Acura Integra User manual

Maintenance

Lubrication

Maintenance

(NormalConditions)

Maintenance

(Severe

Points

Schedule
Schedule

Gonditions)

............4-z

......4-4

......

4-6

Lubrication Points

For the details of lubrication

(such

cedure

as Assembly/Reassembly, Replacement,

points

and type of lubricants to

No. LUBRICAnON POINTS

1

E^g,ne

2 Transmission Manual

Automatic Genuine Honda Premium Formula

Brake line
Clutch line
Power
Release fork

Throttle wire

1

Cruise control actuator wire

8

(Dashboard

o

Throttle cable end

10

Cruise control actuator

11

Brake master
Clutch master
Battery

14

Fuel fill lid
Engin6 hood hinges

to

Hatch hinges 8od

17

Door hjnges, upper

18

Door

19 Rear

20 Power

21 Ai|' conditioning

(lncludes

steering

terminals

ooen detent

b.ake calipers

steering system

gearbox

lManual

(Dashboard

end

lower

cvlinder

cylinder

latch or trunk hinges

compressor Refrigerant

Anti-lock brake line)

transmission)

lower

end

hole)

Danel

(Throttle

and lower

link)

cable end

oushrod

pushrod

and engine

(Actuator

hood latch

oanel hole)

and latch

be applied,

Overhaul, Installation.

API

Service Grade: Use SJ

"Energy

SH
The

oil container may also

mark

shown below. Make sure it
Engines.
SAE Viscositv:

Honda

Genuine MTF*1

Transmission
Genuine Honda DOT3
Genuine Honda
Steering

High Temp

Sup€r

Silicone

link)

Multi-purpose

Honda

White Lithium

Silicone
Genuine Honda Power

38899-PR7-A01)
(For

Refrigerant:

refer

to the illustrated index

etc.) contained in

LUBRICANT

Conserving ll"

"

See chart below.

(ATF)*,

Fluid

Brake Fluid13

DOT3 Brake Fluid*3

grease

P/N 08733

Urea Grease

grease

grease

Grease

grease

Steering Fluid-V

oii ND-O|L8

{P/N38897

HFC-134a

and various work

each section,

"Energy

grade

display the API Certification

-

(R-

oil,

savs

Automatic

8070E

(P/N

-

134a))

Conserving" or

"For

Gasoline

08798 - 9002)

or S*.

PR7 - A01AH

or

Dro-

r(

L(

*1:

Always
does not contain

*2:

Always

shift

*3:

Always

life

of the system.

'4:

Always

transmission

4-2

API

SERVICE

use Genuine Honda Manual

use Genuine

quality.

use Genuine Honda

use

Genuine Honda Power

fluid can

LABEL

proper

the

addtuves.

Honda Premium Formula

DOT 3 B.ake Fluid,

increase

cause

API CERTIFICATION

Transmission

Steering Fluid-V

v,/ear

and

Fluid

Automatic

Using a non-Honda

poor

SEAL

(MTF).

Using motor oil

Transmission Fluid

or S. Using

steering in

any other type of

cold weather.

(ATF).

brake fluid

Recommended engine
Engin€ oil viscosity lor
ambrent lemperature ranges

can cause stiffer

Using a non-Honda

can cause corrosion

power

steering fluid

oil

shifting because

and decrease

ATF

can affect

or automatic

the

it

{

at

@

at

@
@

I

@

qfl-j__,n

til

NOTE:

Lubricate all hinges.
ln corrosive
We recommend

\-_-.-

latches,

areas, more

Honda White

*

_

locks

and

frequent lubrication is

Lithium

once a

Grease.

il/

year.

necessary.

.

4-3

)

Maintenance

Schedule

:

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4-5

Maintenance

Schedule

(Severe

Conditions)

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4-7

ra

Engine

Engine Removal/lnstallation ............. 5-1

Cylinder Head/Valve Train ............... 6-1

Engine

Engine Lubrication .........8-1

Intake Manifold/Exhaust
Cooling

Block

......... ........7-1

System

......

....... 10-1

9-1

\-a

Engine Removal/lnstallation

Speciaf

Engine

Mount/Bracket Torque ....

Tools .......... ...........5-2

RemovaUlnstallation ................

5-3
5-17

)

Special Tools

Rel. No.

o

I

Tool Number

07MAC - SL00200

Description Oty

Ball Joint Remover,

28

mm

I

Page

Reterence

,l

5 10

L

Engine

Make
ly
sitions on the engine
Make
you

CAUTION:
.

Use fender

faces.

