drive shaft HONDA INTEGRA 1994 4.G Workshop Manual

Standards and Service Limits
Automatic Transmission (cont'dl - Section 14
SERVICE t_tMtTMEASUREMENTSTANDARD {NEW}
Transmission(cont dlMainshaft 2nd gear thrust washer thickngss3.97 - 4.00 {0.156 - 0.'t57}4.02 - 4.05 (0.158 - 0.159)4.07 - 4.10 (0.r60 - 0.16114.12 - 4.'15 (0.162 - 0.163)4.17 - 4.20 (0.164 - 0.'t65)4.22 - 4.25 (0.166 - 0.167)4.27 - 4.30 {0.168 - 0.169)4.32 - 1.35 {0.170 - 0.17r)4.37 - 4.40 (0.172 - 0.173)
Wear or damage
I
I
IWear or damage
Thrust washer thicknessMainshaft ball bearing left sideMainshaft 1st gear left sideMainshatt 1st gear right side
3.45 - 3.55 (0.136 - 0.140)1.45 - 1.50 (0.057 - 0.059)3.43 - 3.50 (0.135 - 0.138)
Wearlor damase
Woar or damage
Sub-shaft 4th gear thrust washer thicknessOne-way clutch contact area l.D.Countershaft lst gearParking gearMainshaft feed pip€ A, O.D. {at 15 mm trom end}Mainshaft leed piDe B, O.O. {at 30 mm from end)Countershaft leed pipe O.D. (at l5 mm from end)Sub-shaft feed pip€ O.D. (at 15 mm trom end)Mainshaft sealing ring thickness{29 mm and 35 mm)Mainshaft bushing LO.Mainshaft bushing LD.Countershaft bushing LD.Sub-shaft bushing l.D.Mainshatt sealing ring goove widlh
2.93 - 3.00 (0.115 - 0.1181
83.339 - 83.365 (3.2810 - 3.2821)66.685 - 66.698 12.6254 - 2.6259)8.97 - 8.98 {0.353 - 0.354)5.97 - 5.98 (0.23s0 - 0.2354f7.97 - 7.98 (0.3138 - 0.3142)7.97 - 7.98 {0.3138 - 0.3142)1.980 - 1.995 (0.0780 - 0.07851
6,018 - 6.030 (0.2359 - 0.2374)9.000 - 9.015 (0.3s43 - 0.3549)8.000 - 8.01s (0.31s0 - 0.3156)8.000 - 8.015 (0.3150 - 0.3156)2.025 - 2.060 (0.0797 - 0.0811)
t-
tWear or damage8.95 {0.352t5.95 (0.2341
7.95 (0.313)
7.9s (0.313)
1.80 {0.071)
6.045 (0.2380)
9.03 (0.356)
8.03 (0.3r6)
8.03 (0.3161
2.08 (0.0821
RegulatorSealing ring contact area LD.35.000 - 35.025 {1.3780 - 1.3782)35.050 (1.3799)
Shifting device andparking brake con-trol
Reverse shift fork tinger thicknessParking brako ratchet pawlParking goarThroftlo cam slopper heighl
5.90 - 6.00 {0.232 - 0.236)
27.0 - 27.r (1.063- 1.067)
5.4O {0.213)
lWear or other
t_'--'
Servo bodyShift fork shaft bore Lo.Shift fork shaft v6lve bore LO.14.000 - 14.010 (0.5512 - 0.5516)37.000 - 37.039 (1.{567 - 1.4582)37.045 {1:4585}
Oil pumpOil pump gear side clearanc€Oil pump gear-to-body cl€6rance DriveDriv€nOil pump driven g6ar I.D.Oil pump shaft O.D.
0.03 - 0.05 (0.001 - 0.002)0.210 - 0.265 {0.0083 - 0.0104)0.070 - 0.125 (0.0028 - 0.0049)14.016 - 1{.034 (0.5518 - 0.5525)13.980 - r3.990 {0.5504 - 0.5508)
0.07 (0.003)
W6ar or damageWear or damage
L
3-12

