Ax belt HONDA INTEGRA 1994 4.G Workshop Manual

Standards and Service Limits
Differential (Manual transmissionlSection 15
Differential (Automatic transmissionlSection 15
Steering - Section 17
' When using a new belt, adjust detlection or tension to new values. Run the engine lor 5 minutes then turn it off.Readiust detlection or tension to used belt values.
M€ASUREMENTSTANDARD INEW) SERVICE LIMIT
DifferentialPinion shaft contact area LD. 81881 engine818C1 engineCarrier'to-pinion clearance 81881 engineB18C t engineDriveshafvintermediate shaft contact area LD.81881 engine818C1 engineCarrier to driveshaft clearance 81881 engineBlSC'l engineCarrier-to-intermediate shatt clearanceB188l engine818C1 engine
18.000 - 18.016 (0.7087 - 0.7093)18.000 18.018 (0.7087 - 0.7094)0.0r3 0.045 (0.0005 - 0.0018)0.0'13 - 0.047 (0.0005 0.0019)
28.000 - 28.021 \1.1024-1.1032128.005 - 28.025 (1.1026 1.'1033)0.020 - 0.062 (0.0008 0.0024)0.045 , 0.086 {0.0018 - 0.0034)
0.050 - 0.087 (0.0020 0.0034)0.075 - 0.111 (0.0030 - 0.0044)
o. t aron,0.1 {0.006}
Differentialprnron gearEacklasht. D.Pinion geaFto-pinion shaft clearance
0.05 0.15 (0.002 0.006)'18.042 - 18.066 (0.7103 0.7113)0.055 - 0.095 (0.0022 0.0037)
Adjust
0.15 {0.006)
Sel ring-to-bearing outer race clearance 81881 engin€0 - 0.10 (0 0.004)Adjust
Differential taper roller bearing preloadStarting torque N.m {kgfcm, lbf.in) Bl8Cl engine2.1r - 3.04 {21.5 - 3 r.0, 13.0- 18.7)Adjust
MEASUREMENTSTANDARO INEWISERVICE LIM]T
Difterentialcarfl€rPinion shatt contact area l.D.Carrier-to-oinion clearanceDriveshafvintermediate shaft contact are l.D.Carrier-to-driveshatt clearance
18.000 - 18.018 {0.7087 - 0.7094)0.016 - 0.052 {0.0006 - 0.0020)28.00s 28.025 {1.1026 - 1.1033)0.025 - 0.066 (0.0010 - 0.0026)
0.1 {0.004)
0.12 (0.005)
Differentialprnron gearBacklasht.D.Pinion gear-to-pinion shaft clearance
0.05 - 0.15 (0.002 - 0.006)18.042 - 18.066 (0.7r03 - 0.7113)0.059 - 0.095 (0.0023 - 0.0037)
Adjust
0.15 (0.006)
Set ring-to-bearing outer race clearance0 - 0.r5 (0 - 0.006)Adjust
MEASUREMENTSTANDARD INEWI
Steering wheelRotational play at steering wheel circumferenceStaning losd at steering wheel circumferenceN {kgf, lbfl Engine running
0 - 10 {0 - 0.39)
34 \3.5,7.71
GearboxAngle of rack-guide-screw loosened from lockedposition20" i 5'
PurnpPump pressure with shut-off valve closedkPa (kgtlcm,, psi)6,400 7.400 165 75. 920 - 1. r00)
Power steeringtluidRecommended fluidFluid capacity For overhaulf (US qt, lmp q0 For fluid change
Honda power steering fluid V1.06 (1.12,0.98)
0.79 (0.83,0.70)
Power steeringbelt*Deflection with 98 N (1okgt,22lhfl
between pulleys11.5- 13.5 (0.45 0.53)with used belt8.0 - 10.010.31 0.39)with new belt
Belt tension N lkgf, lbl)Measured with belt tension gauge390 - 540 (40 - 55, 88 - 120) with used belt740 880175 90. 170 200) with new belt

