Head bolts HONDA INTEGRA 1994 4.G User Guide

ll.Remove the engine wire harness connectors and
wi.e ha.ness clamps from the cylinder head and the
intake manitold.
Four fuel injector connectors
Intake air tempe.ature {lAT) sensor connector
Engine coolant temperature (ECT) sensor con-
nector
TDC/CKP/CYP sensor connector
lgnition coil conn€ctor
ECT gauge sending unit connector
Throttle position (TP) sensor connector
VTEC solenoid valve connector
VTEC Dressure switch connector
Manifold absolute pressure (MAP) sensor con-
nector
ldle air control {lAC) sensor connector
EVAP purge controlsol€noid valvo connector
Intake air bypass {lABl control solenoid valve
conneclor
a
o
a
o
a
a
a
a
a
a
a
a
a
12.
13.
Remove the spsrk plug caps and distributor from
the cylinder head.
Remove the upper radiator hose, heat€r hose and
water bypass hose.
WATER BYPASS
HOSE
6r1.0mm9.8 N.m (1.0 kgt m,1.2 tbtftl
14. Remove the sDlash shield.
Remove the engine ground cable.
Romovo the adjusting bolt and mounting bolts, then
remove the power steering (P/S) pump belt and P/Spump.
. Do not disconnect the P/S hoses.
(cont'dl
15.
6x1.0mm9.8 N.m 11.0 kgl.m,7.2 tbt.ttl
6-57
,l

25. Remove the intake manifold.
26. Loosen the adjusting screws.
INTAKENo.4 No.3 No.2No. 1
No. 4No.3 No. 2EXHAUSTNo. 1
GASKET
21.Remove the camshaft holder plates, camshaft hold-
ers, and camshafts.
CAMSHAFT
28. Remove the cylinder head bolts, then remove the
cylinder head.
CAUTION: To prsvent warpage, unscrew th€ bolts
in sequence l/3 turn at a time; repeat until all bolts
aro loosoned.
CYLINDER HEAD BOLT LOOSENING SEOUENCE
6-59

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@

lnstallation
Installthe cylinder head in the reverse order of removal:
NOTE:
. Always use a new head and manifold gasket.
. The cylinder head gasket is a metal gasket Take care
not to bend it.
. Rotate the crankshaft, set the No. 1 piston at TDC
(page 6-51).
. Do not use the middle cover and lower cover for
storing items disassembled.
. Clean the middle cover and lower cover before instal-
lation.
a Replace the washer when damaged or deteriorated
1. tnstall the cylinder head gasket. dowel pins and the
head oil control orifice on the cylinder head
NOTE: Clean the oil control orifice when installing.
O.RINGReplace.
HEADOIL CONTROLORIFICECloan.
2. Tighten cylinder head bolts in two steps. In the first
step, tighten all bolts in sequence to about 29 N'm
(3.0 kgf.m.22 lbf'ft). In the final step, tighten in
same sequence to 81 N.m (8.3 kgnm.60 lbf'ft).
NOTE: Apply clean engine oil to the bolt threads
and under the bolt head.
CYLINDER HEAD BOLT TOROUE SEOUENCE
11 x 1.5 mm81 N.m {8.3 kgf.m,60 lbf ft)
Install the intake manifold and tighten the nuts in a
crisscross pattern in two or three steps, beginning
with the inner nuts.
GASKETRePlace
8 x 1.25 mm23 N.m 12.3 kgl.m.17 tbf.ftt
8 x 1.25 mm24 N,m 12.,4 kgf m,17 tbf.ft)(cont'd)
6-75

