HONDA INTEGRA 1998 4.G Workshop Manual

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Installation
Bl881, 818C1 enginos:
lf the crankshaft is already installed
'1. Set the crankshaft to BDC for each cylinder.
2, Remove the connecting rod caps, and slip short sec-
tions of rubber hose over the threaded ends of the
connecting rod bolts.
3. Install the ring compressor, and check that the bear-
ing is securely in place.
4. Position the arrow facing the timing belt side of the
eng ine.
The arrow must facethe timing belt sideot the engine. Theconnecting rod oil holemust face the intakemanjfold (81881 engine).
CONNECTING ROOOIL HOLE {81881 enginel
Position the piston in the cylinder. and tap it in
using the wooden handle of a hammer.
NOTE; Maintain downward force on the ring com-pressor to prevent rings from expanding before
entering the cylinder bore.
6. Stop after the ring compfessor pops free, and check
the connecting rod-to-crank journal alignment
betore pushing piston in to place,
7.Check the connecting rod bearing clearance withplastigage {see page 7-9).
Apply engine oil to the bolt threads. then install the
rod caps with bearings,
Installthe nuts, and toroue it.
81881 engine: 31 N.m {3.2 kgf.m, 23 lbf.ft)
BlSCt engine: il4 N.m {i[.5 kgf.m, 33 lbf.ft)
(cont'd)
7-17

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Pistons
Installation (cont'dl
ll the crankshaft is not installed
1. Remove the connecting rod caps, then install the
ring compressor. and check that the bearing is
securely in place.
2. Position the arrow and the mark facing the timing
belt side of the engine.
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The arrow must facethe timing belt sideof the engine. Theconnecting rod oil holemust face the intakemanilold (8188'l engine).
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer.
NOTE: Maintain downward force on the ring com-
pressor to prevent rings from expanding before
entering the cylinder bore.
Position all pistons at top dead center.
7-18
818C5 engine:
ll the crankshaft is already installed
1. Set the crankshaft to BDC for each cylinder.
2. Remove the connecting rod caps, and slip short sec-
tions of rubber hose over the threaded ends of the
connecting rod bolts.
3. Install the ring compressor, and check that the bear-
ing is securely in place.
4. Position the arrow facing the timing belt side of the
eng ine.
The mark must facethe timing belt sideof the engine.
The arrow mustlace the timing beltside of the engine.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer.
NOTE: Maintain downward iorce on the ring com-
pressor to prevent rings from expanding before
entering the cylinder bo.e.
6. Stop after the ring compressor pops free, and check
the connecting rod-to-crank journal alignment
before pushing piston in to place.

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7.
8.
9.
Check the sonnecting rod bearing clearance withplastigage (see page 7-9).
Apply engine oil to the bolt threads, then install the
rod caps with bearings.
Install the nut, and finger tight, then set the boxwrench and connecting rod gauge as shown below.
CONNCCNNG RODGAUGE{Commerciallyavailable)
10.
WRENCH
Zero the connecting rod gauge.
Tighten the nut until the connecting rod gauge
reads 0.13 - 0.15 mm (0.005 - 0.006 in).
CONNECNNG HOOGAUGE
1t.
ll the crankshaft is not installed
1. Remove the connecting rod caps, then install the
ring compressor, and check that the bearing is
securely in place.
2. Position the arrow and the mark facing the timing
belt side ot the engine.
The mark must facethe timing belt sideof the engine.
Tb6 arrow must tac6th€ timing belt sideof the engine.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer.
NOTE: Maintain downward force on the ring com-pressor to prevent rings from expanding before
entering the cylinder bore.
Position all pistons at top dead center.