MEASUFEMENTSTANDARD I]{EWI
a gnmentCamber FrontRgarCaster FrontTotaltoe FrontRearFront whe€lturning angle Inward whe€lOutwsrd wh€el
-0. 10' 1 1.-0' 15' l$igl1. 10'r t"0i2(010.081rN 3:i (0.121ff)36' 0o' r 2'30. 30'
A1lc€lbearingEnd playFrontRoaa0 - 0.05 (0 - 0.002)0 - 0.05 {0 - 0.002}
Rim runout (Aluminum wheel) AxialRadialRim runout isteelwhgel) AxialRadisl
STANDARD INEWISEBVICE UMIT
0 - 0.7 {0 - 0.03)0 - 0.7 (0 - 0.03)0 - 1.0 {0 - 0.0{)0 - 1.0 (0 - 0.04)
2.0 (0.08)
1.5 (0.06)
2.0 (0.081
r.5 (0.061
SuspensionSestion 18
BrakeSection 19
Air ConditioningScction 22
.1: When using a new bek, adjust dellection or tension to new values. Run the engine tor 5 minules ihen turn it ott.
Readiust detlection or tension to lsed beh values.'2: 81881 engine'3: 818C1 engine
Unit of length: mm {in)
MEASUREMENTSTANDARD {NEWI
trrling brakePlay in strok€ at 200 N {20 kgf, 44 lbt)lever lorceTo b€ lockod when pulled 6 -10
nolchsa
; oot brake,adalPedal heighl lwith floor mat removod)
Free play
M/T160 (6.30)
155 (6.50)
1-5(0.04-0.20)
Vaster cylinderPiston-to-oushrod clearance0 - 0.4 (0 - 0.2)
f,,s4 brakeOisc thickness FrontRe6rDisc runout FrontR6arDisc parallolism Front and rear
Pad lhickness FrontRoar
STANDARD INEWISERVICE LIM]T
20.9 - 21.1 t0.82 - 0.83t8.9 - 9.1 {0.35 - 0.36)
9.5 - 10.5 {0.37 - 0.41}7.0- 8.0 {0.27 - 0.31)
19.0 (0.75)
8.0 (0.31)
0.10 (0.004)
0.r0 (0.00a)
0.015 (0.0006t
r.6 (0.06)
1.6 (0.06)
MEASUREMENTSTANDABO IT{EWI
Ar conditioningLubricant capacity mf (ll oz) Cond€nserEvaporatorLine or hoseReceiverLubricant type: NO-OlL8 {P/N 38899 - PR7 - A0l)
25 (5/6)
40 t1 1/3)10 (lBt
10 (1/31
CompressorLubricant capacity m{ (ll oz}Lubricant tvge: ND-O|L8 (P/N 38899 - PR7 - A01)Stator coil resistance at 68'F (20'C) 0Pulley-to-pressure plate clearance
140';u (4-23';")
3.4- 3.80.5 r 0.15 {0.02 r 0.006)
Compressorb€h'rDetlection with 98 N (10 kgf, 22 lbf)betlveen pulleys
7.5 - 9.5 {0.30 - 0.37)with used b€lt*'8.5 - 10.5 {0.33 - 0.41}with t/sod belt'35.0 - 7.0 {0.20 - 0.28) with new belt
Belt t€nsion N (kgf, lbl)Measured with belt lension gauge390 - 540 {r0 - 55, 88 - 120} with used beh*'340 - 490 {35 - 50, 77 - 110} with used belt*3740 - 880 {75 - 90, 170 - 200) with new belt
3-15