Unplug the wiring
the coupler and
age.
Mark all wiring and hoses to avoid misconnection.
Also.
or hoses, or intedere with other

Removal/lnstallation

sure

hoist

and

sure the car will not rollolt

are wgrking

be sure that they do not contact other wiring

and safety

iacks

brackets are

under it.

covers to avoid damaging

connectors carelully while holding

the connector

stands ate

attached to the correct

section 11,

{see

placed plopel-

stands and latl while

painted

portion

to avoid d8m-

parts.

po-

sur-

2. Remove the strut brace.

x 1.25

8
24 N.m

17 tbf.tt)

mm

{2.4

kgf.m,

Anti-theft

NOTE:

cuit. Be sure to

-

Disconnecting

-

Removing

hood fuse/relay

Removing the radio

After service, reconnect

When

on.
tomer's 5-digit code to restore radio operation.

1. Remove

radios have a coded theft

get

the customer's

the battery.

box.

power

"CODE"

(see

(7.5

section 20).

the

the word

the hood

No.32

code

A) fuse from the under

to the radio and

is displayed, enter the cus

protection

number

betore

turn

cir-

STRUT BRACE

it

3. Disconnect
positive

the

Disconnect
Iuse/relay

box and

the battery

terminal.

the battery

negative terminal first,

Irom

cables

under hood ABS {use/relay

then

the under-hood

box.

BAITERY CABLES

6x1.0mm

9.8 N.'4

7.2 rbf.ft)

(1

.0 kgf

.m,

(cont'dl

5-3

gine

En

(cont'dl

Remova

l/l nstal lation

Remove
assembly and the

the

intake

air duct, air cleaner housing

bracket.

't.0

6 r

9.8 N.m

mm

(1.0

kgt.m, 7.2

lbf.ft)

Remove

7.
tive emission
return hose

brake

the

(818C5

booster

(EVAP)

engine).

vacuum hose,

control canister hose

evapora-

tuel

and

Remove
canister hose

the evaporative emission

(B

18B1,

{EVAP)

B'18C1 eng;nes).

control

Remove
right side of engine

the engine wire harness connectors on

compartment.

x 1.0 mm

6

N.m

9.8

l1.O

the

kgl.m,

5-4

\

Engine Ramoval/lnstallation

(cont'dl

13. Remove the engine wire harness connectors,
nal and clamps on the left side
menr,

6 x 1.0 mm

9.8 N.m

7.2 tbt.ttl

14. Remove

kgl.m,

11.0

the cruise control actuator.

ot engine compan-

termi-

15.

Remove the engine

to.

Remove the
remove the

pump.

.

Do not disconnect the

MOUNTING BOLTS

x 1.25 mm

I
24 N.m

't7.

Loosen
remove

12.4

the

the air conditioning

ground

adjusting bolt and mounting bolts, then

power

kgt'm, 17 lbl.ft)

pulley

idler

cable at the body end.

steering

(P/S)

P/S hoses.

bolt and adjusting

(Ay'C)

compressor

pump

belt and

bolt, then

belt.

l.

I

I

x 1.25

I
24 N.m

17 tbt.ft)

mm

12.4

kgt.m,

IDLER PULLEY BOLT
10 x 1.25 mm

/14

N'm

14.5

kgf.m,

33 lbt'frl

A/C

COMPRESSOR

EELT

\

5-6

Engine Removal/lnstallation

(cont'd)

Remove the upper

26.
heater hoses.

81881, B18C5

engines:

..f.

c

lower radiator

and

,1

ir

hoses and the

UPPER RADIATOR

27. lAutomatic
hoses.

transmission) Remove

HOSES

the

ATF

cooler

t

HEATER
HOSE

LOWER
HOSE

RADIATOR

LOWCR RADIATOR
HOSE

,

UPPER RADIAToR
HOSE

HEATER

HOSE

24.

29.

Remove
Remove

.

Do not

radiator

the
the A,/C compressor.

disconnect Ay'C

8 x 1.25 mm
24 N.rn

assembly

hoses.

kgl.m,

12.4

(see

page

17 lbf.ft)

10-5).

5-8

7

30. Disconnect
(Primary

pipe

A.

the

HO2S) connector,

818C1 engine:

Replace.

SELF-LOCKING I{UT

r 1.25

8

16 N.m
12 tbt.frt
Beplace.

mm

(1

.6 kgf

.m,

primary

PRIMARY
HO2S

EXHAUST
PIPE A

10 x 1.25 mm
54
Replace.

heated oxygen sensor

remove

then

8 x 1.25
24 N.m
t7 rbt.ftt
Replace.

exhaust

mm

kgl.m.

12.4

GASKET

Replace.

NUT

N.m

{5.5

kgt'.n,

tlo

lbt.ft}

31. Remove the shift rod and extension rod

8 x 1.25 mm

22 N'm

32.

12.2

Remove

'16

kgl.m,

the shift cable

lbt.ttl

(A,/T).

{Mff).

SHIFT

RETAINER

ROD

81881, 818C5 engines:

GASKET
Replace.

