1994 HONDA INTEGRA fuel pump

Filter
Fuel Supply System
Fuel
a Do not smoko while wo*ing on tusl system.
Keop open tlame away ftom your wotk area.a While replaclng th6 tusl liher, be caletul to koop a safodistanc6 betweon battery torminals and any tool3.
The Juel filter should b€ replaced every 4 years or 60,0O0miles (96,OOO km), whichever comes f irst. or wheneverthe fuel pressure drops below the specilied value
127 5 - 324 kPa, 2.8 - 3. 3 kgJ/cmr, 40-47 psi (Bl 8C 1engine: 329-378 kPa, 3.35-3.85 kgf/cmr, 48-55psi) with the fuel pressure regulator vacuum hose dis-
connectedl afte. making sure that the tuel pump and thefuel pressure regulator are OK.
1 , Disconnect the battery negative cable trom the bat-
tery negative terminal.
NOTE; The LS and GS-R model radio may have acoded theft protection circuit, Be sure to get the cus-
tomer's code number before disconnecting the
batterv.
After service, reconnect power to the tadio and turn
it on. When the word "CODE" is displaved, enter
the customer's 5-digit code to restore radio
operation.
2. Place a shop towel under and around the fueltilter.
3. Relieve fuel pressure (see page 11-100).
4. Remove the special banio bolt and the fuel feed pipe
from the fuel tilter.
Remove the fuel filter clamp and tuel Jilter.
When assembling, use new washers, as shown,
NOTE: Clean the llared joint ot high pressure hoses
thoroughly before reconnecting them,
1 1-108
SPECIALBOLT33 N.m(3.4 kgt.h,25 rbf.ft)
SERVICE BOLT15 N.m ll.5 kgt.m,1 I rbr.ftl
WASHERReplace
1O ttl.m(1.O kgf.m,7 tbt.ftl

[":::,::-'
Eecause of its compact impeller design, the fuel pump is installed inside the fueltank, thereby saving space
ng the fuel line system.
FUEL PUMP
FUEL FILTER
FUEL PUMP BRACKET
FUEL PUMP CROSS SECTION lsido vi6rvl
IMPELLERS
CHECK VALVEPUMP CASING
The fuel oumo consists of a DC motor, a circumference flow pump, a relief valve for ptotecting the fuel lir
a check valve for retaining residual pressure, an inlet port, and a discharge port. The fuel pump assembly
the impellers (driven by the motor), the fuel pump casing {which forms the pumping chsmber), and the fuel p
OPERATION(1 ) When the engine is started. the PGi/t-Fl main relay actuates the fuel pump, and the motor turns togeth
impellers.
Differential pressure is generated by the numerous grooves around the impellers.
(2) Fuel entering the inlet porr flows inside the motor from the pumping chambe. and is forced through th
port via the check valve.
lf tuel flow is obstructed at the discharge side of the tuel line, the relief valve will open to bypass the
inlet port and prevent excessive fuel pressure.
(3) When the engine stops, the tuel pump stops automatically. However, a check valve closes by gravity t
residual pressure in the line, helping the engine to aestan more easily.
and simplify-
N lTop vi6w)
PORT
GROOVES
fuel line systems,
embly consists of
fuel pump cover.
together with the
rgh the discha.ge
ss the fuel to the
avitv to retain the
(cont'd)
PUMP COVER
FUEL PUMP ASSEMBLY CROSS SECTION
D|SCHARGE FORT ^ . tNLEr P
IMPELLER
11-109

