service HONDA INTEGRA 1994 4.G Owner's Manual

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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)

Lubrication Points
For the details ol lubrication points and type of lubricants to be spplied, reter to the illustrated index and various workprocedure (such as Assembly/Reassembly, Replacement, Overhaul, Instatlation, etc.) contained in each section.
No.LUBRICATION POII\ITSLUBRICAI\IT
IEngineAPI Service Grade: Use SG or SH "Energy Conserving
II" grade oil.
The oil container may also display the API Certifications€al shown below. Make sure it says'For GasolineEngines.'
SAE Viscosity; See chan below.
Transmission Manual
Automatic
API Service Grades: SF or SG
SAE Viscosity: 1O W-3O or 1O W-4O
Honda Premium Formula or DEXRON@ II
Automatic transmission fluid
3Brake line (lncludes Anti-lock brake linelBrake fluid DOT3 or DOT4
4Clutch lineBfake tluid DOT3 or DOT4
Power steering gearboxSteoring grease P/N 08733-BO7OE
Release fork (Manual transmission)Supe. High Temp Urea Grease (P/N O8798*9OO2)
8
Throttle wire end {Dashboard lower Danel holel
C.uise cont.ol actuatot wire end
{Dashboard lower Danel holel
Silicone grease
I
10'I 'l
12
13
14
15
to
17
18
Throttle cable end (Throttle linkl
Cruise control actuator cable end lActuator link)
Brake master cvlinder Dushrod
Clutch master cylinder pushrod
Engine hood hinges and engine hood latch
Batte.v terminals
Fuel fill lid
Hatch hinges or trunk hinges
Door hinges. upper and lowet
Door oDen detent
.Multi-purpose grease
19Rear brake calioersRust-p,eventive agant
20Power steering systemHonda power steering tluid-V
21Air conditioning compressorRetrigerant oit ND-otL8 |PlN 38899-pR7-A01)(For Relrigerant: HFC-134a (R-134a))
-20 0 20 r}() 60 ao loooF
-30 -20 -'to o 10 20 30 40"c
Recolnmendod engine oilEngine oil viscosity torambient tgmpelalure rangos
API CERTIFICATION SEAL

Engine Removal/lnstallation
@a Make sure jacks and safety stands aro placed ploper-
ly and hoisl brackots arg attachod to the correct po-
sitions on tho engine (se€ ssction 1).
a Mak€ sure tho car willnot roll off stands and tallwhile
you are wotking under it'
CAUTION:
a Use fendet covals to avoid damaging painted
sudaces.
r Unspecified itsms alo common
a Unplug tho widng connectots carefully while holding
the couplor and tha connector portion to avoid
oamage.
a Mark all wiring and hoses to avoid misconnection.
Also, be sulo that thsy do not contact other wiring
or hoses, or interfere with oth€l parts.
NOTE: Anti-theft radios have a coded theft ptotection
circuit. Be sure to get the customer's code number beJore
- Disconnecting the batterY.
- Removing the No. 32 (7.5 A) fuse from the under-
hood tuse/relay box.- Removing the radio
Atter service, reconnect power to the radio and turn it
on. When the word "CODE" is displayed, enter the cus-
tomer's 5-digit code to restore radio operataon.
1. Remove the hood (see section 2O).
2. Remove the strut brace
8 x 1.25 mm24 N.m (2.4 kgf.m,17 rbt.ft)
Disconnect the battery negative terminal lirst. then
the positive terminal.
Disconnect the battery cables from the undel-hood
fuse/relay box and under-hood ABS fuse/relay box.
6 x l.O mm9.8 N.m (1 .O kgf'm,7.2 rbl.ftl
{cont'd)
STRUT ERACE
BATTERY CABLES
5-3

Engine Removal/lnstallation
m
(cont'd)
Remove the intake air duct, air cleaner housing as-semblv and the bracket.
6 x 1.O mm9.4 N.m {l.O ksf.m, 7.2 tbf,ftl
Remove the evaporative emission (EVAp) controlcanister hose and vacuum hose.
VACUUM HOSE
THROTTI.E BODY
7. Remove the engine wire harness connectoE on theright side of engine compartment.
8. Relieve fuel pressure by loosening the service bolton the tuel filter about one turn {see section 1 1).
@ oo not amoke whito working on thofuel system. Keep open flame away trom wo.k arsa.Drain fuel only into an approved container.CAUTION:
a Before disconnocting any fu€l line. reliovo the tuolpressule as doscribed above.a Place a shop towel ov61 the fu6l filter to prevontprossurized tuel from spraying ovel tho aogine.
9. Remove the fuel feed hose.
SERVICE BOLT15 N.m (1.5 kgt.m, 11 tbt.ftl
BAITJO EOLT33 N.m 13.4 kgt.m,25 tbt.ftt
6 x'l.O mm9.8 N-m ll.0 kgt.m.

Gylinder Head
Removal
I
t
Engine removal is not required for this procedure.
CAUTION: To avoid damaging tho cylinder head, wait
until tho ongino coolant temporature drops bolow 100"F
{38"C) beforo loo36ning the rotainin0 bolts.
NOTE:
. Inspect the timing belt before removing the cylinder
neao.
. Turn the crankshaft pulley so that the No. 1 piston is
at top dead center (TDCI (page 6-12).
. Mark all emissions hoses before 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 irom the under-
hood fuse/relay box.- Removing the radio.
After service, reconnect oower to the radio and turn it
on.
When the word "CODE" is displayed, enter the cus-
tomer's 5-digit code to restore radio operation.
1. Disconnect the negative terminalfrom the battery.
2. Drain the engine coolant (see page 10-5).
. Remove the radiator cap to speed draining.
3. Relieve fuel pressure (see Section 1 1).
@ Do not smoke whils working on tusl
systom, keep opon flame or spark away trom work
area. Drain fuol only inlo an approvod containsr.
4. Disconnect the fuel feed hose.
SERVIC€ BOLT
WASHERSReplace.
5, Remove the intake air duct.
Remove the breather
evaporative emission
hose, water bypass hose and(EVAP) control canister hose.