(1.6

NUT

kgf'm,

S€LF.LOCKING

1.25 mm

x

8

16 N.m
12 tbt.fr)
Replace.

PRIMARY
HO25

CONNECTOF

8 x 1.25 mm

24 N.m
17
Replace.

(2.4

lbf.frl

10 x 1.25
54 N.m

40 lbf.ftl

Replace.

{5.5

kgt.m,

GASKET
Replace.

f{UT

mm

kgf'm,

x 1.25 mm

I

N-l'.

22

16 lbf.frl

SHIFT CABLE
COVER

12.2

kgl.m,

LOCK

WASHER

SHIFT CABLE

'l.O

6 x

14 N.m

CONTROL
LEVER

mm

kgf.m, 10 lbt.ft}

{1.4

{cont'd)

5-9

Engine

Removal/lnstallation

(cont'dl

Remove

Disconnect

34.
using the special tool.
proper procedure.

NOTE: Adjust
each other.

the damper

the suspension

{ork.

tool so the

the

lower arm ball

Refer to section

jaws

are

joints

'18

for the

parallel

to

Remove

35.
CAUTION:

.

.

NOTE:

clean enoine oil.

the driveshafts.

Do not

come aoart.

Use care when
Pull it
oil seal or intermediate shaft dust seal.

DRIVESHAFT

pull

on the driveshaft, the CV

prying

out the assembly.

straight to avoid damaging the differential

precision

all

Coat

Iinished

joint

surfaces

/.-:

/

may

with

12 x 1.25 mm

,{:

5-jl0

\

Engine

Removal/lnstallation

(cont'dl

lnstallation

Engine

Installthe

Reinstall
sequence.
excessive

1. Install

AIT:

engine

noise and

bolvnuts

loose.

bolt

reverse order

in the

mount bolts/nuts

the

on the

follow these

vibration, and

tfansmlssion

Failure to

the transmission

of removal

in the

procedures

reduce bushing

mount, then tighten

side. Leave

'12

g

47 thl.ftl

/

o

following

may cause

the mount

x 1.25 mm

(6.5

N.m

life

kgl'm.

the

2. Install
bolvnuts

toose.

engine

the

on the engtne

side

nt, then tighten

mo u

Leave the

side.

10 x 1.25

52 N.m
38 tbf.ft,
Replace.

mount bolt

mm

15.3

the

kgf.m,

l

lf

on the transmission

MOUNT

EOLT

Tighten the mount bolt

3,

AIf l

mount.

L

{

N.m
lbf.fr|

mm

{6.5

kgf.m,

M/T:

12 x 1.25

74 N.m

rbf.ftl

54

12

x 1.25
74 N.m
54 rbf.ftl

17.5

mm

(7.5

mm

kgl.m,

kgl.m,

\

12 x 1.25
64
47

I

I

5-14

Engine

Removal/lnstallation

{cont'dl

Install the

7.
the

left front

numbered sequence

t2 x

O

N.m

83
Fleplace.

10

O

il4

mount, then tighten

shown

'1.25

mm

kgt.m,61

18.5

x 1.25 mm

N.m

kgt'm,33 lbt.ft)

14.5

-

(O

lbl.ft)

12 x 1.25

@

59 N.m
43 lbf.frl
Replace.

the bolts

@).

16.0

mm

in

kgf.m,

.

CAUTION:

.

.
.
.

.

!

that the spring

Check

into

driveshaft

Bleed air
valve open
Adjust the throttle cable

Check the
Check

smoothlY.
Adjust
Alternator

P/S
A/C comDressor belt

Inspect for
.

clicks

Use new spring

{rom the cooling system

(see

page

pedalfree play

clutch

that the transmission

the tension of the

belt

{see

pump

After assembling fuel
ignition switch
that the
two seconds and the
Repeat this operation two
check

line.

(see

belt

tuel leakage

pump

fuel

for tuel leakage at any

on the

clip

place.

clips.

10-6).

(see

following drive belts.

section

section 171.

(do

23).

(see

section

(see

section

line

not

operate

operates

fuel line

end of each

heater

at the

section

1 1).

(see

section

shifts

22).
1ll.

parts,

turn on the

the staner) so

for

approximately

pressurizes.

or three times and

point

into

in

the

12).

gear

{uel

,5-16

I

t:

Mount/Bracket

Torque

(cont'dl

818C5 engine:

REAR STIFFENER

12 x 1.25 mm
57 N.m

42 tbt'trt 24

{5.8

kgf.m,

17

N.m
rbf'ftt

12.4

kgl.m,

ALTERNATOR

--q;;/44N'mtr.5kst'm'

BRACKET

v=ahp

/

w#

q7

10 r

1.25

(

mm

ltri

rH

{ir

I

FRONT STIFFENER

I x'1.25 mm
24 N.m

(2.4

kgf'm,

17 rbf.ft)

12 x 1.25 mm

N.m

57
42 lbf.ftt

15.8

kgt.m,

A/C COMPRESSOR BRACKET

10 x 1.25 mm

N.m

54
40 rbt.frl

P/S PUMP BRACKET

10 x 1.25 mm

/r/r

N.m

;

kgf.m, 33 lbtftl

{4.5

6\---

15.5

kgf.m.

