1994 HONDA INTEGRA clutch

Fuel Supply System
PGM-Fl Main Relay (cont'dl
BLU
BLU/wHt
Bt-xNOTE:. M/T: Clutch pedal mustbe depressed.. A/T: Transmission in
N or E] position.
BLK/ YEL/YEL BLK
Tloubloshooting
{To page 11 113}
- Engino will not sran.- Inspection oI PGM-FI main re-lay and rolay ha.n6!a.
Check lor continuitv between BLKterminal @ and body ground.
Rapair open in BLK wire botwoonPGM-FI main.el6y and GIO'l llo-catod at thormostot housingl.
Measure the voltage betweenYELMHT terminal @ and bodyground.- Roplaco th. ECU IECMI(15 Allus6 in tho under-hood fu!o/r6-lay box.- Ropair opan or short in theYEL/WHT wil6 botwosn thePGM-FI main rolay and the ECU
{EcMl 115 A} luso.
ls there battery voltage?
Turn the ignition switch ON.
Measure the voltage betweenBLK/YEL terminal @ and bodyground.- Reolac. ths No. 24 ACG {ALT}{lcl {15 A:81881 6ngino, 20A: Bl8Cl engin6) tuse in thoundor-dash fuso/rolaY box.- Ropaii op6n or rhon in thoBLK/YEL wiro botwoen thoPGM-FI main ielay and th€ No.24 ACG {ALT) flG} {'15 A:818Bi ongine, 20 A: 818Cionginol fuso.Turn the ignition switch to theSTART position.
Measure the voltage betweenBLUMHT terminsl @ and bodyground.
- Replaco the l\lo. 18 STARTERSIGNAL {7.5 A} fuso in thoundor-dash fuaa/rolay box.- R6pai. open or short in thoBLU/WHT wire botweon thsPGM-FI main relay and tho No.1A STARTER SIGNAL I7.5 AIluse.
11-112

Transaxle
Clutch
Manual Transmission ......................
Automatic Transmission ..................
Differential
Manual Transmission
81881 engine
818C1 engine
Automatic Transmission ...............
Driveshafts
12-1
13-1
14-1
15-1
15-9
15-19
16-1

Glutch
Speciaf Tools ........ ........ 12-2
fffustrated Index ........ .... 12-3
Clutch Pedal
Adjustment ................12-4
Clutch Master Cylinder
Removal/lnstallation .... 12-5
Slave Gylinder
Removal/lnstallation .... 12-6
Pressure Plate
Removal/lnspection ..... 12'7
Clutch Disc
lnspection/Removal ..... 12-8
Flywheel, Flywheel Bearing
fnspection . 12-9
Replacement ............................... 1 2-9
Clutch Disc, Pressure Plate
Installation 12-10
Release Bearing
Removal/lnspection12-11

Special Tools
Ref. No, I Tool NumberDescriptionOty Page Reference
o/^
ri)
@
@
OTJAF_PM7011A
OTLAB PVOO1 OO or
o7 924-PD20003
07NAF-PR30100
07746-0010100
07749-OO10000
07936-3710100
Clutch Alignment Disc
Ring Gear Holder
Clutch Alignment Shaft
Attachment, 32 x 35 mm
Driver
Handle
'I
1
I
1
I
I
12,7
12-1, 8, 9, 10
12-7 , 8, 10
12-10
12-10
12-1 , 8, 10
I
12-2

