1994 HONDA INTEGRA maintenance

INTRODUCTION
How to Use This Manual
This manual is divided into 23 sections. The first page of each sec-
tion is marked with a black tab that lines up with its corresponding
thumb index tab on this page and the back cover. You can quickly
tind the tirst page of each section without looking through a full ta-
ble of contents. The svmbols printed at the top corner of each page
can also be used as a quick reference system.
Each section includes:
1. A table of contents. or an exploded view index showing:
a Parts disassemblv sequence.
a Bolt toroues and thread sizes.
a Page references to descriptions in text.
2. Disassemblv/assembly procedures and tools.
3. InsDection.
4. Testing/troubleshooting.
5. Repair.
6. Adiustments.
Special Information
@ lnai""tes a strong possibility of sevor€ pelsonal iniury
01 loss of life it instructions al€ not tollowed.
CAUTION: Indicates a possibility ot personal inlury or oquipmont
damage if instructions ale not followed.
NOTE: Gives helpful information.
CAUTfON: Detaifed doscriptions ot standad workshop procedures,
salety principlos and servica opelations are not included Pleaso note
that this manual conlains warnings and cautions against somo spocif-
ic sgrvice methods which could cause PERSONAL INJURY, damage
a vehicle or make it unsafe. Pleaso understand that those warnings
cannot cover all conceivablc waYs in which service, whethea or not
recommended bv HONDA, might be done, or of the possibla
hazardous consequences of svery conceivable way, nor could
HONDA investigate all such ways. Anyone using seryice plocedures
or toofa, whethor 01 not recomonded by HONDA, ,nust sttisfY him-
sett thoroughly that neither personal saf€ty nor v€hicle safety will
be jaopaldized.
All information contained in this manual is based on the latest product
information available at the time of printing. We reserve the right
to make changes at any time without notice. No part of this publica-
tion mav be reproduced, stored in retrieval system, or transmitted,
in any Jorm by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of the
publisher. This includes test. figures and tables.
Specificationstrtl:{lt'
Maintenance4Pi
Engine
H
I-""
Fuel and Emissions Za
*Transaxle
*Steeringr-\
lDl\.t/
* Brakes
(lncludins !TEg)o
*Electrical J--*
(lncludins ISBE)
First Edition 7/93 1448 pages
All Rights Reserved
Specifications Apply to U.S.A. and Canada
HONDA MOTOR CO.,LTD,
Service Publication ottice
As sections with r includ€ SRS components.
special precautions are lequiled when servicing.

Maintenance
Lubrication Points .........4-2
Maintenance Schedule ." 4'4

Maintenance Schedule
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Maintenance Schedule
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4-6

Manual Transmission
Special Toofs ............. 13-2
Maintenance
Transmission Oi1,...,........,........,.,..... 13-3
Back-up Light Switch
Replacement ......... 13-3
Transmission Assembly
Removal ..,.......,...... 13-4
lllustrated Index ................................... 13-8
Transmission Housing
Removal ...........,..... 13-10
Reverse Change Holder, Reverse ldler Gear
Glearance lnspestion ....................... 13-1 1
Removaf ................. 13-12
Change Holder Assembly
Clearance Inspection ....................... 1 3-1 3
Removal ................. 13-15
Disassembly/Reassembly ............... 13-16
Mainshaft, Gountershaft, Shift Fork
Removal ...,............. 13-17
Shift Rod
Removal ................. 13-18
Shift Fork Assembly
Index ................ ...... 13-19
Clearance Inspection ....................... 13-20
Mainshaft Assembly
Index ................ ...... 13-21
Clearance f nspection ....................... 13-22
Disassembly .......... 13-25
Inspection .............. 13-26
Reassembly ........... 13-21
Countershaft Assembly
Index ................ ...... 13-28
Clearance Inspection ....................... 13-29
Disassembly .......... 13-30
Inspection .............. 13-31
Reassembly ........... 13-32
Synchro Sleeve, Synchro Hub
Inspection .............. 13-34
Installation ............. 13-34
Synchro Ring, Gear
lnspection .............. 13-35
Clutch Housing Bearing
Replacement ......... 13-36
Mainshaft Thrust Clearance
Adiustment ............ 13-38
Transmission
Reassembly ........... 13-tl1
Transmission Assembly
lnstallation ............. 13-46
Gearshift Mechanism
Overhaul ................ 13-50

- Transmission Oil
NOTE: Check the oil with the engine OFF, and the car on
level ground.
1. Remove the oil filler plug, then check the level and
Maintenance
condition of the oil.
OIL FILLER PLUG44 N.m lia.5 kgf.m,
ORAIN PLUG$ N.m 14.0 kgf.m.29 lbf.fr)
33 tbtftlProper Level
2. The oil level must be up to the filler hole. lf it is
below the hole. add oil until it runs out, then rein-
stall rhe oil filler plug.
3. lf the transmission oil is dirty, remove the drain
plug and drain the oil.
4. Reinstall the drain plug with a new washer, and
refillthe transmission oil to the proper level.
NOTE: The drain plug washer should be replaced at
every oil change.
5 Reinstall the oil filler plug with a new washer.
OilCapacity
2.2 ( ''2.3 US.qt,1.9 lmp.qt) at oil chang€.
2-3 I l2.1Us.ql,2.0lmp.qtl at oyerhaul.
Use only SAE 10 w - 30 or '10 W - 40, API Service
SF or SG grade.
OIL FILLER PLUGa4 N.m l{.5 kgf.m, 33 lbf.ftl
Back-up Light Switch
Replacement
NOTE: To check the back-up light switch,
1. Disconnect the connector, then rem(
light switch connector trom the conn
2. Remove the back-up light switch.
BACX-UP LIGHT SWITCH25 N.m 12.5 kg[.m, 18 lbf.ftl
lnstall the new washer and the back-
Check the transmission oil level (see
Replace.
/itch, see section 23.
remove the back-up
]onnector clamp.
-up light switch.
) page 13-3).
Replace.
13-3