Standards and Service Limits
Differential (Manual transmissionlSection 15
Differential (Automatic transmissionlSection 15
Steering - Section 17
' When using a new belt, adjust detlection or tension to new values. Run the engine lor 5 minutes then turn it off.Readiust detlection or tension to used belt values.
M€ASUREMENTSTANDARD INEW) SERVICE LIMIT
DifferentialPinion shaft contact area LD. 81881 engine818C1 engineCarrier'to-pinion clearance 81881 engineB18C t engineDriveshafvintermediate shaft contact area LD.81881 engine818C1 engineCarrier to driveshaft clearance 81881 engineBlSC'l engineCarrier-to-intermediate shatt clearanceB188l engine818C1 engine
18.000 - 18.016 (0.7087 - 0.7093)18.000 18.018 (0.7087 - 0.7094)0.0r3 0.045 (0.0005 - 0.0018)0.0'13 - 0.047 (0.0005 0.0019)
28.000 - 28.021 \1.1024-1.1032128.005 - 28.025 (1.1026 1.'1033)0.020 - 0.062 (0.0008 0.0024)0.045 , 0.086 {0.0018 - 0.0034)
0.050 - 0.087 (0.0020 0.0034)0.075 - 0.111 (0.0030 - 0.0044)
o. t aron,0.1 {0.006}
Differentialprnron gearEacklasht. D.Pinion geaFto-pinion shaft clearance
0.05 0.15 (0.002 0.006)'18.042 - 18.066 (0.7103 0.7113)0.055 - 0.095 (0.0022 0.0037)
Adjust
0.15 {0.006)
Sel ring-to-bearing outer race clearance 81881 engin€0 - 0.10 (0 0.004)Adjust
Differential taper roller bearing preloadStarting torque N.m {kgfcm, lbf.in) Bl8Cl engine2.1r - 3.04 {21.5 - 3 r.0, 13.0- 18.7)Adjust
MEASUREMENTSTANDARO INEWISERVICE LIM]T
Difterentialcarfl€rPinion shatt contact area l.D.Carrier-to-oinion clearanceDriveshafvintermediate shaft contact are l.D.Carrier-to-driveshatt clearance
18.000 - 18.018 {0.7087 - 0.7094)0.016 - 0.052 {0.0006 - 0.0020)28.00s 28.025 {1.1026 - 1.1033)0.025 - 0.066 (0.0010 - 0.0026)
0.1 {0.004)
0.12 (0.005)
Differentialprnron gearBacklasht.D.Pinion gear-to-pinion shaft clearance
0.05 - 0.15 (0.002 - 0.006)18.042 - 18.066 (0.7r03 - 0.7113)0.059 - 0.095 (0.0023 - 0.0037)
Adjust
0.15 (0.006)
Set ring-to-bearing outer race clearance0 - 0.r5 (0 - 0.006)Adjust
MEASUREMENTSTANDARD INEWI
Steering wheelRotational play at steering wheel circumferenceStaning losd at steering wheel circumferenceN {kgf, lbfl Engine running
0 - 10 {0 - 0.39)
34 \3.5,7.71
GearboxAngle of rack-guide-screw loosened from lockedposition20" i 5'
PurnpPump pressure with shut-off valve closedkPa (kgtlcm,, psi)6,400 7.400 165 75. 920 - 1. r00)
Power steeringtluidRecommended fluidFluid capacity For overhaulf (US qt, lmp q0 For fluid change
Honda power steering fluid V1.06 (1.12,0.98)
0.79 (0.83,0.70)
Power steeringbelt*Deflection with 98 N (1okgt,22lhfl
between pulleys11.5- 13.5 (0.45 0.53)with used belt8.0 - 10.010.31 0.39)with new belt
Belt tension N lkgf, lbl)Measured with belt tension gauge390 - 540 (40 - 55, 88 - 120) with used belt740 880175 90. 170 200) with new belt