HEAr

d'1N ^rNsuLAroR

I --H Gh\

"

\

sxrlomm

12 N.m

tbf.ftt

8.7

11.2

kgf.m.

*o-r$l/

v

\

Valve

Clearance

Adjustment

r.lJ

NOTE:
.

Valves should
temperature
Adjustment is
valves.

.

After adjusting, retorque

177

N.m

1. Remove

ADJUSTING

be adjusted cold; at a cylinder head
less

of

the same for both intake

(18.0

kgf.m, 130 lbf'ft).

cylinder head cover.

SCREW LOCATIONS:

100'F

than

the crankshaft

(38"C).

and exhaust

pulley

bolt to

(

2. Set the No. 1
page

the top, and the TDC

align with the TDC

cover. TDC mark

pulley
lower cover.

Number 1

6-12).

should

piston

"UP"

piston

mark

(painted

align

at TDC:

"UP"

MARKS

GBOOVES

TDC

at top

on the

grooves

groove

pointer

with

dead center

pulley

on the

on timing

white)

on the crankshaft

on

the timing

(TDC)

(see

should be at

pulley

should

belt

back

belt

EXHAUST

POINTER
LOWER

ON

TDC MAFK
(P.inted

whh.l

(cont'd)

6-3

Valve Clearance

Adjustment

Adjust valve

Intske: 0.08 - 0.12 mm
Exhaust: 0.15 - 0.20 mm

Loosen the

feeler

until
amount of drag.

clearances

locknut

gauge

(cont'dl

on No. 1 cylinder.

-

(0.003

-

(0.006

and turn the adjusting

slides back and forth with a slight

LOCKNUT9x0.75mm
25 N.m

{2.5

kgl.m,

inl

0.005

0.008 inl

18lbtft}

screw

7. Rotate the crankshaft 180' counterclockwise to
piston

bring

pointing

be

cylinder.

Number 4

No. 4

straight down. Adjust

piston

at TDC:

to

"UP"

TDC. The

MARKS

"UP"

valves

mark

on No. 4

should

Tighten the locknut and recheck clearance again,

Repeat

adjustment

Rotate the crankshaft 180' counterclockwise
(camshaft

be on the exhaust side. Adjust valves on No,3 cylin-

der.

Number 3 Diston at TDC:

pulley

if necessary.

turns 90'). The

"UP"

MARKS

"UP"

mark

should

8. Rotate the crankshaft
piston

No. 2

bring
be on the intake side. Adjust valves
der.

Number 2

NOTE: Refer to

cover.

piston

at TDC:

page

6-31 when installing

180'

TDC. The

to

"UP"

MARKS

counterclockwise to

"UP"

mark should

No.

on

2 cylin-

cylinder head

Valve

Seals

Replacement

procedure

The
car valve

Y AAA45-2A 1

!@@

always use approved
fight
while

Turn
pistons

Remove the
Remove
Loosen

camshaft

5. Remove
camshaft holders,

Intake

Valve Seals

6. Using

the two uprights
camshaft holders. The

shown below

spring compressor

/8" attachment).

When using

tool tor each

safeguarding

the crankshaft

are at

top dead center

cylinder head cover.
the distributor.
and disconnect

oullevs.

the

camshaft holder

the 6 mm bolts supplied with

(cylinder

applies when using the in-

eye

job

helps increase

tools, equipment

so that the No. 1

the camshafts

to the cylinder head

uprights fit as

head removal

(Snap-on

this tool, as with any

protection.

(TDC).

the timinq belt from the

bolts, then remove

YA8845 with

and ihe user.

and the No. 4

and rocker arms.

the tool, mount

shown.

tool,

Using the

productivity

the

at the end

not required)

8.

Select the 7/8 in.
ment and fasten

the lever arm with

9.

Position

into
to keep the valve
and

10.

Position

lever is
sor attachment rests
spring being compressed.
on the lever

NOTE: Put
prevent

der head.

the

the spark

removing

the lever

perpendicular

the valve keepers

diameter long

the attachment to

the speed

piston

at TDC

plug

hole. Pump

closed while

the valve keepers.

arm under the cross

as shown.

shop towels over

OIL PASSAGE

pin

and insen an

to the shaft and the

on top of the retainer for

Use the rear

from falling

compressor

the No. 4 hole

supplied.

air into the

compressing springs

the oil

attach-

air adaptor

cylinder

shaft so the

compres-

position

passages

into the

cylin-

of

the

slot

to

7. Insert

the cross

the two uprights.

shaft through the bottom hole

of

OIL PASSAGES

i,

(cont'd)

'6-b-'

,'.itil

Timing Belt

-1,

lllustrated

lndex

NOTE:
.

