width HONDA INTEGRA 1998 4.G Workshop Manual

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Valve Seats
Reconditioning
ACTUALSEATINGSURFACE
VALVESEAT
Renew the valve seats in the cylinder head using avalve seat cutter.
NOTE: lf guides are worn (see page 6-26), replace
them {see page 6-27) before cutting the valve seats.
Carefully cut a 45" seat, removing only enoughmaterial to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30. cutterand the lower edge of the seat with the 60. cutter.Check width of seat and adjust accordingly.
Make one more very light pass with the 45o cutter toremove any possible burrs caused by the other cut-rers.
V8lv6 S€at Width (lntake and Exhaustl:
Standard {New}: 1.25 - 1.55 mm {0.0/t{, - 0.061 in}
S€rvice Limit: 2.0 mm 10.08 in)
After resurfacing the seat, inspect for even valveseating: Apply Prussian Blue compound to the valveface. Insert the valve in its original location in thehead, then lift it and snap it closed against the seatseveral times.
PRUSSIAN BLUE COMPOUNO
6-29
o.The actual valve seating surface, as shown by theblue compound, should be centered on the seat.
lf it is too high (closer to the valve stem), you
must make a second cut with the 60" cutter tomove it down, then one more cut with the 45"
cutter to restore seat width.
lf it is too low (closer to the valve edge), you
must make a second cut with the 30. cutter tomove at up, then one more cut with the 45. cutterto restore seat width.
NOTE: The final cut should always be made with
the 45" cutter.
Insert intake and exhaust valves in the head andmeasure valve stem installed height.
Intake Valve Stem Inst8lled Height:
Standard lN6wl: 40.765 - i11.235 mm(1.6049 - 1.6234 in)
Servico Limiti i01.,|85 mm (1.6333 in)
Exhaust Valv€ Stem Installed Height:
Standard {Newl: ,[2.765 - 4:1.235 mm
1.
{1.68i}7 - 1.7022 inl,(1.485 mm 11.7120 inlService Limit:
I_1I
VALVE STEMINSTAI-LED HEIGHT
8.lf valve stem installed height is over the servicelimit, replace valve and recheck. lf still over the ser-vice limit, replace cylinder head; the valve seat in
the head is too deep.

8.
9.
f;:Y:fffrf#:J'uer' Sl[
Measure the clearance between the reverse change
holder and the sth/reverse shift piece pin.
Standard:
Reverse Side: 0.05 - 0.45 mm (0.002 - 0.018 inl
5th Side: 0.4 - 0.9 mm (0.02 - 0.04 in)
Separate the transmission housing from the clutch
housing, and wipe it clean of the sealant.
Remove the 72 mm thrust shim and the oil guide
plate from the transmission housing
72 fifiTHRUST SHIM
10. Remove the l6 mm sealing bolt and the oil gutter
plate.
OIL GUTT6R PLATE
lf the clearance are not within the standard, mea-
sure the width of the grooves in the reverse change
holder.
Standard:
Revsrse Side: 7.05 - 7.25 mm {0.278 - 0.285 in)
5th Side: 7.4-7.7 mm (0.29 - 0.30 in)
REVERSE SIDE
lf the width of the grooves are not within the
standard, replace the rsverse change hbtder with
a new one.
lf the width of the grooves ar€ within the Stan
dard, replace the 9th/revense sHtFI piece wlth
new one.
(cont'

