tow HONDA INTEGRA 1994 4.G User Guide

Rocker Arms - Inspection Using Special Tools
CAUTION:
. Boforo using tho valvo inspoction tool. make 3uro
that th6 air prsssure gaugs on th6 air comprossol
indicatG over 250 kPa {2.5 kgf/cm', 36 psi}
. Inspect the valvs clearanco befors rockel lrm insPoc-
tion.
. Covor the timing belt with a shop towsl to pl€vent
qotting oil on lhe b6lt.
. Check ths mid rocker srm of oach cylindor at TDC.
1. Remove the cylinder head cover.
2. Plug the relief hole wiih the special tool (Air
Stopper).
Remove the bolt and washer from the inspection
hole and connect the valve inspection tool
AIR STOPPEBOTLA' - PR3O2OA
3.
REGULATOR VALVE. Pullths lever andturn to adjust.INSPECTIONHOtt
WASHERReplace.
10 x 1.0 mm20 N.m 12.0 kgf.m,1a tbt'ft|
TOOL
RELIEF HOLE
ICOMMERCIALLY AVAILABLE}
6-43
Apply specified air pressure to the rocker arm pis-
tons after loosening the regulator valve on the valve
inspection tool.
Specified Air Presrure:
250 kPa (2.5 kgt/cm', 36 psi)
- 500 kPa 15.0 kgf/cm'. 71 Psi)
Make sure that the primary and secondary rocker
arms are mechanically connected by the pistons
and that the mid rocker arms do not move when
pushed manuallv.
LOST MOTIONASSEMALY
PfiIMARYROCKER ARM
6.
7.
o lf any mid rocker arm moves independently of
tho primary and secondary rocker arms, replace
the rocker arms as a set.
Remove the tools.
Check the oDeration of the lost motion assembly by
pushing on the mid rocker arm. The lost motion
assemblv should compress fully and operate
smoothly through its full stroke. Replace the assem-
bly if it does not work smoothlY.
8. After insoection, check that the Malfunction
Indicator LamD (MlL) does not come on
NOTE: Refer to page 6-78 when installing cylinder head
cover.

Camshafts
Inspection
4,
5.
9.
1.
Remove the bolts, then remove the camshaft hold-
ers from the cvlinder head.
NOTE: Unscrew the camshaft holder bolts two
turns at a time, in a crisscross pattern.
Lift camshaft out of cylinder head. wipe clean, then
inspect lift ramps. Replace camshaft if lobes are pit-
ted, scored, or excessively worn.
Clean the camshaft bearing surfaces in the cylinder
head. then set camshaft back in place.
Place a plastigage strip across each journal.
Install the camshaft holders, and then tighten the
bolts to the specified torque as shown in the left
column on this page.
NOTE: Do not rotate camshafts during inspection.
Remove the camshaft holders. Measure widest Dor-
tion of plastigage strip on each journal.
Camshaft-to-Holder Oil Clearance:
Standard {New): 0.050 - 0.089 mm
{0.002 - o.Ooil in)
Sswice Limit: 0.15 mm (0.006 in)
(cont'dl
NOTE:
. Do not rotate the camshaft during inspection.
. Remove the rocker arms and rocker shafts.
1. Put the camshafts and camshaft holders on the
cylinder head, and then tighten the bolts to the
soecified torque.
Specified Torque:
O - @: 8 mm bolts 26 N.m {2.7 kgl.m,20 lbt'ftl(D -(D:6 mm bolts 9.8 N.m {1.0 kgt.m, 7.2 lbf'ftl
Seat each camshaft by pushing it toward distributor
end of the cylinder head.
Zero the dial indicator against end of distributor
drive, then push the camshaft back and forth and
read the end play.
Camshaft End Play:
Standard (New): 0.05 - 0.15 mm
10.002 - 0.006 inl
Sawics Limit: 0.5 mm (0.02 inl
oooo@