Refer

.

Mark

.

Replace

.

Do not

.

Clean the middle cover

CAP NUT
6x1.0mm

9.8 N.m

page

to

6-12 for

the direction of rotation

the rubber seals if

use the middle

kgi.m,

{'1.0

7.2 tbftll

positioning

crankshaft and

on the beh before removing.

there is oil leakage between

cover and

and

lower

cover for

lower

cover before installation.

WASHER
Replace when
or deteriorated.

CYLINDER
Refer to
installing.

page

RUBBER

Beplace when
or deteriorated,

SEALS

BACK

pulley

storing

damaged

HEAD

6-33 when

damaged

COVER

installing

before

the cylinder head and

removed

COVER

items.

TIMING BELT

Inspection,
Adjustment,
Replacement,

belt.

cover.

page

6 9

page

6

9

page

6,10

x 1.25

8

mm

(3.8

37 N.m

ADJUSTING BOLT
10 x 1.25
54 N.m

{5.5

kgf.m,

27 lbf.ft)

mm

kgt.m, 40 lbf.ltl

MIDDLE

!

6x 1.0mm

9.8 N.m

kgl.m, 7.2lbf.ftl

11.0
TIMING

DRIVE
Remove

ano ctean.

BELT

PULLEY

any oil

Install

with
surface facing
Remove
and

concave

any oil

clean,

out.

6x1.0mm
'11

(1.1

N.m

SPEED

kgf.m,

8.0 lbI.ft)

{cKF)

ItEi:lufrroN

NOTE: When installing

tighten the crankshaft

O

loosen

@
@

bolt,

retighten

it

to

177

a new

N.m

crankshaft and/or

pulley

bott to 196 N.m

(18.0

kgnm,

130 tbnft).

new bolt:

(20.0

kgf.m, 145 tbf.ft),

COV€R

6x1.0mm

N.m

9.8

7.2lbl.ftl

PULLEY
14

x 1.25 mm
177 N.m
Replacement,

EOLT

(18.0

{1.0

kgf.m,
page

kgf.m,

LOWER
COVER

CRANKSHAFT
PULLEY
Remove any
and clean
timing belt
plate

6-8

side.

130

oil

the

guide

bnftl

6-7

Grankshaft

Pulley

Replacement

Bolt

NOTE:
o

Crankshaft

'14

x 1.25

177 N.m

a

When installing a
bolt:

tighten the

O

lbf.ft),
loosen the bolt,

@

retighten it to 177 N.m

o

pulley

mm

(18.0

bolt

130

kgf m,

new

pulley

bolt to 196 N.m

size and torque

lbtft)

crankshaft

(18.0

and/or

kgf.m, 130 lbift).

value:

(20.0

pulley

new

kgim, 145

When installing the bolt,
flange with engine oil, but don't
and DUllev.

Don't lubricate

PULLEY
HEX 50 mm, OFFSET

OTMAB - PY3O1OA

HOLDEB ATTACHMENI,

lubricate the threads and

lubricate the washer

washer.

SOCKET, 19 mm
07JAA - @1020A
COMMERCIALLY AVAILABLE

\-

Timing

Inspection

Belt

\-a

I

1. Remove

o

Refer to

Inspect the timing

2.
soal(n9.

NOTE:
.

Replace

.

Remove any oil or solvent

the cylinder head cover.

page

6-33 when

belt for cracks and oil or coolant

the belt if oil or coolant

installing.

that

soaked.

gets

on the

belt.

CAUTION:
engin€ cold.

NOTE:
.

The tensioner
sion to the belt automatically
ing adjustment.

.

Alwavs rotate the crankshaft

viewed from the
may
ston.

1.

2.

Always

result in improper adjustment

Remove the cylinder

when installing.)

6-33
Set the

Rotate the crankshaft

the belt.

Set

No. I

the No. 1

adiust iiming belt lension with the

is

spring-loaded to

pulley

piston

at TDC

piston

at

proper

apply

after making the follow-

counterclockwise when

side. Rotating

head cover.

(see

page

five to six revolutions to set

TDC.

it

of the belt ten-

(Refer

6-12).

ten-

clockwise

page

to

I

ADJUSTING BOLT

(5.5

After inspecting.

177 N'm

to

(18.0

kgf.m,

pulley

Rotate

inspect belt.

and

retorque the crankshaft

130 lbnft).

pulley

bolt

Loosen the adjusting
Rotate the

the camshaft
Tighten the adjusting bolt

7.
After adjusting.

8.