Reverse Change Holder,
Clearance Inspection {cont'dl
Reverseldler Gear
Removal
1. Remove the reverse change holder.
2. Remove the reverse idler gear and the reverse idler
oear shaft.
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Measure the clearance between the reverse idler
gear and the reverse change holder,
Standard: 0.5 - 1.1 mm (0.02 - 0.04 in)
Sorvice Limit: 1.8 mm (0,07 inl
4.lf the clearance is more than the service limit, mea-
sure the width of the reverse change holder.
Standa;d: 13.0 - 13.3 mm (0.512 - 0.524 inl
lf the width is not within the standard, reDlace
the reverse change holder with a new one.
lf the width is within the standard, reDlace the
reverse idler gear with a new one.
REVERSE IDLER GEAR
REVERSE CHANGE HOLDER
REVERSE CHANGE HOLDER
REVERSE CHANGE HOLDER
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Change Holder Assembly
Clearance Inspection
Measure the clearance betwe€n the shift Diece and
the shift arm holder.
Standard: 0.1 - 0.3 mm (0.004 - 0.012 inl
Servico Limit: 0.6 mm (0,02 inl
lf the clearance is more than the service limit, mea-
sure the width of the groove in the shift piece.
Standard: 8.1 - 8.2 mm (0.319 - 0.323 in)
. lf the width of the groove is not within the stan-
dard, replace the shift piece with a new one.. lf the width of the groove is within the standard,
replace the shift arm holder with a new one.
SHIFT PIECE
t.-_
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SHIFT ARM HOLDER
SHIFT PIECE
Measure the clearance between the select arm
the interlock.
Standard: 0.05 - 0.25 mm (0.002 - 0.010 in)
Service Limit:0.5 mm {0.02 inl
and
INTERLOCK
lf the clearance is more than the service limit, mea-
sure the width of the interlock,
Standard: 9.9 - 10.0 mm 10.390 - 0.394 in)
. lf the width is not within the standard. replace
the interlock with a new one.. lf the width is wilhin the standard replace the
select arm with a new one.
(cont'd)
13-13

9.Measure the clearance between the select arm
the change piece.
Standard: 0.05 - 0.35 mm {0.002 - 0.014 in)
Service Limit: 0.5 mm {0.02 inl
Removal
Remove the shift piece shaft, then remove the shiftpiece and the interlock.
2. Remove the change holder assembly.
and
10.lf the clearance is more than the service limit, mea
sure the width of the change piece-
Standard: 12.05 - 12.15 mm {0.4744 - 0.4783 inl
CHANGE PIECE
lf the width is not within the standard, replace
the change piece with a new one.
lf the width is within the standard, replace the
select arm with a new one.
SELECT ARM
SHIFT PIECE SHAFT
INTERLOCK

Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub shouldh6 ronlr.o.l ,.. car
Measure the clearance between each shift fork and
its matching synchro sleeve.
Standard: 0.35 - 0.65 mm {0.014 - 0.026 inl
Service Limit: 1-0 mm 10.04 inl
SHIFT FORK
lf the clearance is more than the service limit, mea-
sure the thickness of the sh ift fork finoers.
Standard: 7.il - 7.6 mm (0.291 - 0.299 in)
lf the thickness of the shift fork fingers is not
within the standard, replace the shift fork with a
lf the thickness of the shift fork fingers is within
the standard, replace the synchro sleeve with a
new one.
3. Measure the clearance between the shift piece and
the shift fork shafts.
Standard: 0.2 - 0.5 mm (0.008 - 0.02 inl
Service Limit: 0.8 mm (0.03 inl
SHIFT PIECE
It the clearance is more than the service limit,
sure the width of the shift piece.
Standard: 11.9 - 12.0 mm (0.a69 - 0.a72 inl
lf the width of the shift piece is not within the
standard, replace lhe shift piece with a new one.
lf the width of the shift piece is within the stan-
dard. reolace the shift fork with a new one.
IFT FORK
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SHIFT PIECE