Fuel Supply System
Fuel Pump (cont'dl
Tc.ting
@E o" not smoko during tho tesr. Koop openflrmo away fiom your work area.
lf you susp€ct a problem with the tuel pump, check thatthe lusl pump actually runs; when it is ON, you will hearsome noise if you hold your ear to the luel lill oon withthe fuel fill cap remov6d. The fuel pumD should run fortwo seconds, when ignition switch is first turned on. llthe fuel pump does not make noiss, check as tollows;
1. Removo the rear seat (see section 2O).
-'2. Remove the access panel.
3. Disconnect the 2P connector from the fuel pump.
CAUTION: 86 lure to tum th6 ignition switch OFFbotor6 disconnoctlng th€ wilos,
4. Connect the BLK|yEL @ wire 8nd YEL/GRN @ wirewith a iumpe. wire 8t the PGM-FI main relav con-
nectot.
l.t, .--/ re -Fl. . MAll{ RELAY
BL&YELJumper
Check that battery voltage is available at the tuel
pump connector when the ignition switch is turned
ON (positive probe to the YEL/GRN wire, negativeprobe to ths BLK/WHT wire).
ACCESSPANEL
side
YEL/GRN
a lf battery voltage is available, replace the fuel
pump.
a It there is no voltage, check the tusl pump ground
and wire harness {see page I 1-1 l2).
11-110
Roplacomont
@ oo not smoks whilo worklng on fuel syr-
tem. Kaop opon llamos away from your wolk araa.
1. Remove the rear ssats {soe section 2O).
2. Remove the access oanel.
3. Disconnect the 2P connector from the fuel pump.
4. Remove the fuel pump mounting nuts.
5. Remove the fuel pump trom the luel tank.
6. Install a new washer on the banio bolt, then install
Darts in the revers€ order of removal.
6 N.mlO.6 kgl.m,.4 tbt.ftl
27 .m(2.4 kgt.m,21 tbt.ftl

PGM-Fl Main Relay
Doscription
The PGM-Fl main relav actuallv contains two individual
rerays.
This relay is located at the lett side of the cowl.
One relay is energized whenever the ignition is on which
supplies the battery voltage to the ECM, power to the
fuel injectors, and power for the second relay.
The second relay is energized for 2 seconds when the
ignition is switched on, and when the engine is running,
to supply power to the fuel pump.
PGM-FIMAIN RELAY
FUEL PUMP
Relay Testing
NOTE: lf the car stans and continues to r
Fl main relay is OK.
1. Remove the PGM-Fl main relay.
2. Attach the battery positive terminalto
minal and the battery negative termir
1 terminal of the PGM-FI main relay. T
continuity between the No. 5 terminal
minal of the PGM-FI main relay.
a lf there is continuity, go on 10 ste
a lt there is no continuity, replace the
relay and retest.
To lGN. I
To GROUND
To ST. SWITCH
To ECM {47}
Attach the battery positive terminalto
minal and the battery negative termil
3 terminal of rhe PGM-Fl main .elav. Tl
there is continuity between the No. ;
No.6 terminal of the PGM-Fl main re
a lf there is continuity, go on to st€
a lf there is no continuity, replace th€
relay and retest.
Anach the battery positive terminalto
minal and the battery negative termil
1 terminalof the PGM-Fl main relay, Tl
there is continuity between the No. :
No. 4 te.minal of the PGM-Fl main r
a It there is continuitv, the PGM-FI mi
a lf there is no continuity, replace th(
relav and retest.
No.2
run, the PGM-
nalto the No. 2 ter-
terminal to the No.
lay. Then check for
minal and No. 4 ter-
to step 3.
ce the PGM-Fl main
8Ar C)
ECM {425, 81)
J To FUEL PUMP
inalto the No. 5 ter-
terminsl to the No.
ay. Then check that
No. 7 terminal and
ain relay.
to step 4.
ce the PGM-Fl main
inal to the No. 6 ter-
terminal to the No.
ay, Then check that
No. 5 terminal and
nain relay.
-Flmain relay is OK.
ce the PGM-Fl main
(cont'd)
11-111

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
Evaporative Emission Controls
(cont'dl
Evaporativ€ Emission {EVAPI Two Way Valvo Tasting
l. Remove the tuel fill cao.
2. Remove vapor line trom the two way valve on the
fuel tank and connect to T-fitting trom vacuum
gauge ano vacuum pump as snown.
VACUUM/PRESSURE GAUGEoTJAZ-OOI OOOa
A973X-041-XXXXX
fT-FITTING
Apply vacuum slowly and continuously while watch-
ing the gauge.
Vacuum should stabilize momentarilv at 5-15
mmHg (0.2-0.6 in. Hg).
a It vacuum stabilizes (valve opensl below5mmHg(O.2 in.Hg) or above I 5 mmHg (O.6 in.Hg), install
a new valve and retest.
Move vacuum pump hose from vacuum to pressure
titting, and move vacuum gauge hose trom vacuum
to oressure side as shown.
Pressure should stabilize at 1O-35 mmHg (0.4- 1 .4
in. Hg).
a lf p.essure momentarily stabilizes {valve opensl
at 1O-35 mmHg (O.4- 1.4 in.Hg), the valve is
oK.
a lf pressure stabilizes below 10 mmHg {O.4 in.Hg)
or above 35 mmHg (1 .4 in.Hgl, install a new valve
and retest.
4.
J-.
fF . -,-/ asr^:
,T 4?e
Slowly pressurize the vapor line while watching thegauge.
11-140

