tow ACURA TL 1995 Service User Guide

Main Bearing s
Clearanc eSelection
1.
2 .
3.
4 .
5.
6.
7 .
8 .
T o chec k mai n bearing-to-journa l oi l clearance ,
remov e th e mai n cap s an d bearin g halves .
Clea n eac h mai n journa l an d bearin g hal f wit h a
clea n sho p towel .
Plac e on e stri p o f plastigag e acros s eac h mai n jour -
nal.
NOTE : I f th e engin e i s stil l i n th e ca r whe n yo u bol t
th e mai n cap dow n t o chec k clearance , th e weigh t
o f th e crankshaf t an d flywhee l wil l flatte n th e plasti -
gag e furthe r tha n jus t th e torqu e o n th e ca p bolts ,
an d giv e yo u a n incorrec t reading . Fo r a n accurat e
reading , suppor t th e crankshaf t wit h a jac k unde r
th e counterweight s an d chec k onl y on e bearin g a t a
time .
Reinstal l th e bearing s an d caps , the n torqu e th e 9
m m ca p bolt s t o 3 9 N- m (4. 0 kgf-m , 2 9 Ibf-ft) . Torqu e
the 1 1 m m ca p bolt s to 7 6 N- m (7. 8 kgf-m , 5 7 Ibf-ft) .
Torqu e th e sid e bolt s t o 4 9 N- m (5. 0 kgf-m , 3 6 Ibf-ft) .
Remov e th e cap s an d bearings , an d measur e th e
wides t par t o f th e plastigage .
Mai n Bearing-to-Journa l Oi l Clearance :
Standar d (New) : 0.02 0 - 0.04 4 m m
(0.000 8 - 0.001 7 in )
Servic e Limit : 0.0 5 m m (0.00 2 in )
PLASTIGAG E STRI P
If th e plastigag e measure s to o wid e o r to o narrow ,
remov e th e crankshaft , an d remov e th e uppe r hal f
o f th e bearing . Instal l a new , complet e bearin g wit h
th e sam e colo r cod e (selec t th e colo r a s show n i n
th e righ t colum n o f thi s page) , an d rechec k th e
clearance .
CAUTION: D o no t file , shim , o r scrap e th e bearing s
o r th e cap s t o adjus t clearance .
I f th e plastigag e show s th e clearanc e i s stil l incor -
rect , tr y th e nex t large r o r smalle r bearin g (th e colo r
liste d abov e o r belo w tha t one) , an d chec k again .
NOTE : I f th e prope r clearanc e canno t b e obtaine d
b y usin g th e appropriat e large r o r smalle r bearings ,
replac e th e crankshaf t an d star t over . CAUTION
: I f th e code s ar e indecipherabl e becaus e o f a n
accumulatio n o f dir t an d dust , d o no t scru b the m wit h a
wir e brus h o r scraper . Clea n the m onl y wit h solven t o r
detergent .
Crankshaf t Bor e Cod e Location s
Letter s o r bar s hav e bee n stampe d o n th e en d of the
cylinde r bloc k a s a cod e fo r th e siz e o f eac h o f th e fou r
mai n journa l bores . Us e them , an d th e number s o r bar s
stampe d o n th e crankshaf t (code s fo r mai n journa l size) , t o
choos e th e correc t bearings .
No. 4 JOURNA L(DRIVE PLAT E END )
No. 1 JOURNA L(PULLEY END )
Main Journa l Cod eLocation s (Number s o r Bars )
No.1 JOURNA L(PULLEY END )No. 4 JOURNA L(DRIVE PLAT E END )
Bearin g Desig n
COLOR
GROOV E
UPPER BEARIN G
COLOR
LOWE R BEARIN G
Bearing Identificatio nColor cod e is o n th eedg e o f th e bearing .
NOTE: Whe n usin g bearin g halve s o f differen t colors , i t
doe s no t matte r whic h colo r i s use d i n th e to p o r bottom .
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Connecting Rod Bearings

Clearance
Selection

1. Remove the connecting rod cap and bearing half.

2. Clean the crankshaft rod journal and bearing half

with a clean shop towel.

3. Place a plastigage strip across the rod journal.

4. Reinstall the bearing half and cap, and torque the

nuts to 44 N-m (4.5 kgf-m, 33 Ibf-ft).

NOTE: Do not rotate the crankshaft during inspec-

tion.

5. Remove the rod cap and bearing half and measure

the widest part of the plastigage.

Connecting Rod Bearing-to-Journal Oil Clearance:

Standard (New): 0.022 - 0.046 mm

(0.0009 - 0.0018 in)

Service Limit: 0.05 mm (0.002 in)

PLASTIGAGE STRIP

7.
If the plastigage measures too wide or too narrow,

remove the upper half of the bearing, install a new,

complete bearing with the same color code (select

the color as shown in the right column of this page),

and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings

or the caps to adjust clearance.