31. Remove the shift cable
I x 1.25 mm22 f.m 12.2 kgl'rn'16 tbl.ftl
(A/T).
SHIFT CABLE
32.
33.
CONTROLLEVER
SHIFT CAALEcovER locx usiea6 x 1.0 mm14 N.m t1.4 kgf.m, 10 lbl'ftlReplace.
Remove the damper tork.
Disconnect the suspension lower arm balljoints us-
ing the special tool. Refer to section 1 8 tor the proper
procedure.
NOTE: Adjust the tool so the iaws are parallel to
each other.
REMOVER 28 mmoTMAC-S10020012 x 1.25 mm
5-9
34. Remove the driveshatls.
CAUTION:
a Do not pull on tho ddv$halt, tho CV ioint mav
como apan.
a Uso caro whsn prying out tho assombly.
Pult it slraight to avoid damaging th6 differantial
oil soal or intormodiato shaft dust seal.
NOTE: Coat all precision tinished surfaces with
clean engine oil or grease. Tie plastic bags over the
driveshaft ends.
(cont'd)

Insrall the left front mount, then tighten the bolts in
the numbered sequence as shown (O-@),
O 12 x 1.25 ]n]n83 N.m 18.5 kst.m,61 lbt.ftlReplace.
@ 12 r 1.25 mm59 N.m {6.0 kgl.n,43 tb{.ftlReplace.
@ 10 r 1.25 mm44 N.m (4.5 kgf.m, 33 lbt.ftl
k-
5-15
a Check that the sp.ing clip on the end of each
driveshaft clicks into place.
GAUTION: Uso oow spring clips.
a Bleed air trom the cooling system at the bleed bolt
with the heater valve open (see page 10-5).
a Adjust the th.ottle cable (see section 1 1).
a Check the clutch pedal tree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
Alternator belt {s€e section 23).
P/S pump belt {see section 17).
A/C comoressor belt (see section 22).
a Inspect tor fuel leakage (see section 1 1).
. After assembling fuel line parts, turn on the ig-
nition switch (do not operate th€ starter) so
that the Juel pump operates for approximat€-
lV two seconds and the tuel line pressurizes.
Repeat this operation two or three times and
check for fuel leakage at any point in the fuel
line.
(cont'd)

Timing Belt
Installation
Install the timing belt in the revorce order of removal;
Only key points are described here,
NOTE: Cl€an the middle cover and lower cover beforeinstallation.
L Position the crankshaft and th€ camshaft pulleys asshown before installing the timing belt.
A. Set the crankshaft so that the No. 1 oiston is at
top dead center (TDC). Align the g.oovo on the
t€eth side of the timing belt d.ive pulley to the Opointer on the oil pump.
L Align the TDC marks on intake and exhaust pul-
tevs,
NOTE: To set the camshafts at TDC position for
No. 1 piston, align the holes in the camshafts
with the holes in No. l camshaft holders andinsert 5,0 mm pin punches in the holes.
PIN PUNCHES, 5.0 mm
2. lnstall the timing belt tightly in the sequence
snown.
O timing belt drive pulley {crankshaft) + @Adjusting pulley * @ Water pump pulley - @Exhaust camshaft pulley + @ Intake camshaft pul-
lev.
TDC mark align6d with thepointer on back cover,TDC MARK
6-12

!
1.
2.
Camshafts
Inspection
Loosen the adjusting screws.
Remove the camshaft holders and the rocker arms
NOTE: Mark the rocker arms before removing
them.
Reinstall the camshaft and holders. Tighten the
camshaft holder bolts in a crisscross pattern, begin-
ning with the inner bolts.
9.8 N.m (1.0 kgf.m,7.2 lbf.ft)
Seat the camshafts by pushing them toward the dis-
tributor end of the head with a screwdriver.
Zero the dial indicator against the end of the
camshaft. push the camshaft back and forth and
read the end play.
Camshalt End Play:
St.ndard lNow): 0.05 - 0.15 mm
(0.002 - 0.006 inl
Seivice Limit: 0.5 mm {0,02 in)
Remove the camshaft holder bolts from the cylinder
head.
NOTE: Unscrew the camshaft holder bolts two
turns at a time, in a crisscross pattern.
Lift the camshafts out ot the cylinder head. wipe
them clean, then inspect the lift ramps. Replace the
camshaft if any lobes are pitted, scored, or exces-
srvely worm
Clean the camshaft journal surfaces in the cylinder
head, then set the camshaft back in place. Insert a
plastigage strip across each iournal.
Install the camshaft holders and torque the bolts to
the values and in the sequence shown on page 6-30.
NOTE: Do not rotate camshafts during inspection.
-
6-21
10.Remove the camshaft holders. Measure the widest
ponion of plastigage on each journa..
Camshaft-to Holder Oil Clearance:
Standard lNewl: 0.039 - 0.069 mm(0.0015 - 0.0027 in)
Sarvico Limit 0.15 mm {0.006 inl
11. lf camshaft-to-holder oil clearance is out of toler
ance:
. And the camshaft has already been replaced,
vou must replace the cylinder head.
. lf the camshaft has not been replaced, first check
total runout with the camshaft supported on V-
blocks.
Clmshaft Total Runout:
StEndard {New): 0.03 mm (0.001 inl max'
Servico Limit: o.Oil mm {0.002 inl
- lf the total runout of the camshafts is within tol-
erance, replace the cylinder head.
- lf the total runout is out of tolerance, replace the
camshafts and recheck. lf the oil clearance is still
out of tolerance. replace the cylinder head.
PLASTIGAGE