't 7.Make sure the transmission is in @ position.
Then fill the transmission with ATF and run the en-
gins tor 30 saconds or until spproximately ons quart
iB discharged.
Rsmove the drain hose and reconnect the cooler
return hoae to th€ transmission.
Refillth€ trsnsmission with ATF to the prop€r levol.
18.
19.
FILLER CAP
TOOL MAINTENANCE
1. Empty and rinse aftor each use. Fill the can with
water and pressurize the can. Flush the discharge
line to ensure that the unit is clean.
2. lf discharge liquid does not toam, the orifice may be
blocked.
3. To clean, disconnect the plumbing trom the tank 8t
the large coupling nut.
4. Remov€ the in-line filter trom the discharge side and
clean it necossarv.
5. The fluid orilice is located behind the tilter.
Clean it with the Dick stored in the boftom ot the tank
handle or blow it cl6an with air. Securelv reassem-
ble all Darts.
COUPLII{G I{UT
ORIFICE
FILTER
---0--L--
IO.BI G
14-169

Electrical
Special Tools
Troubleshooting
Tips and Precautions ................................ 23-3Five-stop Tloubleshooting ..............,...-..-... Z3-sSchematic Symbols ................................_. 23-6wire Color Cod€s ..................................... 23-6Relay and Control Unit Locations
Engine Compartment .........,............ ... --. 23-7Dsshboard and Door ..,,......................... 23-gDashboard and Floor ............................. 23-t OOuaner Panel .....-.....23-12Connector ldentification and WireHarness Routing ........ 23-i 3
Index to Circuits and Systems
Airbag ............... ...-..-... 2g-26sAir Conditioning ....,.. Section 2lAltelnator ......_.............. 23-99Anti-lock Brake Systsm (ABS) Section 19Automatic Transmission Section 14Battery .............. .......... 23-66Chafging System ........... 23-98rCigalstte Lighter .....................-...-......-..-.. Z3-2O4Cfock ................. ..........23-197rcruise Controf .......--..-... 23-242Distributor .................... 23-87Fan Controls ................. 23-1ogFuel and Emissions ... Section 1i*Fuses
Under-dash Fuse/Relay Box ................... 23-48Undor-hood ABS Fuse/Retay Box ............ 23-51Under-hood Fuse/Relay Box,.................. 23-52rGauges
Engine Coolant Temperature {ECT)Gauge ................ ..23-126Fuef cauge ............... 2g-123'Gauge Assembly ....--.23-113Speedometer .....-...,,. 23-114Tachometer .....,.....-.. 23-114Ground Distribution ........ 23-60Heater ,,,........,.... ..... Section 2lrHorn ................. ........... 23-199*fgnition Switch ............. 23-70fgnition Syst6m .......-..-.. 23-A7lgnition Timing .............. 23-89Indicator Lights"A/T Gear Position .............. ................... 23-1 32B1ak6 System ...,..,..-.23-127Engine Oil Pressura .............................. _ 23-1 51Low Fuel ............ ......23-125Malfunction Indicator Lamp {MlL} ...,,. Section I l
tfnteglated Control Unit ...29-144*lnterlock System ...................................... 23-1 3gLights, Exteriol
Back-up Lights ........... 23-179Brake Lights .............. 23-t8ltDaytime Running Lights {Csnada} ........... 23-156Front Palking Lights ............................. 23-1 65Flont Side Marker Lights ....................... 23-165Front Turn Signal Lights ........................ 23-1 65*Hazard Warning Lights .........................- 2g-1A4Headlights ................. 23-t6tLicense Plate Lights .............................. 23-1 69Taillights(Harchback) .......... 23-166
{Sedan) .............. .. 23-167Lights. Inteliol
Cargo Area Light {Hatchback) ...... -.. -.. -... 23-177Ceifing Light ........-..-.23-175
Dash Lights Blightness Controt .............. 23-t70Glove Box Lighr ................................... 23-1 69Spotfighr ............ ....-.23-174Trunk Light (Sedanl ............... .............. - 23.-177*Lighting Sysrem .......-.-... 23-152:Moonroof ,,.,.......,..,,,,,.-.23-211PGM-FI Systom ........ S€crion 11Power Distribution .,.-..--..23-54Power Door Locks .............,,..................... 23-233Power Mirors ..,..,....-...- 23-216Power Relays ...........,..... 23-68Power Windows ............ 29-222*Rear Window Defogger ........,... ..........,..... - 23-20,6Reminder Systems
Key-in Remindel System ....,.............,.... 23-1 50Lights-on Reminder System ................... 23-l 5f*Maintenance Reminder system ..,,.... -.. - -. 23-.1 2gSeat Belt Reminder System ..................- 23-125*Side Markel/Turn Signal/Hazard
Ffasher System .,..,..-.23.-1A4Spark Pfugs .........-...-..... 23-97Starting System ....,,.....-. 23-73*Stereo Sound System ...,.......................,,.. 23-l gg
Supplemental Restraint System {SRS} ......... 23-265Vehicfe Speed Sensor {VSS) .............--..-.... 23-122*Wiper/Washer Systom ...............--.........-..- Zg-254
rRead SRS pi€cautions on Page 23-271 betore workingin these areas.
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