1.As illustrated in the removal steps ot this proce-
dure. use a commercially - available air-impact
driver attachment modified to fit the diameter of the
valve guides. In most cases, the same procedure
can be done using the Valve Guide Driver and a
conventional hammer,
COMMCRCIALLY.AVAILABLEVALVE GUIDE DRIVER
az mm +- sz mm{3.43 inl I tz.zt in)
tfr
10.8 mm10.42 inl
5.3 mm(0.21 inl I
_{l
R.mov.l and In3trll.tionVALVE GUIDE DRIVER.5.5 mm07742 - q)101tt0
Select the proper replacement guides and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150"c). Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not us9 a iorch; it may warp ths hsad.
. Do not get ths head hottor than 300"F (150"C);
excsssivo hgat may loogen the valvo soaG.
. To avoid burns, use hsaw glovo3 whon handling
the heated cylindor h€ad.
Working from the camshaft side, use the driver and
an air hammer to drive the guide about 2 mm (0.1
in) towards the combustion chamber. This will
knock off some of the carbon and make removal
easier.
CAUTION:
. Always wear ssfcty gogglos 01 a taca rhiold
whcn using thc air hrmmcr,
. Hold tho.ir hammer diroctly in line with tho
v6lvo goido to prov.nt drmaging tho driv6r.
Turn the head over and drive the guide out toward
the camshaft side of head.
lf a valve guide still won't move, drill it out with a
8.0 mm (5/16 in) bit, then try again.
CAUTION; Drill guid6 only in oxtromc cs3os: you
could dlmsgo tho cylinder hoad if tho guidc brcakr.
VALVE GUIDE DBIVER.5.5 mm07742 - 0010100
6.Remove the new guide(s) from the refrigerator, one
at a time, as vou need them.(cont'd)
l o -_ -\
i oc)

When installing the cylinder head cover. hold the
rubber seal in the groove by placing your fingers on
the camshaft contacting surfaces (top of the semi-
circles).
Once the cylinder head cover is on the cylinder
head, slide the cover slightly back and forth to seat
the rubber seal.
NOTE:
Before installing the cylinder head cover, clean
the cylinder head contacting surfaces using a
shop towel.
Do not touch the pans where liquid gasket was
applied.
6x1.0mm9,8 N.m 11.0 kgt'm,7.2 tffirl
Tighten the nuts in 2 or 3 steps. In the final step'
tighten all nuts, in sequence, to 9.8 N'm (1.0 kgf'm,
7.2 tbf.ft).
After installing, check that all tubes, hoses and con-
nectors are installed correctly.
17.
6-79

Main Bearings
Clearance
To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves.
Clean each main journal and bearing half with a
clean shop towel.
Place one strip of plastigage across each main iour-
nal.
NOTE: lf the engine is still in the car when you bolt
the main caD down to check clearance, the weight
of the crankshaft and flywheel will flatten the plasti-
gage further than just the torque on the cap bolt,
and give you an incorrect reading. Fot an accurate
reading, support the crank with a iack under the
counterweights and check only one bearing at a
trme.
Reinstall the bearing caps and cap bridge (818C1
engine only) then torque the bolts.
81881 engine:77 N'm (7.8 kgf'm,56lbl'ft)
818C1 engine:
No. 1,5 cap bolts 73 N'm (7.'l kgt'm,56lbf'ftl
No. 2, 3, 4 cap bolts 6a N'm (6.5 kgf'm, 49 lbf'ftl
NOTE: Do not rotate the crankshaft during inspec-
tron,
Remove the cap bridge (818C1 engine only), caps
and bearings again, and measure the widest part oJ
the plastigage.
Main Bearing-to-Journal Oil Cl€arance:
Standard (Newl:
No. 1, 2, 4, 5: 0.024 - 0.042 mm
10.0009 - 0.0017 inl
Service Limit: 0.050 mm {0.0020 inl
No. 3:0.030 - 0.0,18 mm(0.0012 - 0.0019 inl
Ssrvice Limit: 0.060 mm {0.0024 inl
PLASTIGAGE STNIP
lf the plastigage measures too wide or too narrow,
(remove the engine if it's still in the car), remove the
crankshaft. and remove the upper half of the bear-
ing. Install a new. complete bearing with the same
color code (select the color as shown in the right
column), and recheck the clearance.
CAUTION: Do not file, shim, or scrapo ihe bo.rings
or the caps to adiust clearance.
lf 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 again.
NOTE: lf the Droper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
reolace the crankshaft and start over.
Selection
CAUTION: lf ths codes are indeciphorable becau3o ot
an lccumulation ol dirt and dust, do not gcrub thgm
with a wirs brush or gcrapsr. Clean them only with 3ol-
vont or doisrggnt.
Crankshaft Bore Code Location
Letters have been stamped on the end of the block as a
code for the size of each of the 5 main journal bores
Use them, and the numbers or bars stamped on the
crank (codes for main journal size), to choose the correct
bearings.
B..ring ld.ntificrtionColor code is
on the edge otthe bearang.Larger crank Dore
Mlin Joumal CodG Locttion3 (Numbors or gaBl
IcD
tr;;lIl
Itr-tl
lE;tl I tlHlt
I Lo.""li L
Smaller Smallermsin bearingjournal (thicker)
-------.r> smaller bearing (thicker)
G'een
Gre€^
GreenBlacr
GreenElackBlue
7-8