lllustrated Index
NOTE:
a Whenever the transmission is removed, clean and grease the release bearing sliding sudace.
a It the pans marked r are removed. the clutch hydraulic system must be bled (see page 12-6).
a Inspect the hoses lor damage, leaks, interterence, and twisting.
*RESERVOIR
HOSEASSISI SPRING
PEDAL PIN
CLUTCH PEDALAdjustment,page 12-4
15 N.m 11.5 kgl.m,11 tbt.ftl
6 x 1,0 mm9.8 N.m ll.0 ksf.m, 7 lbf.tt)
FLYWHEELInspection. page 12-9Replacement, page 12-9
TCLUTCH MASTER CYLINDERRemoval/lnstallation, page 1 2-5
19 N.m ll.9 kgt.m,14 lbf.ftl
.CLUTCH PIPE
15 N.m {1.5 kgl.m,1 1 rbf.ft)
ICLUTCH PIPE
JOtt{T
8 x 1.25 mm25 N.m (2.6 kgl.m,19 lbt.ttl
RELEASE BEARINGRomovaf /lnspection, page 1 2-1 1lnstaffation, page 1 2- 1 2
TRANSMISSIONRomoval. see
CLUTCH DISCRemoval/lnspection. page'1 2-8Installation, page 12-10
8 x 1.25 mm22 N.m (2.2 kgf.m.16 lbl.rr)
section 1312 x 1.0 mm103 N.m llO.5 kgt.m,76 rbf.ftl
PRESSURE PLATERemoval/lnspection. page 1 2-7Installation, page 12,10
TSLAVE CYLINDERRemovaf /lnstallation. page 1 2-632 N.m {3.3 kgf'm,24 tbf.ftl
15 N. m {1.5 kgf.m,'| I tbf.ftl
COTTERBeplace.
I
NInl
9t
v-_fl
ICLUTCH
12-3

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
,
::
***r**''
.,".,u"**;
|
'-"'"'';*1,,0*.,.-,.,*,
I I

Clutch Master Cylinder
Removal/lnstallation
CAUTION:
a Do not sgill b.ake lluid on the car; it may damags the
painl; it biake fluid does contact tha paint. wash it
otf immediately with water.
a Plug lhe end ot the clutch pips and r€servoil hose with
a shop towel to prsvent blake fluid ttom coming out.
1. Remove the brake fluid from the clutch master
cylinde. reservoir with a syringe.
2. Disconnect the clutch oioe and reservoir hose from
the clutch master cvlinder.
CLUICH PIPE15 N'm {1.5 kgl.m,1 1 tbf.ftl
CLUTCHMASTERCYLINDER
Pry out the cotter pin. and pull the pedal pin out ot
the yoke. Remove the nuts.
NUTS13 N.m {1.3 kgf.m,9 lbt.frl
Remove the clutch master cylinder.
NOTE: Do not spill brake fluid on the
cylinder damper.
OAMPERCLUMAIcYL
Install the clutch master cylinder in
der of removal.
NOTE: Bleed the clutch hydraulic s\
12-61.
clutch master
CLUTCHMASTERCYLINDER
!l rn Ine reverse or-
c system (see page
12-5

Slave Cylinder
Removal/lnstallation
CAUTION:
a Do not spill brake tluid on the car. it may damago tho
paint; it brake tluid doos conlacl tho paint, wash it
off immediately with watei.
a Plug tho €nd of the clutch pipe with a shop lowsl to
plevcnt b.ake fluid from coming out.
-61, Super High Temp Urea Grease {P/N
08798-9002).
: Brake Assembly Lube or equivalent rubber
grease.
Disconnect the clutch pipe from the slave cylinder.
Remove the slave cylinder from the clutch housing.
'1.
BOOTRemove and check for signs ol leaking and deterioration.
Install the slave cylinder in the reverse order ol
removat.
NOTE: Make sure the boot is installed on the slave
cylinder.
CLUTCH PIPE15 N.m (1.5 kgf.m, 11 lbf'ftl
SLAVE CYLINOER
-90021-Cl
tP/N 08798
8 x 1.25 mm22 N.m 12.2 kgl'm,16 rbt'ft)
4.
:^....:: Gil^lt i
(Brake A$embryLubol
Bleed the clutch hydraulic system.
a Attach a hose 1o the bleeder screw, and suspend
the hose in a container oJ brake fluid.
a Make sure there is an adequate supply of tluid at
the clutch master cylinder. then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
a Refill the clutch master cylinder with fluid when
done.
a Use only DOT 3 or 4 brake tluid.
12-6