Piston Rings
Replacement
Using a ring expander, remove old piston rlngs.
Clean all ring grooves thoroughly.
o Use a squared-ofl broken ring or ring groove
cleaner with blade to fit piston grooves.
. lop ring groove is 1.0 mm (0.039 in) wide, sec
ond groove is 1.2 mm (0.047 in) wide, and oil
ring groove is 2.8 mm (0.110 in) wide.
. File down blade if necessary.
CAUTION: Do not use a wire brush to clean the
ring lands, or cut ring lands deeper with cleaning
tool.
NOTE: lf the piston is to be separated from the con
necting rod, do not install new rings yet.
Install new rings in the proper sequence and posa-
tion (see page 7 21).
Do not use old piston rings.
PISTON RING
End Gap
Using a piston, push a new ring into the cvlinder
bore 15 - 20 mm 10.6 0.8 in) f rom the bottom.
2. N,4easure the piston ring end gap with a feeler
gauge:
lf the gap is too small, check to see if you have
the proper rings for your engine.
. lf the gap is too large, recheck the cylinder bore
diameter against the wear limits on page 7-13.
lf the bore is over the service limit, the cylinder
block must be rebored.
Piston Ring End-Gap:
Top Ring
Standard (New):0.20 - 0.35 mm
(0.008 - 0.014 inl'1
0.20 - 0.30 mm
{0.008 - 0.012 in}''
Service Limit: 0.60 mm {0.024 in)
Second Ring
Standard {New): 0.40 - 0.55 mm
{0.016 - 0.022 inl
Service Limit: 0.70 mm {0.028 inl
Oil Ring
Standard (New): 0.20 - 0.50 mm
10.008 - 0.020 in)'r
0.20 - 0.45 mm
(0.008 - 0.018 in)''
Service Limit: 0.70 mm (0.028 in)
PISTON RING
15-20mm{0.6 - 0.8 in)
RIKEN manufactured piston ring
TEIKOKU PISTON RING manufactured piston ring
(B 1881 engine only)

Piston Pins
Removal
1. Assemble the Piston
PISTON BASE HEAD07HAF - P120102
Pin Tools as shown.
PISTON PIN BASE INSERT07GAF - PH6o3q)
PISTON BASE SPRING07973 - 6570600
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2.
PISTON07973 -
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PISTON PIN DRIVER SHAFT07973 - PE00310
PILOT COLLARO?LAF - PR3OlOOEmbossed mark facing up.
NOTE: Use a hydraulic press.
When pressing pin in or out,make sure that the recessedportion of the piston alignswith the lips on the collar.
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Adjusr the length A of the piston pin driver.
A: Bl8Bl engine:49.70 mm (1.957 inl
Bl8Cl engine: 51.70 mm (2.035 inr
PIN DRIVER HEAIPE00320
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Place the piston on the piston base and press the
pin out with a hydraulic press.
Installation (81881 engine)
!{1. Use a hvdraulic Dress lor installation.
When pressing the pin in or out, be sure to posi-
tion the recessed tlat on the piston against the
luqs on the base attachment.
The arrow must face thetiming belt side of theengine and the connectingrod oii hole must face therear side of the engine.
CONNECTING RODOIL HOLE
2. Adjust the length B of the piston pin driver and shaft.
B:49.70 mm (1.957 inl
Prca3
PISTON PIN DRIVER SHAFT07973 - PE00310
Embossed mark
ffi-n"ro"r,"l
PILOT COLLAR07LAF - PR30100
PISTON PIN BASE INSERT07GAF - PH60300
PISTON BASE HEAO07HAF - PL20102
PISTON BASE0?973 - 6570500
NOTE: Use a hydraulic press. When pressing pin in
or out, make sure that the recessed portion of the
piston aligns with the lugs on the piston base head.