ConnectingRod Bearings
ClearanceSelection
CAUTION: lf the codss are indeciphsrable bocause of
an accumulation of dirt and dust. do not scrub tham
with a wiro brush or scraper. Clean them only with sol-
vont or dotetgenl.
Connecting Rod Code Location
A number has been stamped on the side of each con-
necting rod as a code for the size of the big end. Use it,
and the letters stamped on the crank (codes for rod jour-
nal size), to choose the correct bearings.
tF;l I tl-lf
liBor'rll I
lEalll t
I 1o.,,,'ll L
Smaller Smallerrod bearingjournal (thicker|
Half of number isstamped on bearingcap and the otherhalf is stamped onrod.
Conn.cting Rod Joumsl Codc LocatioN lLotteE or B.trl
Berring ldcntification
t23
Color code ison the edge ofthe bearing.Larger big end bore
Smaller bearing {thicker)
RedGr€€n
Elack
Bla€kBlue
1. Remove the connecting rod cap and bearing half.
2. Clean the crankshaft rod journal and bea.ing half
with a clean shoo towel.
3. Place the plastigage across the rod journal.
4. Reinstall the bearing half and cap, and torque the
nuts.
81881 sngino: 31 N'm 13.2 kgf.m,23 lbt'ft)
818C1 sngine: 4,1 N.m 14.5 kgf.m. 33 lbf'ft}
NOTE: Do not rotate the crankshaft during inspec-
tion.
Connecting Rod B€aring-to-Journal Oil Clcalancr:
8l88l ongine:
Standard (New): 0.020 - 0.038 mm
{0.0008 - 0.0015 in)
Servica Limit: 0.050 mm (0.0020 inl
818C1 engin€:
Standard (New): 0.032 - 0.050 mm
(0.0013 - 0.(XP0 inl
Service Limit: 0.060 mm (0.0024 in)
ll 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), and
recheck the clearance.
CAUTION: Do not file, shim, or scrape lhe bearing
or the capg tq adiust clgaranca.
lf the plastigage shows the clearance is still incor-
rect, try the next la.ger or smaller bearing {the color
listed above or below that one), and check clear-
ance again.
NOTE: lf the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
reolace the crankshaft and stan over.
1.
PLASTIGAGE STRIP

EndPlay
NOTE; End play should be inspected before removing
crankshaft.
Push the crank firmly awav from the dial indicator, and
zero the dial against the end of the crank. Then pull the
crank firmly back toward the indicator; dial reading
should not exceed service limit.
Crankshaft End Play:
Standard (New): 0.10 - 0.35 mm
(0.04 - 0.01i| inl
S€rvic€ Limit 0.i15 mm (0.018 inl
. lf end play is excessive, inspect the thrust wash€rs
and thrust surface on the crankshaft. Replace pans as
necessary.
NOTE:
Thrust washer thickness is fixed and must not be
changed either by grinding or shimming.
Thrust washers are installed with grooved sides fac-
ing outward.
Crankshaft
lnspection
. Clean the crankshatt oil passages with pipe cleaners
or a suitable brush.
. Check the keyway and threads.
Alignment
Measure runout on all main journals to make sure the
crank is not bent.
The differ€nce between measurements on each jour-
nal must not be more than the service limit.
Crank3haft Total lndicatod Runout:
Bl8Bl engins:
Sisndod {Nsw): 0.03 mm {0.001 in) max.
Sorvice Limit: 0.05 mm {0.002 inl
818C1 engin€:
Standard {Nsw): 0.020 mm (0.0008 in} mar.
SGrvice Limits: 0.030 mm 10.0012 in)
OIAL INDICATORRotate tlvo completerevolutions.
Support with lathe-
7-12

PGM-FI System
Heated Oxygen Sensor lHO2Sl
ztRcot{lAELEiIE'{T
HEATER
- --.'!- - -__-
lrPl _l !l-
-fi-l: The Malfunction Indicator Lamp (MlL) indicates Diagnostic Troubls Code (DTC) 1: A problsm in
/? the Heated Oxygen Sonsor (HO2S| circuit.
The Heated Oxygen Sensor IHO2S) det€cts th6 oxygon contont in th6 exhaust gas and signals th6 ECM. In operation,
the ECM receiv€s th6 signals trom the sensor and vari€s the duration during which tu6l is iniocted. To stabilize thd sen-aor's output, tho sensor has 8n intarnal heater and the sensor olemant is coatod with a catslyst. The HO2S is installod
in TWC housing (B18Cl engine) or exhaust pipe B (Bl8Bl €ngine).
sEl{SORTERMII{ALS
:tz-t6l-/ --.- \
VOLTAGE (V}sTotcHtoltETncAIR-FUEL BANO
HEATEBTEBMIT{ALSRICH - AN. - LEAI{FUELRATIO- Th! mll h.. bo.n raportad on.- Wlth thr SCS rhon coon cto.connoctad lr.. p!9. 1t-341,cod. t l. Indlcltrd.
Oo th€ ECM Res€t Procodure {soopag€ 11-35).
Stan the 6ngine. Hold th6 engine
A3,qgq rpm with no load {A/T in
Lryl or lll position, M/T in nourralluntil the radiator lan com6s on.then lot it idle lor ot least on6minutg beforo road t€6tin0.
Connoct ths SCS short connoctorto th6 sorvic€ check connectorlsoo p.g6 1 1-34).
Rood t€st witlthe automatictransmission in L?l position (M/T:4th gear).Stsrting st l,600 rpm, acc6lorateu6ing wide open throttlo for atlesgt 5 seconds. Thsn dgcol€rstefor at lorst 5 s€conds with th€throttlo completoly closed.
Intarmittd[ t llurc, lyri.m b Of!l thla tlmc. Ch.ck lor poor con-nacdona o? loota wlrat |l C223(loc.trd at right $ock towo.l,Cr 13 (HO2S| lnd ECM.
Ooes the MIL blink and doos itindic6t6 cod6 1?
Go to plga and partonn tad fotcod. 43 lr.a p.go l1-501.
1 1-46