177 N.m

to

crankshaft counterclockwiFe

pulley

{18.0

N.m

54

{0 rbr.ftt

For adjustment only,
do not remove,

Direction of
rotation.

bolt 1/2 turn

to the

retorque the crankshaft

130 lbf.ftl.

kgf.m,

(180')

qdebified

kgf.m,

only.

3-teeth

torque.

pulley

on

bolt

{

.

6-9

Gylinder

Head

lllustrated

CAUTION:

When handling a mstal

SPRTNG

RETaTNER\_>6

EXHAUST VAL
SPRING

EXHAUST VALVE
SIEM SEAL

VALVE SPRING
SEAT

EXHAUST VALVE
GUIDE

Index

(cont'd)

VALVE KEEPERS

\

[\

-----------rg

ga€kot,

ENO PIVOT BOLT
63
46 tbt.ftl

,@

take care

N.m

{6.4

not

to

CYLINDER IIEAO
AOLT

11 x'1.5

85 N.m
Apply
the threads.

kgf.m,

fold it

o. damage the

mm

(8.7

kgtm, 63 lbf.ft)

engine oilto

contact surfac6 ol the

VALVE KEEP€NS

/l

/ |

/\ {e

s------.--

r

€.-=---

€<_-

gasket.

I

SPRING AEIAINER

INTAKE

VALVE SPRING

INTAKE VALVE STEM
VALVE

SPRING SEAT

INTAKE VALVE
Inspection.
Replacement,
Reaming,

page

page

page

GUIDE

6

26

6,27

6 28

SEAL

{

DOWEL PIN

CYLINDER HEAD GASKET

(3

LAYERS OF METALI

Replace.

EXHAUST

VALVE

DOWEL PIN

CYLINDER
Warpage, page

HEAD

6,30

L

\

Gylinder

Head

Removal

Remove

ventilation

the

ltosE

(cont'dl

fuel return hose

(PCV)

hose.

and

positive

crankcase

9.

Remove the throttle cable,

10.

Remove the throttle control cable
mission only).

NOTE:
.

Take care not to bend the cable when removing

it. Always replace
one.

.

Adjust the throttle cable and throttle
cable when installing

THROTTLE
CABLE

CONTROL

kinked cable

any

(s€e

(automatic

section 11 and 14).

trans-

with a new

control

Remove
bypass hose

the brake booster vacuum

and vacuum hose.

VACUUM HOSE

hose, water

11.

Remove

wire harness

intake manifold.

a

a
a
a
a
a

a

a

the engine wire harness

Four

fuel injector

Intake

air temperature
Engine coolant
nector

TDC/CKP/CYP

lgnition coil connector

gauge

ECT
Throttle
Manifold
necto r
ldle air control

purge

EVAP
Crankshaft
nector

clamps f.om

sensor connector

sending

position

absolute

(lAC)

control solenoid valve

speed

the cylinder head and

connectors

(lATl

temperature

unit connector

(TP)

sensor connector

pressure

valve connector

fluctuation

ADJUSTING NUT

ADJUSTING

connectors

sensor connector

sensor con,

{ECT)

(MAP)

sensor con-

connector

(CKF)

sensor con-

and

the

6-18

Gylinder

Head

Removallcont'd)

19. Remove the

N.m

mm

kgt:m, 38 lbl.ft}

{5.3

the cylinder head

10 x 1.25
52

20. Remove

side engine

mount.

cover.

12

x 1.25 mm
74 N.m
sil lbtft)

SIDE ENGINE
MOUNT

kgt.m,

17.5

21.

Remove the timing belt

22.

Remove

the camshaft

(see

page

pulleys

6- 10).

and back cover.

CAMSHAFT
PULLEYS

L

t

L

I'

CYLINOER HEAD
COVER

23. Remove

the exhaust manifold.

SELF.LOCKING
8 x 1.25

GASKET

Replace.

mm

3'l N.m

13.2

Replace.

NUT

kgl.m, 23 lbf.ftl

Valves,

Valve

Springs

and Valve

Seals

Removal

\-

Measure

Cam Lobe Height
fNTAKE:
EXHAUST:

cam Iobe

33.716 mm

33.528 mm

height.

Standard

11.3271inl

(1.3200

(Newl

inl

NOTE: ldentify
removed
nal

1.

so that

position.

Tap

e€ch valve

valve keepers

sor.

valves

and valve

each item

stem with a

before

springs

can be reinstalled

plastic

mallet

installing

the spring

as they

in its

origi-

loosen

to
compres-

are

Inspect

this area for

wear.

\

Install

the spring

remove

VALVE SPRING COMPRESSOR
KD No.383, with #35
Snap-on CF711

valve keeper.

compressor. Compress

JAW or

;;:'

-:..