7.Apply liquid gasket to the hesd mating surface of
th€ No. 1 and No. 5 camshaft holders on both the
intako and exhaust side. Confirm that the camshaft
koywEys face up, then place those holders, together
with th€ No.2, No. 3 and No.4 camshaft holders,
on th€ cylind6r head.
NOTE: The arrows msrked on the camshaft holders
should point to the timing belt.
INTAKE
t/
bl
ffi
rfl?x
rt
EXHAUST
Apply liquid gaskot
to lh6 3had€d aroas.
Temporarily tighton the bolts of tho camshaft hold-
6rs and thE camshaft holder plates,
lrlo. 6
d
ro
I
CAIISHAFT HOIDERS
Ho. a No.3 1to.2
rllttt
888
CAMSHAFT HOI,I'ER
9. Tighten the bolts in the sequence shown below.
(D - @: 8 x 1.25 mm 27 N.m {2.8 kgf.m,20 lbt ttl
(D - (D: 6 x 1.0 mm 9.8 N.m (1.0 kgrl.m, 7.2 lbf'ft}
10. Install the back cover and camshaft pulleys.
CAMSHAFT
ooooo0o
10 x 1.25 mm56 N.ln l5.t kgf.m,4r lbl.trl
6x1.0mm9.8 N.m 11.0 kgtm, t.2lbf'ft)
(cont'd)
6-77

18. Install the sub-shaft assembly in the transmission
housing {see page 14-138).
19- Install the reverse idler gear and gear shatt holder
(see page 14-154).
20. Install the differential assembly in the torque con-
verter housing.
21. Install the mainshaft and countershaft sub-assembly
together in the torque converter housing.
MAINSHAFTSUB.ASSEMBLY
COUNTERSHAFTSUB.ASSEMBLY
22.Turn the shift fork so the large chamtered hole is fac-
ing the fork bolr hole. then installthe shift fork with
the reverse selector and torque the lock bolt. Bend
the lock tab against the bolt head.
SHIFT FORK
LOCI( WASHERReplace.
6 x 1.0 mm4 N.m(1.4 kgl.m, rO lbt.ft)
Large chamfered holefaces this way.
,,1
24.
lnstall the reverse gear with the collar and needle
bearing on the countershalt.
Align the spring pin of the control shaft with the
transmission housing groove by turning the control
shalt.
Place the transmission housing on the torque con-
verter housing with a new gasket and the dowel pins.
CONTROL
/K"\
//2"\TRANSMISSION HOUSING
Install the transmission housing bolts along with the
t.ansmission hanger and the connector stay, then
torque the bolts in two or more steps in the sequence
shown.
TOROUE: 44 N.m (4.5 kgf.m, 33 lbf'ft)
TRANSMISSIONHANGER
25.
CONNECTOR
14-159

lnstallation
CAUTION; BG Glrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1. Before installing the gearbox, slide the rack all the
way to right.
2. Pass the right side of the steering gearbox above
and through the right side of the rear beam.
3. Hold the steering gearbox and slide the rack all the
wav to the left.
4. Raise the left side of the steering gearbox above
and through the left side of the rear beam.
5. Install the pinion shaft grommet and insert the pin-
ion shaft up through the bulkhead.
NOTE: Align the tab on the pinion shaft grommet
with the slot in the valve bodv.
6. Install and tighten the gearbox mounting bolts.
NOTE: After installing the gearbox, check the air
hose connactions for interference with adjacent
pans.
58 N.m 15.9 kg[.m, $ lbl.ftl
TAA
38 N m 13.9 kgl.m, 28 lbt.ftl
17-63
YELLOW GEAR TOOTH
7.Center the steering rack within its stroke.
Make sure that the cable reel of the SRS is centered
as follows:
. Turn the steering wheel left approx. 150 degrees,
to check the cable reel position with indicator.
. lfthe cable reel is centered. the yellow gear tooth
lines up with the alignment mark on the cover.
. Return the steering wheel right approx. 150
degrees to position the steering wheel in the
straight ahead position.
ALIGNMEi'IT MARK
Slip the lower end of the steering joint onto the pin-
ion shaft (line up the bolt hole with the groove
around the shaft), and tighten the lower bolt.
NOTE:
. Connect the steering shaft and pinion with the
cable reel and steering rack centered.
. Be sure that the lower steering ioint bolt is se-
curely in the groove in the steering gearbox pin-
ion.
. lf the steering wheel and rack are not centeted,
reposition the serralions at lower end of the
steering joint.
(cont'dl
22 N.m 12.2 kgi.m, 16lbf.ftlLOWER BOLT