Inspection (cont'dl
3.
4.
Measure the piston pin-to-piston clearance.
NOTE: Check the piston for distonion or cracks.
fl the piston pin clearance is greater than 0.022 mm
(0.0009 in), remeasure using an oversize piston pin.
Piston Pin-to-Piston Clearancer
Standard lNewl:0.010 - 0.022 mm
(0.0004 - 0.0009 in)
Check the difference between piston pin diameter
and connecting rod small end diameter.
Piston Pin-to-Connecting Rod Interlerence:
Standard {New)i
B18Bl engine:
B18Cl, 818C5 engines:
0.013 - 0.032 mm
10.0005 - 0.0013 inl
0.017 - 0.036 mm(0.0007 - 0.0014 inl
Piston PinsConnecting Rods
End Play
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NOTE: End play should be inspected before removing
the crankshaft.
Connecting Rod End Play:
Standard (New): 0.15 - 0.30 mm
10.006 - 0.012 in)
Service Limit: 0.40 mm (0.016 in)
a
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It out-of-tolerance, install a new connecting rod.
lf still out-of-tolerance, replace the crankshaft (see
pages 7-'10 and 7-26)
7 -24

Selection
81881, 818Cl engioes:
Each rod falls into one of four tolerance ranges (from 0
to + 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in)
increments) depending on the size of its big end bore,
It's then stamped with a number (1,2,3, or 4) indicating
the range.
You may find any combination ot 1,2,3, or 4 in any
en9rne.
Normal Bore Size: /|8.0 mm (1.8, in)
NOTE:
. Reference numbers are for big end bore size aid do
NOT indicate the position of the rod in the engine.
a Inspect connecting rod for cracks and heat damage,
CONNECTING ROD BOREREFERENCE NUMBERHalf of number is stamped onbearing cap, th6 other half onconnectrng rod,
Inspect boltsand nuts forstress cracks.
B18C5 enginc:
Each rod falls into one of four tolerance ranges (from
+0.006 to + 0.024 mm {+0.0002 to + 0.0009 in). in 0.003
mm (0.0001 inl increments) depending on the size of its
big end bore. lt's then stamped with a number (21, 22,
23, 24,25 or 261 indicating the range.
You may tind any combination of 21, 22, 23, 24, 25 ot 26
in any engine.
Normal Bore Size: 48.0 mm {1.8!, in}
NOTE:
a Reference numbers are for big end bore size and do
NOT indicate the position of the rod in the engine.. Inspect connecting rod fo. cracks and heat damage.
CONNECNNG NOO BOREREFERENCE NUMAERHalf oI number is stamped onbearing cap, the other half onconnecting rod,
Inspectand nuts forstress cracks,

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Crankshaft
lnstallation
-Q Before installing the crankshaft, apply a coat of
E engine oilto the main bearings and rod bearings.
1. lnstall the thrust washers in the No. 4 iournal of the
cylinder block.
Grooved side facingoutwaro,
Insert bearing halves in the engine block and con-
necflng roos.
Hold the crankshaft so rod journals for cylinders No.
2 and No.3 sre straight up.
Lower the crankshaft into the block, putting the rod
iournals into connecting rods No.2 and No.3.
Installthe rod caps and nuts finger-tight.
No. 1No. 4
CONNECTING ROO
7-26
1.
Rotate the crankshaft clockwise, put journals into
connecting rods No. 1 and No.4, and install the rod
caps and nuts tinger-tight.
NOTEI lnstall caps so the bearing recess is on the
same side as the recess in the rod.
Check rod bearing clearance with plastigage (see
page 7-9), then tighten the capnuts in 2 steps.
lst step: 20 N.m (2.0 kgf m, 14 lbf.ftl
2nd step:
81881 engine:31 N.m (3.2 kgf.m, 23 lbf.ftl
818C1,818C5 enqines:44 N.m (4.5 kgf.m,33 lbt.ftl
NOTE: Reference numbers on connecting rod are
tor big-end bore tolerance and do NOT indicate the
position of piston in the engine.
Install the main bearings/caps and cap bridge(818C1, 818C5 engines only).
NOTE: Coat the bolt threads with oil
CAP BRIDGE{B18Cl engine onlyl
BEARING
MAIN BEARING
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