light HONDA INTEGRA 1994 4.G Workshop Manual

Fuel and EmissionsSection 11
ClutchSection 12
Unit ot length: mm {in)
MEASUREMENTsTAt{ItAno (NewlSERVICE UMIT
.u.l pumpDisolacoment in l2 V, 10 seconds 81881 engine
m, (fl oz, lmp oz) 818C1 engins222 17 .5,7 -81 min. | 12011.1' 1'21
364 (12.3, 12.8) min. I too (:.1, g.st
F aa3uro rggulatorPressure with regulator vacuum hose disconnected
kPa (kgflcm', psi) Bl8Bl engineBl8Cl engin€275 - 32a 12.8 -3.9,39.6 - 46.9)329 - 378 (3.35 - 3.85, 47.6- 5.47)
tualt6nkCaprcity, {US gal, lmp gal)50 (13.2, 11.01
En9in6ldle sDeed with headlight and cooling fan ofi rpm7501 50 (M/T: neut..ll750I 50 {A/T: E or E position}
Fast idle rpm1,600 i 2(x' lM/T: nsurr6l)l,eoo I 200 (A/T: E or E po6itioo)
ldl6 CO %0.1 max.
MEASUREMENTSTAM'Ad' IiEWISERVICE UMIT
clutch padslP6d6l height to lloor
SirokePedal play
Disengagement height to floor
164 (6.46)
130 - 140 (5.12 - 5.51)12 - 21 (0.47 - 0.83)83 (3.27) min.
Clutch sudace runout0.05 10.002) max,0.'15 (0.006t
clutch discRiv€t h€ad depthThickness
1.3 (0.05) min.8.4- 9.1 (0.3 - 0.36)0.2 (0.011
6.0 (0.24)
Pr6sur6 plat€WarpageOiaphragm spring linger alignment0.03 (0.001) mrx.0-6 (0.02) ma*0.15 (0.006)
0.8 (0.03)
{n+
3-7

ITEMMETRICIENGLISHIM)TES
WHEELALIGNMENTCamber
CasterTotalToe
FrontRearFrontFrontRear
-0.10'-0.45'
1'1o'omm | oinIn 2 mm I ln 0.08 in
BRAKE SYSTEMType Front
RearPad Surface Area FrontRearParking Brake Type
Power-assisted selt-adiustingventilated discPoweFassisted self-adjusting solid discio.u cm. x z | /,/5 so tn x z21.0 cm, x2 | 3.26 sq in x 2Mechanical actuating, rear two wheel brakes
TIRESize Front and r€ar
Spare Tire
P195/60R14 858*1P195/55R15 84V*2T115t0D14*3T135/70O15.4
ELECTRICAL8atteryStarterAlternatorFusesIn Under-dash Fuse/Relay BoxIn Under-hood Fuse/Relay Box
In Under-hood ABS Fuso/Rolay BoxHeadlights
Front Side Marker LightsFront Turn SignauParking LightsRear Turn Signal LighlsStop/Ta illig htsHigh Mount Brake Light'5Fear Side Marker LightsBack-up LightsLiconse Plate LightsCeiling LightsCargo Area Lights (3 DOOR)Trunk Lights l4 DOOR)SpotlightsGlove Box LightGauge LightsIndicator Lightslllumination and Pilot LightsHeater lllumination Lights
High
I2V-36AH6HR'12 V -'1.4 kW12V-90A
7.5 A, 10 A, 15 A, 20 A, 30 A7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A50 A, 100 A10A, 15A,20A,40A12V-6sW{HB3}12V-55W(HB4)12V-3CP12V -32n CP12V -32 CP12V -32n CP12V -21W
12V-3CP12V -32 CP12V-8W12V-5W12v-3.4W12V-3.4W12V-5W12V-3.4W12V-3.4Wv - 0.84 w, 0.91 w, 1.12 W, 1.r W, 3 W12 V - 0.84 W. 0.91 W, 1.4 W. LEO12V-1.4W
sAE 168sAE 1157sAE 1 't 55sAE 1157sAE 7440sAE 168sA€ 1156
*1: RS, LS*2: GS-R*3: RS*1: LS, GS-R*5: Except high mount brake light installed in rcar spoiler.
3-19