PGM-FI System
rj-t
--t-.
Fuel Supply System
-+-lt@t- -t 13 |- ' "- - --i--
T,-n The Maltunction Indicator Lamp (MlL) indicares Diagnostic Trouble Code (DTC) 43: A problem in
- L:!-i - the Heated Oxygen Sensor (HO2S) circuit. or a probtem in the Fuel Supply System.
NOTE:. Use DIGITAL MULTIMETER.. U6e 2 Volt rang6.
o oooooo oooooo I oo oooooooooooooooooooQoo ooo ooooo I oooo ooooooooooooooo
426
JUMPER WIRE
o ooooo oooo ooo I oo oooooo Isdtcllodsl ooo ooooooooo oooo ooo oo ooo I oooo ooooooooooooooo
D14 {+l
I
426 t-l vohrgo rhould rl.n.t
| 0.4-0.5 V wh.n th..- ignirioo .wilch i! firdt|rtrod o.r, Itd docr!6ato b.low O.1 V in L..th6n two minutaa.
- Tho MIL h.s boen reportod on.- With rhe SCS short con-noctor connocted (soo paga1l-34), codo 43 b indlcat.d,
From codr I troebl.-lhoorlng lprgo 1146).
ls the code 43 accompanied bythe MIL and poor driveability?Go to Fuol Supply .y.t.m (|ecpag6 1t-971.
Do the ECM Reset ftocedure lseepage 11-35).
Connect the SCS short connectorto the service check connector{see page 'l1-34).
Start the engine. Hold the engineat 3,00O rDm with no load {A/T in
@or@ position, M/T in neutral)until the radiator Ian comes on,then let it idle for at least onemanute,
Intonnitl.nt t llure, tydom lr OKat thi. tim. lto.t drlv. mly b.nocaararyr.Chock lor poo? connactlona otloots wiro at C223 lloc.t.d atrlghl lhock towo.]. Cl13lHO2Sland ECM,
Raise the engine speed to 3,000rpm and hold that throttle positiontor at least one minute.Do not vary the throttle positioneven if the rpm drops.
Ooes the MIL blink and does itindicate code 43?
Turn the ignition swilch OFF.
Connect the test harness betweenthe ECM and conneclors {seepage 1 1-371.
With the ignition switch OFF, waitfor at least two minutes.
lnstall a jumper wire on the testharness between A6 and A26.
11-50
1To page 1 1-5'l l

PGM-FI System
Manifold Absolute Pressure (MAP) Sensor
fxai - lfil1 The Malfunction Indicator Lamp (MlL) indicates Diagnostic Trouble Code (DTC) 3: An electrical
-:- -?- problem in the Manifold Absolute Pressure (MAPI Sensor circuit.
The MAP sbnsor converts manitold absolute pressure into electrical signals and inputs the ECM.
OUTPUTVOLTAGE
600 700
(in. Hsl GAUGEREADIIIO{mft Hg)
YEL/RED lBlSBl onginc)YEL^YHT lBlaCl .ngin.l | + I
{+l
SENSOR
1.5
- Tho MIL has boon roportod on.- Wirh tho SCS rhort connoctorconnectod lsoo pags 11-34),codo 3 b indicatsd.
Do the ECM Reset Procedure {soepage 11-35).
Intormittont tailuro, lystom ir Ol(at thls timo {tort drivo may bsnocessary).Chack to? Door connocllon oiloosa wiroa 6t C223 {locltod atright shock tow6rl, C'l 14 (MAP
sonaorl and ECM.
ls the MIL on and does it indi-cate code 3?
Turn the ignition switch OFF.
Disconnect the 3P connector tromthe MAP sensor,
Turn the ignition switch ON.
{To page 11-53)
11-52