Countershaft
Inspection (cont'd)
5. lf the clearance is out of tolerance. remove the
28 mm distance collar and measure the width.
6. Select and install a new distance collar. then
recheck.
DISTANCE COLLAR, 28 mm
7. Alter replacing the distance collar, make sure the
clearance is within tolerance.
No.Part Numberwidth
190503-PC9-OOO39.00 mm (1.535 in)
t90504-PC9-00039.10 mm (1 .539 in)
90505-PC9-00039.20 mm (1.543 in)
90507-PC9-O0039.3O mm (1.547 in)
590508-PC9-OOO39.05 mm (1 .537 in)
90509-PC9-00039.1 5 mm {'1.541 in)
790510-PC9-00039.25 mm (1.545 in)
I90511-PCg-00038.90 mm (1.531 in)
I90512-PC9-OO038.95 mm (1.533 in)
14-140
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Ouarter Glass
Installation (cont'd)
lf the old quarter glass is to be reinstalled land
either of the clips are broken off the molding), apply
a light coat ot primer (C 100, or equivalent|, then
apply the butyl tape to the molding as shown.
NOTE:
. Be careful not to touch the quarter glass where
adhesive will be applied.
. Do not peel the separator off the butyl tape.
//////.t Bulyl lape locations 18628, or equivalent)""' Thickness:3.2 mm {0.13 in)
Width: 6.4 mm (0.25 in)
BUTYL TAPE
300 mmn1.8 in)
lf the old quarter glass is to be reinstalled (and
either of the clips are broken off the molding), seal
the body holes with pieces of urethane tape. Set the
quarter glass upright in the opening, make align-
ment marks across the quaner glass and body with
a grease pencil at the three points shown, then
remove the quarter glass.
NOTE: Be careful not to touch the quarter glass
where adhesive will be applied.
6.With a sponge, apply a light coat of glass primer to
the inside face of the quarter glass as shown, then
lightly wipe it off with gauze or cheesecloth.
NOTE:
. Do not apply body primer to the quarter glass,
and do not get body and glass primer sponges
mixed up.
. Never touch the primed surfaces with your
hands. lf you do, the adhesive may not bond to
the quarter glass properly, causing a leak after
the quarter glass is installed.
. Keep water, dust, and abrasive materials away
from the primed surface.
/////1: Apotv slass oimer here.
6mm{0.24 in}
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Standards and Service Limits
Cylinder Head/Valve Train (B18Bl engine)Section 6
*: Measured between the camshaft and rocker arm.
NH: NIHON HATSUJO manufactured valve spring
CH: CHUO HATSUJO manufactured valve spring
MEASUREMENTSTANDARD (NEW) I SERVICE LIMIT
Compression250 rpm and wide open throttle Minimum
kPa (kgf/cm', psi) Maximum variation930 (9.5, 135)200 Q.0,281
Cylinder headWarpageHeightta,|* - 132.05 (5.195 - 5.199)0.05 (0.002)
CamshaftEnd playCamshaft-to-holder oil clearanceTotal runoutCam lobe height lNEX
0.05 - 0.15 (0.002 - 0.006)0.030 - 0.069 (0.0012 - 0.0027)0.03 (0.001) max.33.7 16 11.327 4l33.528 ( 1.3200)
0.5 (0.02)
0.15 (0.006)
0.04 (0.002)
ValveValve clearance (Cold)" lNEX
Valve stem O.D. lNEX
Stem-to-guide clearance lNEX
0.08 - 0.12 (0.003 - 0.005)0.16 - 0.20 (0.006 - 0.00816.580 - 6.590 (0.2591 - 0.2594)6.550 - 6.560 (0.2579 - 0.2583)
0.02 - 0.05 (0.001 - 0.002)0.05 - 0.08 (0.002 - 0.003)
ouu to.rutt6.52 rc.2571.0.08 (0.003)
0.1 1 (0.004)
Valve seatwidth lNEX
stem installed height lNEX
1 .25 - 1.55 (0.049 - 0.061 )1.25 - 1 .55 (0.049 - 0.061 )40.765 - 41.235 (1.6049 - 1.6234142J65 - 43.235 (1.6837 - 1.70221
2.0 (0.08)
2.0 (0.08)
41.485 (1.6333)
43.485 (1.71201
Valve springFree length (Reference)IN NHCHEX
41.27 (1.6251
41.28 (1.625)
44.32 t1-7 451
Valve guidet.D. lNEX
Installed height lNEX
6.61 - 6.63 (0.260 - 0.261)6.61 - 6.63 (0.260 - 0.261)13.7 5 - 1 4.25 (0.541 - 0.561 )15.75 - 16.25 (0.620 - 0.640)
6.6s (0.262)
6.65 (0.262)