,

'orl

spring

and

"

._vn-'r'.'i),

VALVE

SPRING COMPRESSOR

ATTACHMENT

-

07757

PJ1010A

\

6-23

I

Valves,

Valve Springs

and

Valve Seals

.i

'iii

Removal

Installthe special

3.

VALVE GUIDE

COMMERCIALLY

P/N 57900 or KD3350

LISLE

(cont'dl

tool as shown

SEAL REMOVER

AVAILABLE

valve Dimsnsions

lntaks
A

Standard

B

Standard

C Standard

C Sorvice

Standard

D

D Service Limil:

(Newl:

(New):

{New):

Limit:

(Now):

30.90 - 31.10

-

11-217

103.80

14.087

6.580
(0.2591

6.55 mm

1.35
(0.053
'1.15

1.221inl

-

104.10 mm

-

4.098 in)

-

6.590 mm

-

0.2594
(0.258

-

1.65 mm

-

0.065
(0.0'15

mm

mm

in)

in)

inl

inl

v

,l

tI

i{

lf

4. Remove the

valve seal.

Exhaust
A

B Standard

C Standard

C Service
D Standsrd

D Servic€ Limit:

Vslve Dimonsions

Standard

lNew):

(New):

{N6w}:

Limit:

lNow):

-

1.106 in)

-

0.2583
(0.257

mm

-

0.077

(0.057

mm

in)

mm

in)

27.90 - 28.10

11.098
1O4.OO - 10,1.30

l,[.09/t - 4.106

5.550 - 6.560

10.2579

6.52 mm

1.65 - 1.95

(0.065

1.45 mm

\

mm

in)

inl

in)

Installation

Sequence

\-

Exhaust

and intake

valve seals

are NOT

interchanoeable.

@A..'..--uoruEKEEPER'

NOTE: Place
spring with closely wound coils
toward the cylinder head.

the end of valve

9-...-'PRTNGREYATNER

VALVE

SPRING

EXHAUST

SPRING}

IBLACK

Replace.

VALVE

SEAL

,@.t.'

( (Sz)

V

I<--

INTAKE

VALVE
IWHITE SPRINGI
Replace.

SPRING
SEAT

SEAL

I

NOTE:

lnstall

before installing

VALVE

GUIDE

SEAL INSTALLER

-

07GAD

PH70100

the valve

spring seats

the valve

seals.

PLASTIC MALLET

6-25

Valves,
Valve

'alve

Valve

Valve Springs

Seals

Installation

Inslallauon

and

Valve

-

Valve

valve

Guides

Movement

tvtovemenr

-

installing

When
valve stems
guides,
smoothly.

When valves and

end of

proper

tic mallet).

NOTE: Tap the

not bend the stem.

do

with oil belore

make sure

and

valve

each

seating

of valves and

valve

valves in the

inserting them

valves

springs are

stem

stem

in

two or three times

valve keepers

only along

cylinder

move up and down

place,

PLASTIC MALLET

head, coat

into valve

tap the

lightly

to ensure
(use

lts axrs so

plas

you

guide

Measure the

while rocking the stem

tor

thrust {wobble

lntake Valve
Standard

Service
Exhaust Valve

Standard {New}:

Service

{Newlr

Limit:

Limit:

to stem clearance

method).

Stem-to-Guide Clearance:

0.04 - 0.10

10.002

0.16 mm

Stem-to-Guide Clearance:

0.10 - 0.16
(0.004

0.22 mm

Valve extended

in the direction

mm

-

-

in)

0.004
{0.005

mm

0.006 inl
(0.009

in)

in)

10

with a dial indica-

of normal

from seat

mm out

\-

lf measurement

a new valve.

usrng
lf measurement
reassemble using a
lf measurement still
alternate method below,
guide,

if necessary.

NOTEr An alternate

clearance

sured
guide, measured with an inside
ga

uge.

Take the

stem and

The diiference between the

and the smallest
the

lntake Valve Stem-to-Guide Clearance:
Standard

Service
Exhaust

Standard

Service

is to subtract the O.D.

with a

measurements in three

three

service limit

(Newl:

Limit: 0,08 mm

Valve Stem-to-Guide Clearance:

(New):

Limit: 0.11

exceeds the service

is now within the service

new valve.

exceeds

method of checking

micrometer, from the

places

inside the

stem measurement should

0.02 - 0.05

10.001-{.002 inl
(0.003

0.05 - 0.08 mm

-

mm

0.003
{0.004

{0.002

limit, recheck using

replace valve and

then

of the valve stem, mea-

micrometer or ball

places

valve

largest

mm

guide

in)

in)

in)

limit, recheck

limit,

guide

to stem

l.D. o{ the valve

along the valve

guide.

measurement

not exceed

L

\

Replacement

1.