If the plastigage shows the clearance is still incor-

rect, try the next larger or smaller bearing (the color

listed above or below that one), and check clear-

ance again.

NOTE: If the proper clearance cannot be obtained

by using the appropriate larger or smaller bearings,

replace the crankshaft and start over.
CAUTION: If the codes are indecipherable because of

an accumulation of dirt and dust, do not scrub them

with a wire brush or scraper. Clean them only with sol-

vent or detergent.

Connecting Rod Code Location

Numbers or bars have been stamped on the side of each

connecting rod as a code for the size of the big end. Use

them, and the letters or bars stamped on the crank

(codes for rod journal size), to choose the correct bear-

ings.

Half of number is

stamped on bearing

cap and the other

half is stamped on

connecting rod.

Connecting Rod Journal Code Locations (Letters or Bars)

No. 4 No. 2

No. 1 JOURNAL

(PULLEY END)

Bearing Identification

Color code is on the

edge of the bearing.
No. 6 JOURNAL

(DRIVE PLATE END)

Smaller

rod

journal

NOTE: When using bearing halves of different colors, it

does not matter which color is used in the top or bottom.ProCarManuals.com

Fuel Pressure
Relieving
Before disconnectin g fue l pipe s o r hoses , releas e pres -
sure fro m th e syste m b y loosenin g th e servic e bol t o n
top o f th e fue l rai l ('9 7 - 9 8 models : to p o f fue l filter) .
• D o no t smok e whil e workin g o n th e fue l system .
Kee p ope n flame s o r spark s awa y fro m you r wor k
area.
• B e sur e t o reliev e fue l pressur e whil e th e ignitio n
switc h is off .
1 . Mak e sur e yo u hav e th e anti-thef t cod e fo r th e radio ,
the n writ e dow n th e frequencie s fo r th e radio' s pre -
se t buttons .
2 . Disconnec t th e batter y negativ e cabl e fro m th e bat -
ter y negativ e terminal .
3 . Remov e th e fue l fil l cap .
4 . Us e a bo x en d wrenc h o n th e servic e bol t o n th e
fue l rai l ('9 7 model : o n th e fue l filter ) whil e holdin g
th e banj o bol t wit h anothe r wrench .
5 . Plac e a ra g o r sho p towe l ove r th e servic e bolt .
6 . Slowl y loose n th e servic e bol t on e complet e turn .
'9 6 model :
SERVIC EBOLT12 N- m(1.2 kgf-m , 8. 7 Ibf-ft )
FUE L RAI L SHO
P TOWE L
'97 - 9 8 models :
SERVICE BOL T12 N- m (1. 2 kgf-m ,8.7 Ibf-ft )
FUELFILTE R
SHOP
TOWE L
NOTE:
A fue l pressur e gaug e ca n b e attache d a t th e ser -
vic e bol t hole .
Alway s replac e th e washe r betwee n th e servic e
bol t an d th e banj o bol t wheneve r th e servic e bol t
i s loosened .
Replac e al l washer s wheneve r th e bolt s ar e
removed .
(cont'd)
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Fuel Injector s
Replacemen t
Do no t smok e whe n workin g o n th e fue l system . Kee p ope n flame s awa y fro m you r wor k area .
1 . Reliev e fue l pressur e (se e pag e 11-119 ).
2 . Remov e th e engin e cover .
3 . Disconnec t th e connector s fro m th e fue l injectors .
4 . Disconnec t th e vacuu m hos e an d fue l retur n hos e fro m th e fue l pressur e regulator .
NOTE : Plac e a ra g o r sho p towe l ove r th e hose s befor e disconnectin g them .
5 . Disconnec t th e fue l hos e fro m th e fue l rail .
6 . Remov e th e retaine r nut s fro m th e fue l rai l an d harnes s holder .
7 . Disconnec t th e fue l rail .
8. Remov e th e fue l injector s fro m th e intak e manifold .
'96 model :
ENGINECOVER
O-RIN G
Replace .
CUSHIO NRINGReplace .
FUE L
INJECTO R
SEALRINGReplace .
HARNES S
HOLDE R
FUE L
RAIL S
PCVVALV E
12 N- m(1.2 kgf-m ,
8. 7 Ibf-ft )
22 N- m(2.2 kgf-m ,
1 6 Ibf-ft )
