cylinder head HONDA INTEGRA 1994 4.G Owner's Manual

Valve Seats
ACTUALSEATINGSUBFACE
VALVESEAT
PRUSSIAN
Reconditioning
1. Renew the valve seats in the cylinder head using a
valve seat cutter.
NOTE: lf guides are worn (see page 6-24), replace
them (see page 6-251 before cutting the valve seats,
2. Carefully cut a 45' seat, removing only enough
material to ensure a smooth and concentric seat.
3. Bevel the upper edge of the seat with the 30o cutter
and the lower edge of the seat with the 60' cutter.
Check width of seat and adjust accordingly.
4. Make one more very light pass with the 45" cutter to
remove any possible burrs caused by the other cut-
ters.
Valvo Seat Width llntake and Exhaustl:
Standard: 1.25 - 1.55 mm {0.049 - 0.061 inl
Servics Limit:2.0 mm 10.08 inl
SEATWIDTH
After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue compound to the valve
face, and insert valve in original location in the
head, then lift it and snap it closed against the seat
severaltimes.
!
6-27
7.
The actual valve seating surface, as shown by the
blue compound, should be centered on the seat.
. lf it is too high (closer to the valve stem), you
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45'
cutter to restore seat width.
. lf it is too low (closer to the valve edgel, you
must make a second cut with the 30' cutter to
move it up, then one more cut with the 45" cutter
to restore seat width.
NOTE: The final cut should always be made with
the 45' cutter.
Insert intake and exhaust valves in the head and
measure valve stem installed height
Intako Valve Stem Install€d Height:
Standard (New): /$.765 - '11.235 mm
{1.604It - 1.6234 in}
Service Limit: ill.il85 mm (1.6:133 inl
Exhaust Valvo Stem lnstalled Height:
Standard {Newl: ,12.765 - i|:|.235 mm
11.6a37 - 1.1022 in1
Service Limit /B.il85 mm (1.7120 inl
lf valve stem installed height is over the service
limit, reDlace valve and recheck. lf still over the ser-
vice limit, replace cylinder head; the valve seat in
the head is too deeo.
8.

t
Gylinder Head
Installation
Installthe cylinder head in the reverse order of removal:
NOTE:
. Always use a new head gasket.
. Cylinder head and cylinder block surface must be
ctean.
. "UP" mark on the timing belt pulleys should be at the
top.
. Do not use the middle cover and lower cover for stor-
ing items disassembled.
. Clean the middle cover and lower cover before instal-
lation.
. Replace the washer when damaged or deteriorated.'1. Cylinder head dowel pins and the oil control orifice
must be aligned,
NOTE:
. When handling a metal gasket, care should be
taken not to told it or damage the contact surface
of the gasket.
. Clean the oil control orifice when installing.
CYLINDER HEAD GASKET
{3 LAYERS OF METALIReplace.
OOWEL PINSorl coNtnolORIFICEClean.
O.RINGReplace.
Tighten the cylinder head bolts in two steps. In the
Jirst step tighten all bolts, in sequence, to about 29
N.m {3.0 kgf.m, 22 lbl.ltJ; in the final step, tighten in
the same sequence to 83 N.m (8.5 kgf.m, 61 lbf'ft).
NOTE:
. Apply engine oil to the cylinder head bolts and
the washers.
. Use the longer bolts at positions No. 1 and No. 2
as shown.
CYLINDER HEAD BOLTS TOROUE SEOUENCE
@o@@@
NOTE: lf camshaft-to-holder oil clearances (see page 6-
21) are not within specitication, the head cannot be
resurfaced.
lf camshaft'to-holder oil clearances are within specifica-
tions, check the head for warpage.
lf warpage is less than 0.05 mm (0.002 in) cylinder
head resurtacing is not required.
lf warpage is between 0.05 mm (0.002 in) and 0.2 mm
(0.008 in), resurface cylinder head.
Maximum resurface limit is 0.2 mm (0.008 in) based
on a height of 132.0 mm (5.20 in).
Measure along edges, and 3 ways across center.
Cylinder Hoad Height:
Standard (New): 131.95 - 132.05 mm
{5.195 - 5.191t in}
PRECISION STRAIGHT EOGE
Put longer bolts here.

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