1994 HONDA INTEGRA Workshop 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.

Install the intake manifold and tighten the nuls in a
c.isscross pattern in 2 or 3 steps, beginning with the
inner nuts.
CAUTION: Check to. fold3 or 3cratchc! on ihc aur-
taco ol tho ga3kot. Roplscs with a nlw gaeket if
damagod.
Tighten the intake manifold bracket bolts.
GASXETReplace.
E x 1.25 mm 8 x 1,25 mm2ir N.m l2.it kg{.m, 23 N.m 12.3 kgf.m.17 tbf.ftl 17 tbl.frt
Install the exhaust manifold and tighten the new
self-locking nuts in a crisscross pattern in 2 or 3
steps, beginning with the inner nuts.
. Use new self-lockiflg nuts.
4.
5.
8 x 1.25 mm24 N.m (2,a kgf.m,
SELF.LOCKING NUT8 x 1.25 mm31 N.m (3.2 kgt m,23lbfftlEXHAUST11Replace.
l0 x 1.25 mma,t N.m 14.5 kgf.m,33 tbt.ft)
GASKEIReplace.
8 x 1.25 mm2il N.m 12.4 kg{.m,17 rbtftl
m
CAUTION:
. Mlka 3uro thrt thc k.ywlyr on tho c.mthlttr lrc
facing up .nd No. I pi3ton i3 8t top d.rd clnt.r(TDCt.
. Rcphct th! rocksr armr in thsir o.iginal potltlom.
6, Place the rocker arms on the oivot bolts and ths
valve stems.
lnstallths camshafts, then installth€ camshaft sosls
with ths open side (spring) facing in.
Apply liquid gasket around the rubber cap, then
installthe rubber cao.
7.
8.
(cont'd)
6-29

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

SpecialTools
Tool NumbarDctcriptionPlea Rctllanca
6-72
6-17
&45
6-43
6-11
6-67
6-71,72
6-67
Valve Guide Reamer, 5.5 mm
Holder Handle
Tappet Adiuster Wrench
Air Stoppet
Pulley Holder Attachment, HEX 50 mm,
Offset
Valv€ Spring Compressor Attachment
Extension
Valve Guide Driver, 5.5 mm
Valve Spring Compressor Attachment
07HAH - PJ7010A or
OTHAH _ PJTOIOB
07JAB - 001020A
07LAA - PR30100
OTLAJ _ PR3O2OA
07MAB. PY3OlOA
OTMAF _ PRgO'IOA
07742 - 0010100
07757 - PJ 1010A
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6-34