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Replacement
Do no t smok e whil e workin g o n th e fue l
system . Kee p ope n flam e awa y fro m you r wor k area .
1 . Plac e a sho p towe l unde r th e fue l pressur e regula -
tor , the n reliev e fue l pressur e (se e pag e 11-119 ).
2 . Disconnec t th e vacuu m hos e an d fue l retur n hose .
3. Remov e th e tw o 6 m m retaine r bolts .
NOTE :
• Replac e th e O-ring .
• Whe n assemblin g th e fue l pressur e regulator ,
appl y clea n engin e oi l t o th e O-rin g an d assembl e
i t int o it s prope r position , takin g car e no t t o dam -
ag e th e O-ring .
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Fuel Filte r
Replacemen t
• D o no t smok e whil e workin g o n fue l system .
Kee p ope n flam e awa y fro m you r wor k area .
• Whil e replacin g th e fue l filter , b e carefu l t o kee p a saf e
distanc e betwee n batter y terminal s an d an y tools .
Th e fue l filte r shoul d b e replace d wheneve r th e fue l pres -
sur e drop s belo w th e specifie d valu e [26 0 - 31 0 kP a
(2.6 5 - 3.1 5 kgf/cm
2, 37. 7 - 44. 8 psi ) wit h th e fue l pressur e
regulato r vacuu m hos e disconnecte d an d pinched ] afte r
makin g sur e tha t th e fue l pum p an d th e fue l pressur e
regulato r ar e OK .
1 . Mak e sur e yo u hav e th e anti-thef t cod e fo r th e radio ,
the n writ e dow n th e frequencie s fo r th e radio' s pre -
set buttons .
2. Disconnec t th e batter y negativ e cabl e fro m th e bat -
ter y negativ e terminal .
3 . Plac e a sho p towe l unde r an d aroun d th e fue l filter .
4 . Reliev e fue l pressur e (se e pag e 11-119 ).
5 . Remov e th e banj o bol t an d th e fue l fee d pip e whil e
supportin g th e fue l filte r wit h anothe r wrench , a s
shown .
6 . Remov e th e fue l filte r clam p an d fue l filter .
7 . Whe n assembling , us e ne w washer s a s shown .
NOTE : Clea n th e flare d join t o f hig h pressur e hose s
thoroughl y befor e reconnectin g them .
'96 model :
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Valve Cap s
Descriptio n
Caps wit h on e projecte d ti p an d on e fla t en d ar e
installe d wit h th e fla t en d towar d th e insid e o f th e
valv e body .
Cap s wit h a projecte d ti p o n eac h en d ar e installe d
wit h th e smalle r ti p towar d th e insid e o f th e valv e
body . Th e smal l ti p is a sprin g guide .
TOWAR D OUTSID E O F VALV E BOD Y
TOWAR D INSID E O F VALV E BOD Y
Caps wit h on e projecte d ti p an d a hollo w en d ar e
installe d wit h th e ti p towar d th e insid e o f th e valv e
body . Th e ti p is a sprin g guide .
TOWAR D OUTSID E O F VALV E BOD Y
TOWAR D INSID E O F VALV E BOD Y
Caps wit h hollo w end s ar e installe d wit h th e hollo w
en d awa y fro m th e insid e o f th e valv e body .
Cap s wit h notche d end s ar e installe d wit h th e notc h
towar d th e insid e o f th e valv e body .
Cap s wit h fla t end s an d a hol e throug h th e cente r ar e
installe d wit h th e smalle r hol e towar d th e insid e o f
th e valv e body .
TOWAR D OUTSID E O F VALV E BOD Y
TOWAR D INSID E O F VALV E BOD Y
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Accumulator Pisto n
Remova l
1. Remov e th e sna p ring .
2 . Remov e th e accumulato r sleev e an d spring .
3 . Remov e th e sealin g bolt .
4 . Remov e th e one-wa y bal l sprin g ('9 6 model) .
NOTE : D o no t remov e th e stee l ball .
5 . Wra p a sho p towe l aroun d th e accumulato r piston ,
an d appl y ai r pressur e t o th e flui d passag e t o remov e
the piston .
• Do no t plac e you r finger s in fron t o f piston .
• Do not use high air pressure; use an OSHAapprove d 3 0 PS I nozzle .