ll
il
Standards and Service Limits
ElectricalSection 23
*1: Do not adiust the gap, replace spark plug it it is out of spec.*2r When using a new belt, adjust d€tl€ction or tension to new valu€s. Run tho engine lor 5 minutes thon turn it off.Readiust de{lection or tension to usod belt values.
MEASUREMENTSTANDARD {NEWI
lgnilion coilRat€d voltago VPrimary winding resistance at 58'F (20'C) OSecondary winding resistance 6t 68'F (20"C) kO0.6 - 0.812.4 - 19.2
lgnition wireResistance ar 68"F (20'C) k025 max.
Spark plugTvpeGap B18Bl engineB18Cl engine
STANDARD INEW}SEN$CE UM]T
See Section 231.0 - 1.1 {0.039 - 0.043}1.3 {0.051)rl
lgnition timingAt idling" BTDC (Red)- rpmM/T16" r 2. -750 r 50 (Neurra0
16" t 2" -750 r 50 |!]or L?.lposition)Alternator b€lt'2Deflecrion wilh 98 N {10 kgf,22lbllbetween pulleys9.0 - 11.0 (0.35 - 0.43) with us6d b6li6.0 - 8.0 {0.24 - 0.31} with new b6lt
Eelt t€nsion N (kgf, lbf)Measured with belt tension gsuge340 - 490 {35 - 50, 77 - 110) with used bolt690 - 880 {70 - 90, 154 - 198} with now boh
AlternatorOurput l3.5 V at hot ACoil resistance (rotor) at 68"F {20"C} 0Slip ring O.D.Brush lengthErush spring tonsion N (kgt, lbf)
STANDARD INEWISENUCE UMTT
902.914.4 t0.57)r0.5 (0.41)
3.210.33, 0.73)
tnn ro.rrr1.5 (0.06t
StanerOutputMica depthCommulatot runoutCommutator O.D.Brush lengthBrush spring tension (new) N lkgt, lbf)
0.5 - 0.8 (0.02 - 0.03)0 - 0.02 (0 - 0.0008)29.9 - 30.0 (1.177 - 1.r81)15.0 - 15.5 (0.s9 - 0.61)17.7 - 23.5 fi.8 - 2.4,4.0 - 5.3)
0.2 (0.0081
0.05 t0.@2)29.0 (1.142)
10.0 (0.39)

Design Specifications
]TEMMETRICENGLISHNOIES
:' vENSTONSOveralllength 3 DOOR
4 DOOR
Ov€rallWidth
Overall Height 3 DOOR
4 DOOR
Wheelbase 3 DOOR
4 DOOR
Track F/R
Ground Clearance
Seating Capacity
4.380 mm
4.525 mm
'1,710 mm
1,335 mm
1,370 mm
2,570 mm
2,620 mm
't,475/1,470 mm
150 mm
Four (3 DOOR)
172.1in
178.1 in
67.3 in
52.6 in
101.2 in
103.1 in
5|8.1/57.9 in
Five (4 DOOR)
,rerght (usA)cross V€hicle Weight Rating {GVWR)3,680lbs
'le,ght {CANADA)Gross Vehicls Weight Rating {GVWR)1,670 kg
:\GINEType81881 engine
818C1 engine
Cylinder Arrangement
Bore and Stroke
Displacement
Compression Ratio
81881
818C1
81881
B18C I
81881
B 18C1
81881
818C1
engrne
engane
engrne
engine
engine
engine
engine
engine
L!brication Systom
OilPump Displacement
Wster Pump Displacement
FuelRequired
81881
B18C 1
81881
B 18C1
91881
engrne
engrne
engine
engine
engine
818C1 engine
Water-cooled, 4-stroke DOHC
gasoline engine
Watercooled, 4-stroke DOHC
VTEC gasoline engine
Inline 4-cylinder, transverse
81.0 x 89.0 mm
81.0 x 87.2 mm
1,834 cm3 (mf )
1,797 cm3 (m{)
3.19 x 3.50 in
3.19 x 3.43 in
112 cu-in
110 cu-in
9.2:1
10.0 : 1
Eelt driven, OOHC 4 valve per cylinder
Belt driven, DOHC VTEC
4 valve per cylinder
Forced and wet sump, trochoid pump
50, {53 US qt, 44 lmp qt)/minute'l
71 f {75 US qt, 62 lmp qt)/minute"
140 f (148 US qt, 123 lmp qt)/minute*!
140 f (148 US qt. 123 lmp qt)/minute*'
UNLEADED gasoline with 86 Pump
Octane Numb€r or higher
Premium UNLEADED gasoline wilh
91 Pump Octane Number or higher
STARTERTypo
NormalOutput
NominalVoltage
Hour Rating
Direction of Rotation
Weight
Gear reduction
1.4 kW
12V
30 seconds
Clockwise as viewed lrom g6ar end
3.7 k9 | 8.3lbs
CLUTCHClutch Type
Clutch Facing Area
M/TSingle plate dry, diaphragm spring
Torq!e converter
203 cm' I 31 sq-in
TRANSMISSIONTransmission Type M/T
Primary Reduction
Synchronized 5-speed forward, 1 reverse
Electronically controlled
4-speed automatic. 1 rcverse
Diract 1 : 1
'1: At 6,000 engine
'2: At 7,600 engine
rpm
rpm
(cont'd)
3-17

