crankshaft HONDA INTEGRA 1994 4.G Owner's Manual

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

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

Engine Block
Speciaf Tools .............7'2
lllustrated Index ................................... 7-3
Flywheel and Drive Plate
Repfacement .........7-7
Main Bearings
Clearance ,.............. 7-8
Selection ................ 7-8
Connecting Rod Bearings
Clearance ............... 7-9
Selection ................ 7-9
Crankshaft
Removal .................7-10
End Play .................7-12
lnspection ........,,,.,,7-12
fnstallation .............7'22
Cylinder Block
Inspeetion ..............7-13
Bore Honing .....,.,,.7'14
Pistons
Inspaction ..............7-15
Installation .............7-16
Piston Rings
Replacement .........7-16
End Gap .................7-17
Ring-To-Groove C|earance,,,,.,,,...... 7 -17
Alignment ..............7-18
Piston Pins
Removal ........,........7-18
Installation (818B1 engine) ............. 7-19
fnstaffation (818C1 enginel ............. 7-20
fnspection ..............7-2O
Connecting Rods
End Play .................7-21
Sefeetion ..........,,,,,,7-22
Oil Seal
fnstaffation .............7-25
Installation
(engine removal not requiredl.. .......7-26

lllustrated Index
NOTE:
. Apply liquid gasket to the mating surfaces of the right
side cover and oil pump housing before installing
them.
. Use liquid gasket, Pan No.08718 - 0001.
. Clean the oil pan gasket mating surfaces before
installing it.
Bl8Bl engine: wAsHEF
Lubricate all internal parts with engine oil during
reassemory.
6x1.0mm12 N.m (1.2 kgf.m,I lbf.ftl
6x1.0mm11 N.m (1.1 kgf.m,8lbtft)
OIL SCREEN
11 x 1.25 mm76 N.m17.8 kgl.m, 56 lbf ftlApply engine oilto the bolt
threads and the washers.NOTE: After torquingeach cap, turn crankshaftto check lor binding.
DRAIN PLUG44 N.m {4.5 kgf.m,33 tbtfr)
GASKETReplace.
6x1.0mm1'l N.m {1.1 kgt.m, I lbtft)
OIL PAN
O.RING
GASKETReplace.
BEARING CAP
12 x 1.0 mm103 N.m (10.5 kgf.m, ?6lbf ft)
MANUALFLYWHEEL
'12 x 1.0 mm74 N.m {7.5 kgt m,54lbf.ftlTorque sequence, page 7 7
DRIVE PLATECheck for cracks,
AUTOMATIC TRANSMISSION
WASHER
6x1.0mm11 N.m {1.1 kgl.m,8 tbf.frt
CRANKSHAFTEnd play, page 7-12Runout, Taper, andOut-of-Round, pages 7 12, 13Instsllation, page 7 22
MAIN BEARINGRadial clearance, page 7-8
Sel€ction, page 7-8NOTE: New main bearingsmust be selected by matching
crank and block identificationmarkrngs.
Apply liquid gasket
to block mating surface.
OIL SEALInstallation, page 7-25,
RIGHTSIDE COVERDOWEL PINSOIL PUMPOverhaul, page 8-9THRUST WASHERSGrooved sides face outward.NOTE: Thrust washer thicknessis tixed and must not be changedby grinding or shamming.
8 x 1 .25 mm2,1 N.m {2.4 kgt m,17 tbt.ft)
OIL SEALInstallation, page 8-11Apply engrneorl.Replace.
Apply liquid gasket
to block mating
6x1.0mm'11 N.m {1.1 kgf'm, 8 lbl ft)(conr'dl
7-3

BEARINGCAP BRIDGE
No. a 3, /a CAP BOLTSll x 1.5 mm64 N.m {6.5 kgt m,49 tbf.ftlApply engine oilto tho boltthreads and the washers.NOTE: Aftertorquingeach cap, turn crankshaftto check for binding.
No. 1,5 CAP BOI-TS11 x 1.5 mm73 N.m {7.4 kgf.m,56 tbt'ft|Apply engine oil.
BEARING CAP
CRANKSHAFTEnd play, page 7-12Runout, Taper, andOut-of-Round, pages 7'12. 13Installation, page 7-22
YHRUST WASHERSGrooved sides lace outward.NOTE: Thrust washer thicknessis fixed and must not be chano€d
MAIN BEARINGRadial clearance. page 7 8S6l€ction, page 7-8NOTE: New main bearingsmust be selected by matchingcrank and block identificationmarxrngs.
OIL JEI BOLY16 N.m 11.6 kg{'m, 12lbtftlBe caretul not to damage.
OIL PUMPOverhaul, page 8-9Apply liquid gasket
to block matingsurface.
OIL SEALInstallation,pages 7-25, 26
11 N.m 11.1 kgt m,8 lbf ftl
Replace.
6r1.0mm
OIL JETInspection,page 8-8
OIL SEALInstellelion,page 8-11Replace.
RIGHT SIDECOVERApply liquid gasketto block matingsurface.
6x1.0mm11 N.m {1.18 rbf.ftlkSf.ft,
DOWEL PIN
DOWEL PIN
O.RING.Apply engineorl.Replace.
8 x 1.25 mm24 N.m {2.4 kgt m,17 tbtft)
(cont'd)
7-5

lllustrated IndexF
(cont'd)
NOTE: New rod bearings must be selected by
connecting rod and crankshaft identification
(see pages 7-8,9)
matching
marKrngs
Lubricate all internal parts with engine oil during
reassemorv.
PISTON RINGSReplacement, page 7'16Measurement. page 7-17Alignment, page 7 18
PISTON PINRemoval, page 7-18lnstallation, pages 7 19, 20Inspection, page 7'20
PISTON INSTALLATION DIRECTION
EXHAUST
INTAKE
Removal, page 7'11Measurement, page 7 15Inspect top of each cylinder borefor carbon build-up or ridgobetore removing piston.Remove ridge it necessary, page 7'11CONNECTING ROOEnd play, page 7-21
CONNECTING RODEEARINGSClearance, page 7-9Selection, page 7-9
CONNECTING ROD NUT818B1 ongine8x 0.75 mm31 N.m {3.2 kgf.m,23 lbf ftl818C1 engine9 x 0.75 mma,a N.m (4.5 kgt m, 33 lbf.ft|After torquing each bearangcap, rotate crankshaft tocheck for binding.
r-(,
Selection, page 7-22Small end measurement. page 7-21
BLOCXCylinder bore inspection, page 7 13Warpage inspection, page 7'14Cylinder bore honing, page 7-14
CONNECTING ROD BEARING CAPInstallation, page 7'23NOTE: Install caps so the bearing recess ison the same side as the recess in the rod.
r@
-1@

Flywheel and Drive Plate
Replacement
Manual Transmission:
Remove the eight flywheel bolts, then separate the lly-
wheel from the crankshaft flange. After installation,
tighten the bolts in the sequence shown.
r10.5 kgi.m,76lbt.ftl
RING GEAR HOLOERo?LAB - PV00100,07924 - PO2IX)03 or07924 - PD20/m2
\
n.t=?4
fut!!-+-rt=tz-21I lvaz'Z-+
ENGINEBLOCK
o -o.r \
/ oo^t,
\..?bi
/ AK{:{AAo
rs#*ffi_9
Automatic Transmission:
Remove th€ eight drive plate bolts, then separate the
drive plate from the crankshaft flange, After installation,
tighten the bolts in the sequence shown.
r t.0 mmt,l N.m(7.5 kg{.m, 54 lbf.ft}
7-7