Cylinder HONDA INTEGRA 1994 4.G Owner's Guide

Cylinder Head
Installation (cont'dl
9. Apply liquid gasket to the head mating surtaces of
the No. 1 and No. 6 camshaft holders, then install
them, along with No. 2,3, 4, and 5.
NOTE:
o "1" or "E" marks are stamoed on the camshaft
holders.
. Do not apply oil to the holder mating surface of
camshaft seals.
. Apply liquid gasket to the shaded areas.
. The arrows marked on the camshatt holders
should point to the timing belt.
No.6 No.5No.2 No. 1
10. Tighten the camshaft holders temporarily.
. Make sure that the rocker arms are properly
positioned on the valve stems.
INTAKE CAMSHAFT HOLDERS
11. Tighten each bolt in two steps to ensure that the
rockers do not bind on the valves.
6r1.0mm9.8 N.m 11.0 kgf.m,7.2lbtft)
Install keys into camshaft grooves.
NOTE: To set the camshafts at TDC position for No.
1 piston, align the holes in the camshafts with the
holes in No. 1 camshaft holders and insert 5.0 mm
pin punches in the holes.
I r 1.25 mm37 N.m {3.8 kgf.m, 27 lbf.ttl
6x1.0mm9.8 N.m (1.0 kgf.m,7.2 tbtft)
Push camshaft pulleys onto camshafts, then tighten
the retaining bolts to the torque specified.
KEYS
13.
tfitml

14.
16.
Installthe timing belt {see page 6-12).
Adjust the valve clea.ance (see page 6-31.
Install the rubber seal in the groove of the cylinder
head cover. Seat the seal in the recesses for thg
camshaft first, th€n work it into the groove around
the outside edges,
NOTE:
. Before installing the rubber seal, thoroughly
clean the seal and the groove.
. When installing, make sure the seal is seated
securely in the corners of the recass€s with no
gap.
CYUNDER HEADCOVER
RUBAER SEAL
17.Apply liquid gask€t to the rubber seal at the eight
corners of the recesses.
NOTE:
. Use liquid gaskst, Part No. 08718 - 0001.
. Check that the mating surfaces are cl€an and dry
before applying liquid gasket.
. Do not install the parts if 20 minutes or mor6
havs elapsod sinco applying liquid gasket.
Instead, reapply liquid gasket after removing old
reaidue.
. After assembly, wait at lsast 20 minutes before
filling the engine with oil.
Apply liquid g.sket tothe shaded areas.
(cont'd)
6-31

Gylinder Head
lnstallation (cont'dl
18. 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 cvlinder 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
aDplied.
6x1.0mm9.8 N.m 11.0 kgt'm,7.2 tbf.trl
6-32
'lllllllllmlmti'""
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).
20. After installing, check that all tubes, hoses and con-
nectors are installed correctlY.

Cylinder Head/Valve Train
818C1 engine
Special Tools ............. 6-34
wEc
Troubleshooting Flowchart
WEC Solenoid Valve ................... 6-36
VTEC Pressure Switch ................. 6-38
VTEC Solenoid Valve Inspection .... 6-41
Rocker Arms
Manual Inspection .....,................. 6-42
Inspection Using Special
Tools ....................................,.....,.. 6-/|i|
Valve Glearance
Adiustment ............ 6-44
Timing Belt
lllustrated 1ndex ............................... 6-46
Inspection .............. 6-48
Tension Adiustment ........................ 6-48
Removal ................. 6-4{l
lnstallation ............. 6-51
Crankshaft Pulley Bolt
Replacement .........6-47
Cylinder Head
lllustrated Index ............................... 6-53
Removal .................6-55
Warpage ................6-74
lnstallation ............. 6-75
Rocker Arms
Removal ................. 6-60
Location ................. 6-61
lnspection .............. 6-62
Arm-to-Shaft G|earance .................. 6-63
Installation ............. 5-64
Camshafts
Inspection .............. 6-65
Valve Guides
Valve Movement .............................. 6-70
Replacement .........6-71
Reaming ................. 6-72
Valve Seals
Reconditioning ......6-73
Valves. Valve Springs and Valve Seals
Removal ................. 6-67
lnstallation Sequence ..........,.......,... 6-69
Valve lnstallation ............................. 6-70

VTEC
Rocker Armsnlrungf rtrrrri' - rYrorrtrcr rrrDPEUtrl,rl
1. Set rh6 No. I Diston at TDC.
2. Remove the ignition wire cover and the wires.
3. Remove the ignition clamps while pulling up on the
lock.
4.Remove the cylinder head cover.
Push the mid rocker arm on the No. 1 cylinder man-
ually.
Check that the mid rocker arm moves independent-
ly of the primary and secondary rocker arms.
6 x 1.0.nm9.8 N.m 11.0 lgfm, 7.2 lbf.ftl
SECONDARYROCKER ARM
7. Check the mid rocker arm of each cvlinder at TDC.
. lf the mid rocker arm does not move, remove the
mid, primary and secondary rocker arms as an
assembly and check that the pistons in the mid
and primary rocker arms move smoothly.
. lf any rocker arm needs replacing, replace the
primary, mid, and secondary rocker arms as an
assemblv.
NOTE: Refer to page 6-78 when installing cylinder head
cover.
w

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.

