Ax belt HONDA INTEGRA 1994 4.G Owner's Manual

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

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

Removal
NOTE:
. Turn the crankshaft pulley so the No. 1 piston is at
top dead center {TDC) before removing the belt (see
page 6-51).
. Inspect the water pump when removed the timing
belt {see page 10-9).
Remove the wheel well splash shield (see page 6-
57 ).
Loosen the adiusting bolt and mounting bolts, then
remove the power steering (P/S) pump belt.
I x 1.25 mm2a N.m l2.a kgt.m, 17 lbt ttl
Loosen the adjusting bolt and idler pulley bracket
bolt, then remove the air conditioning (Ay'C) com-
oresso. belt.
D1INBOLT10 x 1.25 mmira N.m (4.5 kgf.m, 33 lbf'ttl
AOJUSTING
ADJUSNNG
BELT
4. Loosen the adiusting nut and mounting nut, then
remove the alternator belt.
NUTI x 1.25 mm24 N.m {2.a lgf.rn,17 tbf.ftl
MOUNTING NUT10 x 1.25 mm4,t N.m lia.5 kgl.m,33 tbt ftl
Remove the cruise control actuator (see page G58).
Bemove the side engine mount.
10 x 1.25 mm52 N.m 15.3 kgt m, 38 lbtftl
CNGINCMOUNT
12 x 1.25 mm74 N.m (7.5 kgt m,s4 lbf.trl
(cont'd)
6-49

Timing Belt
Removal lcont'd)
1.Remove the cylinder head cover.
. Refer to page 6-78 when installing.
Remove the pulley bolt and crankshaft pulley (see
page 6-47).
Remove the middle cover and the lower cover.
NOTE:
. Do not uss the middle cover and lower cover for
storing items disassembled.
a Clean the middle cover and lower cover before
installation.
Loosen the adjusting boh 180'.
Push the tensioner to r€move tension from the tim-
ing belt, then retighten the bolt.
Remove the timing belt from the pulleys.
10.
12.
11.
8.
a
6x1.0mm9.8 N.m 11,0 kgf'm, 7.2 lbl'ftlWASHERReplace whenor deteriorated.
CYLINDEROOVERRel€r to pago 6-78when inslalling.
NMING BELTAdjustment, page 6-48
MIDDLECOVER
RUABER SEALSReplac6 whenor deteriorated.
6x1.0mm9.8 N.m {1.0 kgf.m,7.2 rbnftl
LOWER COVER
6r1.0mm9.8 N.m 11.0 kgf.m,7.2lbtftl
CRANKSHAFT PULl"EYRemove any oil andclean on the timing beltguide plat6 side.
BELTTENSIONER
TIMING BELTGUIDE PLATElnstallwith concavesurface facing out.Remove any oiland clean.PULI.TY BOLT17? N m {18.0 kgf.m, 130lbtftlADJUSNI{G BOLT10 x 1,25 mm5,t N.m 15.5 kgf.m,.(l rbf.fttFor adjustm€nt only,
@^Rv@

Timing Belt
lnstallation
Install the timing belt in the feverse order of removal;
Only key points are described there.
NOTE: Clean the middle cover and lower cover before
installation.
1. Position the crankshaft and the camshaft pulleys as
shown betore installing the timing belt.
A. Set the crankshaft so that the No. 1 piston is at
top dead center {TDC). Align the groove on the
teeth side of the timing belt drive pulley to the V
pointer on the oil pump.
B. Align the TDC marks on intake and exhaust pul-
leys.
2. Install the timing belt tightly in the sequence
shown.
O Timing belt drive pulley (crankshatt) * @
Adjusting pulley * @ water pump pulley * @
Exhaust camshaft pulley * @ Intake camshaft pul-
lev,
(cont'd)
6-51

Timing Belt
Installation (cont'dl
1Loosen and retighten the adjusting bolt to tsnsion
thB belt.
Rotate the crankshaft about 4 or 6 turns countsr-
clockwise so that the belt positions on the pulleys.
Adjust ths timing bolt tension (see pags &48).
Ch€ck ths crankshaft pullsy and the camshaft pul-
lsys at TDC.
CRANKSHAFT PULLEY:
1.lf a camshaft pulley is not positioned at TDC.
.emove the timing belt and adiust the positioning
following the procedure on page 6-51, th6n r6install
rhe riming belt.
NOTE: Refsr to page 6,19 for timing b€lt removal.
Aft€r installation, adiust the tension of each b€lt.
o See section 23 for alternator belt tension adiust-
menr.
. See section 22 tot NC compr€ssor b6lt tension
adjustm€nt.
. See section 17 for P/S pump b6lt t€nsion adiust-
menL
4.
5.
b.
CAMSHAFT PULI..EY:
"UP- MANKS
6-52

Cylinder Head
Removal
Engine removal is not required or this procedure.
CAUTION: To avoid damaging tho cylinder head, wail
u[tilths.nginc coolant tsmperaturo drops bolow 100"F(38'Cl bafore loos6ning tho retaining bolts.
NOTE;
. Inspect the timing belt before removing the cylinder
head.
Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (TDc) {page 6-51).
Mark all emissions hoses betore disconnecting them.
Anti-theft radios have a coded theft protection circuit.
Be sure to get the customer's code number before- Disconnecting the battery.- Removing the No.32 (7.5 A) fuse trom the under-
hood fuse/relay box.- Removing the radio.
After service, reconnect power to the radio 8nd turn it
on.
When the word "CODE" is displaved. enter the cus-
tomer's 5-digit code to restore radio operation,
Disconnect the negative terminal from the battery.
Drain the engine coolant (see page 10-5).
. Remove the radiator cap to speed draining.
Relieve fuel pressure (see section 111.
l@ Do not 3moke whilo working on fuel
a
a
'1.
systgm. ko6p opon tlamo ot Spark away trom work
aroa. Drain fugl only into an approved containsr,
4. Disconnect the fuel feed hose.
SERVIC€ BOLT15 N.m (1.5 kgtm, rl bf.tt)WASHERSReplace.
BANJO BOLT
5. Remove th€ strut brace,
6. Remove the intake air duct.
8 x 1.25 mm24 N.m (2.1kg[.m, 17 lbtftl
INTAKE AIR
(cont'd)
6-55

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