Rear Edge Closing Adjustment
Open the glass about a foot, then close it to check where
rear edge begins to rise. lf it rises too soon and seats too
tightly against the roof panel, or too late and does not
seat tightly enough, adjust it.
1. Remove the headliner (see psge 20-98).
2. Remove the glass.
3. Remove the motor {see page 2O-8O).
4. Align the tilt-up position of the lifter on each side.
Check that the alignment left and right. then install
the motor.
Install the glass, then check for water leaks.
NOTE: Do not use high pressure wate..
lnstall the headliner.
Glass and Sunshade Redacernent
1. Open the sunshade.
2. Tilt-up the glass.
3. Remove the bolts, then remove the glass from rheglass bracket.
V : 8oh locations, 6
4. Remove the screw and lift the sunshade rail on each
side.
5. Silde the sunshade
sunshade.
V : Scraw locations, 2
forwa.d, then remove the
SUNSI{ADE
l-tII
)
6
7
Installation is the reverse of the removal procedure.
Check for water leaks.
NOTE: Do not use high pressure water.
GLASS BRACKET
20-79

Moonroof
Motor, Drain Tube and Frame Replacement
CAUTION: B€ caretul not to damag€ lhe seats, dash-
board and other interior trim.
1. Remove the glass (see page 2O-79) and headliner
(see page 20-98).
2. Disconnect the motor connector, and remove the
clips securing the ceiling light wire harness.
3. Remove the bolts and nuts, then remove the motor,
if necessarv,
NOTE: Make sure both sliders are parallel when in-
stalling the motor.


: 8olt, nut locationg
A

: Bolt, 2
6x1.Omm I9.8 N.m ILd tt.o kgf.-, I,.?- ", _,/
< : CliD locations. 2
CEILIING LIGHT
FRAME
B : Nut, 3
20-80
4.Disconnect the drain tubes.
Remove the bolts, then remove the trame from the
car.
NOTE: You may require assistance when removing
the frame.


: Eolt locations, I
6 x 1.0 mm
DRAIN TUBETo install, slide the draintube over the ftame nozzleat least 10 mm {O.4 in}.
6.
TUBE CI-IP
Pull the drain tubes out the front and rear pillars.
NOTE; Betore pulling out the drain tube, tie a string
to the end of it so it can be reinstalled.
Installation is the reverse ol the removal procedure.
NOTE:
a Clean the surtace of the frame.
a Check the trame seal.
a Check for water leaks.
7.
9.8 N.m (1.0 kgt m,7.2 rbr.ttl )
FRAME
FRONT

Moonroof
Rear Edge Closing Adjustment
Open the glass about a foot, then close it to check where
rear edge begins to rise. It it rises too soon and seats too
tightly against the roof panel, or too late and does not
seat tightly enough, adjust it.
1. Remove the headliner (see page 20-1OO).
2. Remove the glass.
3. Remove the motor (see page 20-87).
4. Align the tilt-up position of the lifter on each side.
o.
5.
7.
Check that the alignment lett and right, then install
the motor.
Install the glass. then check for water leaks.
NOTE: Do not use high pressure water.
Install the headliner.
Glass and Sunshade Replacement
1. Open the sunshade.
2. Tilt-up the glass.
3, Remove the bolts, then remove the glass from the
glass bracket.
Using the moonroof
BOLTS6 x 1.O mm9.8 N'm lt O kgf m,
4.
5.
7.2 tbt.ftl
Remove the screws and lift the sunshade rails.
Silde the sunshade forward. then remove the
sunsnaoe.
SUlTSHADERAIL
Installation is the.everse ot the removal procedure.
Check for water leaks.
NOTE: Do not use high pressure water.
GLASS BRACKET
20-86