Valves, Valve Springs and Valve Seals
Removal
1.
2.
NOTE: ldentify valves and valve springs as they are
removed so that each item can be reinstalled in its oriqi-
nal Dosition.
Tap each valve stem with a plastic mallet to loosen
valve keepers before installing the spring compres-
sor.
lnstall the spring compressor. Compress spring and
remove vatve Keeper.
07757 - PJ10r0A
Installthe special tool as shown.
Remove the valve seal.
COMMERCIALLY AVAILABLEVALVE GUIDE SEAL REMOVERLISLE P/N 5t9d) or KO3350
SEALREMOVER
VALVE SPRING COMPRESSORxo No.3tB. whh r35 JAW o.
lntaks Valvo Dimonsions
A Standard (New): 30.90 - 31.10 mm
|.1.217 - 1.221inl
I Standard (Nowl: 103.80 - 10'1.10 mm
{4.087 - 4.098 inl
C Standard lNow): 6.580 - 6.590 mm
{0.2591 - 0.259/r in}
C Servico Limit 6.55 mm (0.258 inl
D Standlrd (N€w): 1.35 - 1.65 mm
10.053 - 0.065 inl
D Ssrvice Limit: 1.15 mm (0.045 in)
Exhau3t Valve Dim6nsions
A Standard {New): 27.90 - 28.10 mm
11.098 - 1.106 inl
B Standard (Newl: 104.00 - 104.30 mm(4.094 - 4.106 inl
C St.ndard (New): 6.550 - 6.500 mm
10.2579 - 0.2583 inl
C Servico Limit 6.52 mm (0.257 in)
D Standard {New): 1.65 - 1.95 mm
10.065 - 0.077 inl
D Service Limit: 1.,[5 mm (0.057 in)

Valves, Valve Springs and
Valve Seals
Valve lnstallation
When instaliing valves in the cylinder head, coat
valve stems with oil before insening them into valve
guides, and make sure valves move up and down
smoothlv.
When valves and springs are in place, lightly tap the
end of each valve stem two or three times to snsure
proper seating of valves and valve keepsrs (use plas-
tic mallet).
NOTE: Tap the valve stem only along its axis so you
do not bend the stem.
PLASNC MALI.IT
?ur
Valve Guides
Valve Movement
Measure the guide-to-stem clearance with a dial indica-
tor while rocking the stem in the direction of normal
thrust (wobble method).
lntake Valve Stsm-to-Guide Clearance:
Strndlrd (Newl: 0.0i1- 0.10 mm
(0.002 - 0.004 in)
Ssrvicc Limit: 0.16 mm {0.006 in)
Exhsust Valye Stom-to-Guide Clearance:
Standard {N€w): 0.10 - 0.16 mm
{0.0O'l - 0.006 in)
Slrvica Limit: 0.22 mm {0.000 in)
Valve extended 10 mm out from seat
lf measurement exceeds the service limit, recheck
using a new valve.
lf measurement is now within the service limit,
reassemble using a n€w valve.
lf measurement still exceeds limit, recheck using
alternate method below. then replace valve and
guide, if necessary.
NOTE: An alternate method of checking guide to stem
clearance is to subtract the O.D. of the valve stem, mea-
sured with a micrometer. from the l.D. of the valve
guide, measured with an inside micrometer or ball
gauge.
Take the measurements in three places along the valve
stem and three places inside the valve guide.
The diiference between the largest guide measurement
and the smallest stem measurement should not exceed
the service limit
lntake Valve Stom-to-Guide Clearance:
Standard (Newl: 0.02 - 0.05 mm(0.001-0.002 in)
Service Limit 0.08 mm (0.003 in)
Exhaust Valve Stom.to.Guid€ Clearanco:
Standard (Newl: 0.05 - 0.08 mm(0.002 - 0.003 inl
Srrvico Limit 0.ll mm 10.00't inl
6-24

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.

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

Gamshafts
Inspection (cont'd)
10, lf camshaft-to-holder oil clearance is out of loler-
ance:
- And camshaft has already been replaced, you
must replace the cylinder head.
- lf camshaft has not been replaced, first check
total runout with the camshaft supported on V-
blocks.
Camehaft Total Runout:
Sisndard (New): 0.015 mm (0.0006 inl
Service Limit: 0.03 mm (0.0012 in)
Rotat€ camshsftwhile measuring
- lf the total runout of the camshaft is within toler-
ance, replace the cylinder head.- lf the total runout is out of tolerance, r€Dlace the
camshaft and recheck. lf the oil clearance is still
out of tolerance. replace the cylinder head.
6-66
IiITAKEEXHAUST
PRIMARY33.i{'l1 mm
(1.3154 inl
33.111 mm(1.3036 in)
MID36.377 mm
l't.4322 inl
35.720 mm
(1.4063 inl
SECONDARY34.547 mm(1.3601 in)
34.381 mm(1.3536 in)
11. Check cam lobe wear.
Clm Lobs Hcight Standard (N.w):
Check this are6 tor wsar.
Crm Porition
INTAKE
MtosEc
CXHAUST
SEC MID PRI
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