REAR COVE R
SHOP TOWE L
COMPRESSE D AI RHOS E NOZZL EOSHA-Approve d 3 0 ps itype only .
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Countershaft
Inspection (cont'd )
4. I f th e clearanc e i s ou t o f tolerance , remov e th e 1st -
hold clutc h distanc e colla r an d measur e it s length .
5. Selec t an d instal l a ne w 1st-hol d clutc h distanc e col -
lar , the n recheck .
1ST-HOL D CLUTC H DISTANC E COLLA R
No.
1
2
3
4
5
6
7
8
9
10
1 1
Par t Numbe r
9045 1 -PY4 - 01 0
9045 2 -PY4 - 01 0
9045 3 -PY4 - 01 0
9045 4 -PY4 - 01 0
9045 5 -PY4 - 01 0
9045 6 -PY4 - 01 0
9045 7 -PY4 - 01 0
9045 8 -PY4 - 01 0
9045 9 -PY4 - 01 0
9046 0 -PY4 - 01 0
9046 1 -PY4 - 01 0 Thicknes
s
72.0 0 m m (2.83 5 in )
72.0 5 m m (2.83 7 in )
72.1 0 m m (2.83 9 in )
72.1 5 m m (2.84 1 in )
72.2 0 m m (2.84 3 in )
72.2 5 m m (2.84 4 in )
72.3 0 m m (2.84 6 in )
72.3 5 m m (2.84 8 in )
72.4 0 m m (2.85 0 in )
72.4 5 m m (2.85 2 in )
72.5 0 m m (2.85 4 in )
6. Afte r replacin g th e 1st-hol d clutc h distanc e collar ,
make sur e tha t th e clearanc e i s withi n tolerance .
7 . Attac h a dia l indicato r t o th e sid e o f th e 2n d gear .
DIAL INDICATO R
3RD CLUTC HASSEMBL Y1ST GEA R2ND GEA R
8. Measur e 2n d gea r axia l clearanc e whil e pushin g th e
1s t gea r toward s th e revers e clutc h assembly .
NOTE : Tak e measurement s i n a t leas t thre e places ,
an d us e th e averag e a s th e actua l clearance .
STANDARD : 0.0 5 - 0.1 3 m m (0.00 2 - 0.00 5 in )
1ST-HOL D
CLUTC H
ASSEMBL Y
THRUST WASHER ,45.5 x 60 m m
9. I f th e clearanc e i s ou t of tolerance , remov e th e
45. 5 x 6 0 m m thrus t washer , an d measur e it s thickness .
10 . Selec t an d instal l a ne w 45. 5 x 6 0 m m thrus t washer ,
the n recheck .
THRUS T WASHER , 45. 5 x 60 m m
No .
1
2
3
4
5
6
7
8
9
10
11
1 2
13
Par t Numbe r
9041 1 - P5 D - 000
90412-P5D-00 0
90413-P5D-000
90414-P5D-00 0
90415-P5D-00 0
90416-P5D-000
90417-P5D-000
90418-P5D-00 0
90419-P5D-000
90420 - P5 D - 00 0
904 2 1-P5D - 00 0
9042 2 - P5 D - 00 0
9042 3 - PS D - 00 0 Thicknes
s
1.3 0 m m (0.05 1 in )
1.3 5 m m (0.05 3 in )
1.4 0 m m (0.05 5 in )
1.4 5 m m (0.05 7 in )
1.5 0 m m (0.05 9 in )
1.5 5 m m (0.06 1 in )
1.6 0 m m (0.06 3 in )
1.6 5 m m (0.06 5 in )
1.7 0 m m (0.06 7 in )
1.7 5 m m (0.06 9 in )
1.80 m m (0.07 1 in )
1.8 5 m m (0.07 3 in )
1.9 0 m m (0.07 5 in )
11. Afte r replacin g th e 45. 5 x 6 0 m m thrus t washer ,
make sur e tha t th e clearanc e i s withi n tolerance .
PARKINGGEAR
2ND GEAR
1ST GEAR
I
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8. Install the snap ring.

SNAP RING

9. Remove the special tools.

10. Install the disc spring in the direction shown.

NOTE: The 3rd and 4th Clutches on '97 model do

not the disc springs.

'96 MODEL: 2ND, 3RD, 4TH and 1ST-HOLD

CLUTCHES

'97 - '98 MODELS: 1ST-HOLD CLUTCH

DISC SPRING

Install in this direction.

CLUTCH DRUM

PISTON

'96 MODEL: REVERSE and 1ST CLUTCHES

NOTE: Install the 1st clutch disc spring if it was

removed from the 1st clutch piston.

'97 - '98 MODELS: 1ST, 2ND and REVERSE

CLUTCHES

DISC SPRING

Install in this direction.

CLUTCH DRUM
11. Soak the clutch discs thoroughly in ATF for a mini-

mum of 30 minutes.

12. Starting with a clutch plate, alternately install the

clutch plates and clutch discs. Install the clutch end

plate with the flat side toward the disc.

NOTE: Before installing the plates and discs, make

sure the inside of the clutch drum is free of dirt and

other foreign matter.

CLUTCH END PLATE

CLUTCH

DISC

13. Install the snap ring.

SCREWDRIVER

SNAP RING

(cont'd)ProCarManuals.com