Connector ldentification and Wire Harness Routing
Roar wiro Harn$s (Hatchbsckl
Connector or
Torminal
Numbor of
CavitiosLocationConnecta tollotos
c501
c502
c503
c504
c505
c506
c507
c508
c509
LStt
c51 1
c512
c513
c514
c515
c516
c517
c5r 8
c519
c520
c521
c522
c523
c524
c525
c526
10'14
10
12
25
2
1
1
2
I
2
20
20
2
6
b
2
2
2
4
Behind left kick panel
Behind left kick panel
Behind dashboard lower cover
Behind dashboard lower cover
Behind dashboard lower cover
Driver's door
Center tloor
Center lloor
Left qusrter panel
Fuel tank
Fuel tsnk
Right quarter panel
Right quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left side corner of cargo area
L€ft side corner of cargo area
Left side corner of cargo area
Left rear corner of cargo area
Center ot cargo area bulkhead
Right rear cornor oJ cargo area
Center of cargo area bulkhsad
Right side of cargo area
Right side of cargo area
Main wire harness (C4211
Main wire harness (C422)
Under-dash fuse/relay box (C912)
Under-dash fuse/relay box (C91 5)
Dashboard wire harness (C554)
Driver's door wire harness {C6011
Driver's seat belt switch
Palking brake switch
Driver's door switch
Fuel pump
Fuel gauge sending unit
Passenger's door switch
Right rear speaket
Left rear speaker
Noise condenser
Connector C517
Connector C516
Power antenna motor
Cargo area light
Traile. lighting connector
LeJt taillight
License plate lights
Right taillight
Tailgate latch switch
Tailgate wire harness (C752)
Tailgate wire harness (C751)
G501
G502
G503
Behind left kick psnel
Left side of Jloor
Center ot cargo area bulkhead
Body ground, via rear wire
harness
Body ground, via rear wire
harness
Body ground, via rear wire
harness
23-28

Connector ldentification and Wire Harness Routing
Rear Wire HamsEs (S6danl
Connector ol
Torminal
Number ot
Caviti6sLocaiionConnocts toNotos
c501
c503
c504
c505
c506
c507
c508
c509
c510aEt t
c512
L9 IJ
c514
c515
c516
c517
c518
c519
c520
c521
c522
c523
c527
c52A
LCZY
c530
c531
c532
c533
c534
c535
c536
6
1,|
2
1
I
4
4
10
10
12
25
'I
1
a
1
2
2
20
20
2
6
4
4
6
Behind left kick panel
Behind left kick panel
Behind dashboard lower cover
Behind dashboard lower cover
Behind dashboard lowe, cover
Driver's door
Center floor
Center floor
Left B-pillar
Fuel tank
Fuel tank
Right B'pillar
Above right side of trunk
Above left side ot trunk
Left quarter panel
Left quarter panel
Left quarter panel
Left side corner of trunk
Above center of trunk
Left side corner of trunk
Left rear corner of trunk
Right rear corner of trunk
Right rear corner of trunk
Left ,ear door
Right rear door
LeJt quarter panel
LeJt side oJ rear window
Above right side of trunk
Right quarter panel
Right side of rear window
Left side ot trunk lid
Center ot trunk lid
Right side ot trunk lid
Main wire harness (C421)
Main wire harness (C422)
Under-dash tuse/relay box {C912}
Under-dash fuse/relay box (C915)
Dashboard wire harness (C554)
Driver's door wire harness (C6O l )
Driver's seat belt switch
Parking brake switch
Driver's door switch
Fuel pump
Fuel gauge sending unil
Front passenger's door switch
Right rear speaker
Left rear speaker
Noise condenser
Connector C517
Connector C516
Power antenna motor
Trunk light
Trailer lighting conneclor
Left outer taillighr
License plate lights
Right outer taillighr
Left rear door wire harness
(c651)
Right rear door wire harness
(c656)
Lett rear door switch
Rear window delogget (+ )
High mount btake light
Right rear door switch
Rear window defogger (- )
Left inner taillight
T,unk latch switch
Right inner taillight
G501
G502
G503
Behind lett kick panel
Left side of floor
Above center of trunk
Body ground, via rear wire
narness
Body ground, via rear wire
narness
Body ground, via rear wire
narness
23-30