Engine Removal/lnstallation
(cont'd)
14.Remove the engine ground cable at the body end.
Remove the adiusting bolt and mounting bolt, then
remove the power steering (P/Sl belt and pump.
a Do not disconnect the P/S hoses.
8 r 1.25 mm24 N.m (2.4 kgf.m. 17 lbl.ftl
6. Loosen the idler pulley bolt and adjusting bolt, then
remove the air conditioning (A/C) compresso. belt.
IDLER PULLEY BOLT10 x 1.25 mm44 N.m 14.5 kgt.m, 33 lbl.ftl
5-6
A/C COMPRESSOR BELT
17. (Manusl transmission) Remove the clutch slave
cylinder and pipe/hose assembly.
a Do not disconnect the pipe/hose assembly.
6 x 1.O rl|mll N.m { 1.1 kgt.m,SLAVE CYLINDER
8.0
8 x 1.25 mm24 N.m {2.4 kgl.m,17 lbt.ftl
18. Remove the transmission ground cable and hose
cramp.
6 x 1.O mm1l N.m 11 ,1 kgt.m,I tbt.ftl

Insrall the left front mount, then tighten the bolts in
the numbered sequence as shown (O-@),
O 12 x 1.25 ]n]n83 N.m 18.5 kst.m,61 lbt.ftlReplace.
@ 12 r 1.25 mm59 N.m {6.0 kgl.n,43 tb{.ftlReplace.
@ 10 r 1.25 mm44 N.m (4.5 kgf.m, 33 lbt.ftl
k-
5-15
a Check that the sp.ing clip on the end of each
driveshaft clicks into place.
GAUTION: Uso oow spring clips.
a Bleed air trom the cooling system at the bleed bolt
with the heater valve open (see page 10-5).
a Adjust the th.ottle cable (see section 1 1).
a Check the clutch pedal tree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
Alternator belt {s€e section 23).
P/S pump belt {see section 17).
A/C comoressor belt (see section 22).
a Inspect tor fuel leakage (see section 1 1).
. After assembling fuel line parts, turn on the ig-
nition switch (do not operate th€ starter) so
that the Juel pump operates for approximat€-
lV two seconds and the tuel line pressurizes.
Repeat this operation two or three times and
check for fuel leakage at any point in the fuel
line.
(cont'd)

6-3
Valve Clearance
Adjustment
NOTE:
. Valves should be adjusted cold; at a cylinder head
temperature of less than 100'F (38"C).
Adjustment is the same for both intake and exhaust
valves.
. After adjusting, retorque the crankshaft pulley bolt to
177 N.m (18.0 kgim, 130 lbf.ft).
1. Remove cylinder head cover.
ADJUSTING SCREW LOCATIONS:
2. Set the No. 1 piston at top dead center (TDC) (see
page 6-12). "UP" mark on the pulley should be at
the top, and the TDC grooves on the pulley should
align with the TDC groove on timing belt back
cover. TDC mark (painted white) on the crankshaft
pulley should align with pointer on the timing belt
tower cover.
Number 1 Diston at TDC:
INTAKE
EXHAUST
TDC MARKSlPeinted whitel
CRANKSHAFTPULLEY
"UP" MARKS
TDC GROOVES

Valve Seals
Replacement (cylinder head removal not requiredl
NOTE: Cylinder head removal is not required in this
procedure.
The procodure shown below applies when using the in-
car valve spring compressor (Snap-on YA8845 with
Y AAA$-2A 718" attachment).
@@ whcn u3ing this tool, a: with any tool,
always u!€ agproved cyr Protcction. Using th.
right tool for cach iob hclps incraa3. produstivity
whilo 3ltrgu8rding tool!, cquipmcnt lnd the u3c1'
1. Turn the crankshaft so that the No. I and the No' 4
pistons are at top d€ad center (TDC).
2. Remove the cylinder head cover.
3. Remove the distributor.
4. Loosen and disconnect the timing belt from the
c8mshaft pulleys.
5. Remove the camshaft holde, bolts, then r€move the
camshaft holder, the camshaft and rocksr arms.
lntakc V!lv6 Sclls
6. Using the 6 mm bolts supplied with the tool, mount
the two up.ights to the cylinder head 8t the end
camshaft holde.s. The uprights fit as shown.
7. Insort the cross shaft through the bottom hole ot
the two up.ights.
6-5
OIL PASSAGE
OIL PASSAGES
Select the 7E in. diameter long compressor attach-
ment and fasten the attachment to the No. 4 hole of
the lever arm with the speed pin supplied.
Position the piston at TDC and insert an air adaptor
into th€ spark plug hole. Pump air into the cylinder
to keep the valv€ closed while cgmpressing springs
and removing the valve keepers.
Position the lever arm under the cross shaft so the
lever is psrpendicular to the shEft and ths compres-
sor attachment rests on toD of the rstainer for th€
spring being compressed. Use the rear position slot
on the lever as shown.
NOTE: Put shop towels over the oil passag€s to
prevent the valve keepers from falling into the cylin-
der h€ad.
(cont'd)