I
Replacement
1. As illustrated in the removal steps of this proce-
dure, use a commercially-available air-impact driv-
er attachment modified to fit the diameter of the
valve guides. In most cases. tho same procedure
can be done using the Valve Guide Driver and a
conventional hammer.
COMMERCIALLY AVAILABI,I
VALVE GUIDE DRIVER
RGmov.l rnd In3tlllationVALVE GUIDE DRIVER, 6.6 mm
0?942 - 6570100
Select the proper replacement guides and chill
them in the freezer section of a refrigerator for
about an hour.
Use a hot plate or oven to evenly heat the cylinder
head to 300'F (150'Cl. Monitor the temperature with
a cooking thermometer.
CAUTION:
. Do not use a torch; it may warP the hgad.
. Do not get ths head hottq than 3OO'F 1150"C);
excessive hgat may loos€n thG valvs soat3.
. To avoid burns, usa hoavy glov93 whon handling
the heated cylinder hoad.
-----T_-
lrl
11.3 mmlo.il,l in)
f sz --| 12.21i^l
6-25
4.Working from the camshaft side. use the driver and
an air hammer to drive the guide about 2 mm {0.1
in) towards the combustion chamber. This will
knock oft some of the carbon and make removal
eaSrer.
GAUTIOiI:
o Alwrys woar safety goggles or a face shiold
wh6n using tho Eir hammer.
. Hold ths air hammsr directly in lins with the
vrlvr guidc to prsvont damaging tho drivor.
Turn the head over and drive the guide out towatd
the camshaft side of head.
lf a valve guide still won't move, drill it out with a 8
mm (5/16 in) bit, then try again.
CAUTION: Drill guid$ only in oxtremo cases: You
could drmrgo tho cylinder hosd if ths guido br"akr.
VALVE GUIDE DRIVER,6.6 mm
07942 - 65701q)
Remove the new guide{s} from the refrigerator, one
at a time, as you need them.
{cont'd)
OO ",
O (V /rl -1-- ) o

Valve Guides
Replacement {cont'd}
7. SliD a 6.5 mm {0.25 in) stsel washor and the correct
driver attachment over the end of the driver {The
washer will absorb some of the impact and extend
the life of the driver).
.,F-q-re
tt-T-IIttlDRVEn 6,5 mm t0.25 in) ATTACHMENT
WASHER
8, Install the new guide(s) from the camshaft side of
the head; drive each one in until the attachment
bottoms on the head. lf you have 8ll sixteen guides
to do, vou may have to reheat the head one or two
more I|mes.
Valv6 Guida Instsllod Hcight:
lntaks: 13.75 - 14.25 mm
(o.sal - 0.561 inl
Exhru3t: 15.75 - 16.25 mm
{0.620 - 0.640 in}
Reaming
NOTE: For new valve guides only.
Coat both reamer and valve guide with cutting oil.
Rotate the reamer clockwise the full length of the
valve guide bore.
Continue to rotate the reamet clockwise while
removing it from the bore.
Thoroughly wash the guide in detergent and water
to remove any cutting residue.
Check clearance with a valve (see page 6-24).
. Verify that the valve slides in the intake 8nd
exhaust valve guides without ex€rting pressure.
VALVE GUII'E REAMER, 6.6 MM
079E4 - 667ot0c
REAMER HANDLE
s

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
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