Engine Block (81881 engine)Section 7Unit of length: mm (in)
3-3
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R: RIKEN manufactured piston ringT: TEIKOKU PISTON RING manufactured piston ring
E' - Declror
MEASUREMENTSTANDARD (NEW}SERVICE LIMITCylinder blockWarpage of deck surfaceBore diameterBore taperReboring limit
0.07 (0.003) max.81.00 - 81.02 (3.189 - 3.190)0.10 (0.004)
81.07(3.192)0.05 (0.002)
0.25 (0.010)PistonSkirt O.D. at 15 mm (0.6 in) from bottom of skirtClearance in cylinderGroove width (For ring) TopSecondoil
80.98 - 80.99 (3. 1 88 - 3. 1 89)0.01 - 0.04 (0.0004 - 0.0016)1 .030 - 1.040 (0.0406 - 0.0409)1.230 - 1.240 (0.0484 - 0.0488)2.805 - 2.820 (0.1 104 - 0. 1 1 10)
80.97 (3.188)
0.05 (0.002)1.06 (0.042)
1.26 (0.050)
2.84 (0.112!.Piston ringRing-to-groove clearance TopSecond RT
0.045 - 0.070 (0.0018 - 0.0028)0.040 - 0.065 (0.0016 - 0.0026)0.045 - 0.070 (0.0018 - 0.0028)
0.13 (0.0051
0.13 (0.005)
0.13 (0.005)
Ring end gap Top
Secondoil
HT
RT
0.20 - 0.35 (0.008 - 0.014)0.20 - 0.30 (0.008 - 0.012)0.40 - 0.55 (0.016 - 0.022)0.20 - 0.50 (0.008 - 0.020)0.20 - 0.45 (0.008 - 0.018)
0.60 (0.024)
0.60 (0.024)
0.70 (0.028)
0.70 (0.028)
0.70 (0.028)Piston Pino.D.Pin-to-piston clearance20.994 - 21.000 (0.8265 - 0.8268)0.010 - 0.022 (0.0004 - 0.0009)Connecting rodPin-to-rod interferenceSmall end bore diameterLarge end bore diameter NominalEnd play installed on crankshaft
0.013 - 0.032 (0.0005 - 0.0013)20.968 - 20.981 (0.8255 - 0.8260)48.0 (1 .89)0.15 - 0.30 (0.006 - 0.012)0.40 (0.016)CrankshaftMain journal diameterNo. 1, 2, 4 and 5 journalsNo. 3 journalRod journal diameterTaperOut-of-roundEnd playRunout
54.976 - 55.000 (2.1644 - 2.1654)54.970 - 54-994 (2.1642 - 2.1651144.976- 45.000 (1.7707 - 1.771710.005 (0.00021 max.0.005 (0.0002) max.0.10 - 0.35 (0.004 - 0.014)0.03 (0.001) max.
0.010 (0.0004)0.010 (0.0004)
0.45 (0.018)
0.05 (0.002)Bea ringMain bearing-to-journal oil crearanceNo. 1, 2, 4 and 5 journalsNo. 3 journalRod bearing-to-journal oil crearance
0.024 - 0.042 (0.0009 - 0.0017)0.030 - 0.048 (0.0012 - 0.0019)0.020 - 0.038 (0.0008 - 0.0015)
0.050 (0.0020)
0.060 (0.0024)0.0s0 (0.0020)
L rlllllllllrltruE