Valve Clearance
Adiustment
NOTE:
. Valves should be adjusted cold; at a cylinder head
temperature of less than 100"F (38'C).
. Adjustmsnt is the same for intake and exhaust
vatves.
o After adjusting, retorque the crankshaft pulloy bolt to
177 N.m ( 18.0 kgf.m, 130 lbf.ft).
1. Remove cylinder head cove..
ADJUSTING BOLT LOCANONS:
IMTAKE
No. 4 No.3 No. 2 No. 1
No.4 No.3 No.2 No. 1
EXHAUST
Set No. 1 piston at TDC. "UP" mark on the pulley
should be at top, and TDC grooves on the pulley
should align with the pointer on back cover. TDC
grooves (white paint) on the crankshatt pulley
should align with pointer on the timing belt lower
cover.
Numbr. 1 pirton .t TDC:
6-44
FOI{IER Ot{LOWEF COVERTDC MANKlP.int d whit.t
3.
4.
Diroction ofaotation.
Adjust valv6 clearanc6 on No. 1 cylinder.
Intlkc: 0.15 - 0.19 mm (0.006 - 0.0,07 inl
Exh.u3t 0.17 - 0.21 mm (0.007 - 0.m8 inl
Looson lh6 locknut and turn the adjusting screw
until feeler gaugo slides back and fonh with a slight
amount of drag.
TAPPET AI\,USTEN WREI{CI{O'LAA - PRIOIq'
7 x 0.75 mrn20 f+|n (2.0 kgf'm. 14lbtftl
FEEEN GAUGE

Tightsn the locknut and recheck clearance again.
Rep6at sdjustm6nt if necossary.
Rotsts tha crankshaft 180' counterclockwiss
(c8mshaft pulley turns 90'). The "UP" mark should
be on th€ sxhaust 8id6, Adiust vslves on No. 3 cylin-
oer,
Nurrb.r3tittondTDC:
FEEI.IR GAUGE
.UP' MANKS
7. Rotato crankshaft 180' countsrclockwise to bring
No.4 piston to TDC. The "UP" mark should bo
pointing straight down. Adjust valves on No. 4
cylinder.
Numb.r 4 pidon .t Tt C:
8, Rotate crankshaft 180" counterclockwis€ to bring
No. 2 piston to TDC. The "UP" marks should be on
the intaks sid6. Adjust valves on No. 2 cylinder.
Nonb.r 2 pirton .l TltC:
NOTE: Refer to page 6-78 when installing cylinder head
cover.
6-45

Timing Belt
. ReJerto page 6-51 for positioning crankshaft and pulley before installing belt.. Mark the direction of rotation on the belt before removing.
. Replace the rubber seals for oil leakage between the cylinder head and cover.. Do not use the middle cover and lower cover for storing items disassembled.
. Clean the middle cover and lower cover before installation.
lllustrated lndex
NOTE:
WASHERReplace whenCAP NUTx 1,0 mm9.8 N.m 11.0 kgf.m,7,2lbttrlor deteriorated.
CYLINDERHEAO COVERReter to page 6'78when installing.
RUBBER SEALSReplace when damagedor deteriorated,
TIMING BELTInsp€ctaon, page 6-48Adjustment. page 6-48R€placement. page 6'49
MIDDLE COVER
5xl,0mm9.8 N.m (1.0 kgt m,7.2 rbtftt
8 x 1.25 mm56 N.m 15.7 kgt m,41 tbtftl6x1.0mm9.8 N.m (1.0 kgt.m,7.2lbf ftl6x1.0mm9.8 N.m {1.0 kgl.m,7.2lbf.ftl
Installwith concavesurface lacing in.Clean.
TIMING SELDRIVE PULLEYRemove any oil and clean.
10 x 1.25 mm5a N.m 15.5 kgl.m.(} tbf.ftlFor adiustment onlydo not remove.
BOLTInstallwith concavesurface tacing out.Remove any oiland clesn.1il x 1.25 mm177 N.m 118,0 kgtm, 130lbtft)Replacement, page 6-47
COVER
PULLEYRemove any oil and cleanon the timing belt guideplate side.NOTE: When installing a new crankshaft and/or new bolt:
O tighten the crankshaft pulley bolr to 196 N.m (20.0 kgf.m. 145 lbf.ft),
@ loosen bolt,
@ retighten it to 177 N.m fl8.0 kgf.m, 130 lbnft).
3-E
6-46

Timing Belt
lnspection
Remove the cylinder head cover.
. Refer to page 6-78 when installing.
Inspect the timing belt for cracks and oil or coolant
soaking.
NOTE:
. Replace the belt if oil or coolant soaked.
. Remove any oil or solvent that gets onthe b€lt.
Rotate pulleyand inspect b6lt.
After inspecting. retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf.m, 130 lbf.ft).
Tension Adjustment
CAUTION: Always adlust timing bslt tsnsion with th6
engine cold.
NOTE:
. The tensioner is spring-loaded to apply proper ten-
sion to the belt automatically after making the follow-
ing adjustment.
a Alwavs rotate the crankshaft counterclockwise when
viewed trom the pulley side. Rotating it clockwise
may result in improper adjustment of the belt ten-
sion.
Remove the cylinder head cover. (Refer to page 6-
78 when installing.)
Set the No. 1 piston at TDC (see page 6-51).
Rotate the crankshaft 5-6 revolutions to set the belt.
Set the No. 1 piston at TDC.4.
AINUSTING AOLT5/a N.m 15.5 kg{.m, to lbtftlFor adjustment only,
5.
7.
8.
A
.//\v-/
Directionrotat|on,
Loosen the adjusting bolt 1/2 turn (180') only.
Rotate the crankshaft counterclockwise 3 teeth on
the camshaft pulley.
Tighten the adjusting bolr.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgf.m, 130 lbf'ft).
6-48