Timing Belt
lllustrated Index
NOTE:
. Refer to page 6-12 for positioning crankshaft and pulley before installing belt.
. Mark the direction of rotation on the belt before removing.
. Replace the rubber seals tor oil leakag€ between the cylinder head and cover.
a Do not uss the middle cover and lower cover for storing itsms disassembled.
. Clean the middle cover and lower cover before installation.
CAP NUT6xl.0mm9.8 N'm (1.0 kgf.m,7.2lbtft) WASHER
\oReplaco when damagedor deteriorated.
6x1.0mm
CYLINDER HEAD COVERRefer to pago 6-31 wheninstalling.
RUBBER SEALSReplace when damagedor deleriorsled.
BACK OOVER
lnstallwith concavesurface facing in.Clean.
8 x 1.25 mm37 N.m 13.8 kgl.m,27 lbf'ft)
AD.'USTING BOLT10 x t.25 mm5/r N.m 15.5 kgl.m, ,o lbtft)For adjustrnent only,do not r€move,
BOLT
COVER
6x1.0mm9.8 N'm (1.0 kg{.m. t.2 lbf.tt}
9.8 N,m 11.0 kg{.m,7.2 lbl.frl
Adlustment, pago 6-9Replacement, page 6"10
TIMIMi BELTInspection, page 6-9ALTERNATORBELTAdjustm6nt,Soction 23
CRANKSHAFTPULI"EYRomov6 any oiland clgaa on thgtiming bolt guideplato side.
TIMING BELTDBIVE PULLEYRemove any oiland clean,
LOWEnCOVER
lnstall with concavesurface facing out,Remove any oilano ctean.
NOTE: When installing a new crankshaft and/or new bolt:
O tighten the crankshaft pulley bolt to 196 N'm (20.0 kgf'm, 145 lbf'ft),
O loosen bolt,
O retighten it to 177 N.m (18.0 kgt.m, 130 lbf'ftl.
'14 x 1,25 mmlt7 t{.m 118.0 kgl.m, 130lbtftlReplacsmenl, page 6-8
6-7

Timing Belt
Inspection
Remove the cylinder head cover.
. Reler to page 6-3'l when installing.
Inspect the timing belt for cracks and oil or coolant
soaking.
NOTE:
. Replace the belt if oil or coolant soaked.
. Rsmove any oil or solvent that gets on the belt.
Rotate pulley
and inspscr bell.
After inspecting, retorque the crankshaft pulley bolt
to 177 N'm ('18.0 kgf'm, 130 lbt'ft).
Tension Adjustment
CAUTION: Always Ediust timing belt tonsion with tho
cngin. cold.
NOTE:
. The tensionet is spring-loaded to apply proper ten-
sion to the belt automaticallv after making the follow-
ing adjustment.
. Always rotate the crankshaft counterclockwise when
viewed trom the pulley side Rotating it clockwise
may result in improper adjustment ot the belt ten-
sion.
Remove the cylinder head cover. (Refer to page
6-31 when installing.)
Set the No. 1 piston at TDC (see page 6-12).
Rotate the c.ankshaft 5 - 6 revolutions to set the
bslt.
4. Set the No. I piston at TDC.
3.
ADJUSNNG BOLT54 N.m (5.5 kqf.m,a0 rbr.ftlFor adiustment only,do not remove,
5.
6.
7.
8.
Direction olrolatlon.
Loosen the adiusting bolt 1/2 turn (180') onlv
Rotate the crankshaft counterclockwise 3-teeth on
the camshaft pulley.
Tighten the adjusting bolt to the specified torque.
After adjusting, retorque the crankshaft pulley bolt
to 177 N.m (18.0 kgl.m. 130 lbf.ft).
6-9