.
I I1. Loosen locknut A, and back otf the clutch switch | 9. Release the clutch pedal 15-2O mm (O.59-O.79 I I
{or adiusting boltl until it no longer touches the clutch I int trom ttre fully depressed position and hold it there. I I
, ::":"" rocknut c, and rurn the push rod in or out | iliiiliffi:l1l:J"'1"-:H"l:tJ:i"i#fT: I I
. il*:*j':"'-(@)andheisht(olatthe
|
,:.;:,nterrockswitch3/4torrurrturnturtner.
I tf
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I I

Pressure Plate
RING GEAR HOLDER07LAB-PVOOl OO or07924-PD20003
Removal/lnspection
Check the diaphragm spring fingers for height us-
ing the special tools and a feeler gauge.
Standard lNew): 0.6 mm (0.02 inl Max.
Service Limit: O.8 mm {O.O3 in}
FEELER GAUGE
07NAF-PR3010007936-3710100
. lf the height is more than the service limit, replace
the pressure plate.
2. Install the special tools.
3. To prevent warping, unscrew the pressure plate
mounting bolts in a crisscross pattern in several
steps, then remove the pressure plate.
CLUTCH ALIGNMENT SHAFT07NAF-PR30100HANDLE07936-3710'l OO
PRESSURE PLATE
CLUTCH ALIGNMENT OISCOTJAF_PM7011A
4.Inspect the pressure plate surface
and burning.
Inspect the fingers of the diaphrag
at the release bearing contact ar
DIAPHRAGM SPRING
Inspect for warpage using a stru
er gauge.
NOTE: Measure across the prer
pornls.
Standard (Newl: 0.03 mm (0.0
Sorvice Limit:0.15 mm (0.0O6
STRAIGHT EOGE
FEELER GAUGE
PI
lf the warpage is more than
replace the pressure plate.
6.
I surface for wear, cracks,
diaphragm spring for wear
nracr area.
PRESSURE PLAT€
straight edge and feef
pressure plate at three
0.001 in) Max.
)O6 inl
12-7

InspectionReplacement
Flywheel, Flywheel Bearing
Inspect the ring gear teeth for wear and damage.
Inspect the clutch disc mating surface on the
flywheel fo. wear, cracks, and burning.
Measure the flywheel runout using a dial indicator
through at least two full tu.ns. Push against the
Ilywheel each time you turn it to take up the crank-
shaft thrust washe. clearance.
NOTE; The runout can be measu.ed with engine in-
stalled.
Standard (ttlervl: O.O5 mm (O.002 inl Max.
Service Limit: 0.15 mm 10.006 inl
RING GEABFLYWHEEL
DIAL II{DICATOR
It the runout is more than the service limit, leplace
the flvwheel.
Turn the inner race of the flywheel bearing with your
finger. The bearing should turn smoothly and quiet-
ly, Check that the bearing outer race fits tightly in
the flvwheel.
FLYWHEELBEARING
It the race does not turn smoothly, quietly, or fit
tight in the flywheel, replace the flywheel bearing.
Install the special tool.
Remov€ the flywhe€l mounting bolts in a criascross
pattern in several steps 8s shown, then remove the
tlywheel.
MOUI{TII{G BOLTS
3. Remov€ the flywheel bsaring from th€ tlywheel.
(cont'd)
FLYWHEEL
12-9