Valve Clearance
Adjustment lcont'dl
a
4.
Adjust valve clearances on No. 1 cylinder.
lntlkc: 0.08 - o.l2 mm (o.(Xxl - 0.qr5 in)
Exhru3t 0.16 - 0.20 mm {0.0,05 - 0.008 in}
Loosen lhe locknut and turn the adjusting screw
until feeler gauge slides back and fonh with a slight
amount of drag.
LOCKNUT9x0.?5mm25 N.m 12,5 kgf.m, 18lbt'ft|
6.
Tighten the locknut and recheck clearance again.
Repeat adjustment if necessary.
Rotate ths crankshaft 180" counte.clockwise(camshaft pulley turns 90'). The "UP" mark should
be on the exhaust side. Adjust valves on No. 3 cylin-
der.
I{umbcr 3 pidon !t TDC:
EXHAUST CAITISHAFTPULI,IY
INTAKE CAMSHAFTPULLEY
.UP' MANKS
7. Rotate the crankshaft 180'counterclockwis€ to
bring No. 4 piston to TDC. The'UP" mark should
be pointing straight down. Adjust valves on No. 4
cylinder.
Numb€r il piston at TDC:
8. Rotate the crankshaft 180' co u nie rclockwise to
bring No. 2 piston to TDC. The "UP" mark should
be on the intake side. Adjust valves on No. 2 cylin-
oer.
Numbor 2 pirton !t TDC:
NOTE: Refer to page 6-31 when installing cylindor hEEd
cover.
"UP'MARKS
-UP" MARKS

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.

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.

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

Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are
removed so that each item can be reinstalled in its orioi-
nal position.
1. Using an appropriate-sized socket and plastic mal-
let. lightly tap the valve retainer to loosen the valve
keepers before installing the valve spring compres-
sor.
Install spring compressor. Compress spring and
remove valve keeper.
VALVE SpRtNG VALVE SPRING
COMPRESSoR COMPRESSoR ATTACHMENT
ATTACHMENT EXTENSION
(cont'd)
Snap-on CFrll
6-67

Valve lnstallation
When installing valves in cylinder head, coat valve
stems with oil before inserting into valve guides, and
make sure valves move up and down smoothly.
When valves and springs are in place, lightly tap the
end of each valve stem two or three times to ensure
proper seating of valve and valve keepers (use ham-
mer handle).
NOTE: Tap the valve stem only along its axis so you
do not bend the stem.
Valves, Valve Springs and
Valve SealsValve 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).
lntaks Valvr Stom-to-Guide Clearance:
Standard (Newl: 0.05 - 0.11 mm
{0.002 - 0.OO'l in)
Ssrvice Limit: 0.16 mm (0.006 in)
Exhaugt Vdve Stem-to-Guide Clsarancg:
Standald lNowl: 0.10 - 0.16 mm
(0.00'l - 0.006 in)
Sorvics Limit: 0.22 {0.0m 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 new valve.
. lf measurement still exceeds limit, recheck using
alternate method below, then replace valve and
guide, if necessary.
NOTE: An alternate method ot checking guide to
stem clearance is to subtract the O.D. of the valve
stem. measured with a micrometer, from the l.D. ot
the valve guide, measured with an inside microme-
ter or ball gauge.
Take the measurements in three places along the
valve stem and three places inside the valve guide.
The difference between the largest guide measure'
ment and the smallest stem measurement should
not exceed the service limit.
lntafte Valvs Stom-to-Guida Clearance:
Stardard (Nowl: 0.025 - 0.055 mm(0.0010 - 0.0022 inl
Service Limit: 0.08 mm (0,003 in)
Exhaust Valvo Stem-to-Guide Clearance:
Standard lNew): 0.050 - 0.080 mm
10.0020 - 0.0031 in)
S€rvics Limit: 0.11 mm {0.0oil inl
6-70

Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using
valve seat cutters.
NOTE: lf guides are worn, replace them before cut-
ting the valve seats.
Carefully cut a 45o seat, removing only enough
materialto ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30' cutter
and the lower edge of the seat with the 60'cutter'
Check width of seat and adjust accordingly.
Make one more very light pass with the 45o cutter to
remove anv possible burrs caused by the other cut-
ters.
Valve Seat Width:
Stlndard: 1.25 - 1.55 mm {0.0,19 - 0.061 in)
Ssrvico Limit 2.0 mm 10.08 in)
SEAI wlDTH
After resurfacing the seat, inspect for even valve
seating: Apply Prussian Blue Compound to the
valve face, and insen valve in original location in
thc hea.l. then lift it and snap it closed against the
seat several times.
ACTUAL SEATINGSURFACE
VALVESEAT
PRUSSIAN BLUE
1.
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 steml, 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 edge), 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 alwavs be made with
the 45'cuttef.
lnsert intake and exhaust valves in the head and
measure valve stem installed height.
Intake Vllve St€m ln3tslled Hsighl:
Stsndard (Now): 37.'155 - 37.935 mm
(1.4750 - f .il935 in)
Sorvico Limit: 38.185 mm 11.5033 in)
Exhaust Valvo Stom In3talled Hoight:
Standard (Now): 37.165 - 37.6:15 mm
11.4{X}2 - 1.,1817 inr
Sewico Limit: 37.885 (1.i1915 in)
VALVE STEMINSTALLED HEIGHT
8. lJ valve stem installed height is over the service
limit, replace valve and recheck. lf still over the ser-
vice limit. replace cylinder head; the valve seat in
the head is too deeD.
6-73