As illustrated
air-impact valve
to fit

the diameter
cases, the
special tool

below

same

and a conventional

mm

87

{3.43

or

VALVE

GUIDE DBIVER,

07942 - 6570100

use a commercially

guide

driver

attachment modified

of the valve

procedure

can be

hammer.

*f-::rt

in)

12.21inl

6.6 mm

available

guides,

In most

done using

6.il mm
{0.25

the

inl

rr

l1-r

11.3 mm
inl

10.44

Working trom
8n air hammer
in)

towards
knock off
easter.

CAUTION:
.

Always
when driving

.

Hold
valve

Turn

5.

the head

the camshaft

the

camshaft side,

to drive

the combustion

some of

wear

the air
guide

the carbon

safety
valve
hammer

prevent

to

over and drive

side

of head.

guide

the

chamber.

and make

goggles

guides.

direcfly in line

damaging

the

use the

guide

driver and

about 2

or

a face shield

the driver.

out toward

(0.1

mm

This

will

removal

with

the

Select the
them in the
about

Use a hot
head
a

\,

cooking thermometer.

CAUTION:
.

Do not

.

Do not
exces3ive

.

To avoid
the heat€d

proper

freezer section

an hour.

plate

to 300"F

use a torch; it

ger

heat may

burns, uss

cylinder

replacement guides

or oven

(150"C).

tho head hotter

to evenly heat

Monitor

may warp

loo3en

gloves

heaw

head.

and chill

of a refrigerator

the cylinder

the

temperature with

the hoad.

than

300.F

ltS0"C);

the valvo

seats.

when

handling

for

VALVE GUIDE DRIVER.
079i12 - 6570100

mm

guide

(5/16

still won't move.

in)

bit, then try again.

guides

Drill

the cylinder head

lf a valve

8.0
CAUTION:

could damage

mm

6.6

only in extreme

OO

'o

drill it out

guide

it the

c,

with a

cases; You

breaks.

6. Remove
time, as

the new

you

need

guide{s)

them.

from the freezer,

one

at a

{cont'd)

6-27

Valve

Seats

Reconditioning

Renew

valve

NOTE:
them

Carefully
material

Bevel
and
Check width

Make
remove
rers.

V8lv6
Standard

S€rvice Limit:

the valve seats

seat cutter.

guides

lf

page

{see

cut a 45" seat, removing

to ensure

the upper

lower

the

one more very light

any

S€at Width

{New}:

in the cylinder

are worn

6-27)

a smooth and

edge of the

edge

of the seat

of seat and adjust

possible

(lntake

1.25

2.0 mm

(see

before cutting

seat with

pass

burrs

caused by

and Exhaustl:

-

1.55

mm

10.08

head

page

6-26), replace

the valve

only enough

concentric

the 30. cutter

with the 60.

accordingly.

with

the 45o cutter

the other cut-

-

{0.0/t{,

in)

0.061 in}

using a

seats.

seat.

cutter.

to

o.

The actual valve

blue

compound, should

lf it
must make
move
cutter to restore
lf it is
must make a
move

to restore

NOTE:

the 45"

Insert

1.

intake

measure valve
Intake

Valve

Standard

Servico
Exhaust Valv€
Standard

Service Limit:

seating

is too high

it down,

too

at up, then

The final
cutter.

Stem Inst8lled

lN6wl:

Limiti

{Newl:

(closer

a second cut with

then one more

seat width.

(closer

low

second cut with

one more cut with

seat width.

cut should always

and exhaust valves

stem installed

40.765
(1.6049

i01.,|85

Stem Installed

,[2.765
{1.68i}7

,(1.485

surface, as shown

be centered

to the valve

to the valve

Height:

-

i11.235

-

1.6234 in)
(1.6333

mm

-

4:1.235

-

1.7022 inl

mm

11.7120 inl

on the seat.

the 60"

cut with

the 30.

the 45.

be made with

in the head

height.

mm

in)

Height:

mm

by the

stem),

cutter to

the 45"

edge),

cutter to

cutter

you

you

and

I_1

I

\

VALVE

STEM

After

resurfacing

seating:

face.

Insert

head,

then lift it

several

ACTUAL
SEATING
SURFACE

times.

VALVE
SEAT

the seat, inspect

Apply Prussian

the valve in its

and snap it

for

Blue compound

original location

closed against

even valve

to

the valve

in

the

the seat

8. lf valve
limit,

replace valve

vice limit,

the head is too

stem installed

and recheck. lf

replace

cylinder head;

deep.

INSTAI-LED

height is

the valve

HEIGHT

over the
still over

service

the ser-

seat in

PRUSSIAN BLUE

COMPOUNO

6-29

Cylinder

Head

Wapage

NOTE:

22) arc

resurfaced.

lf
tions,

lf camshaft-to-holder

nol within

camshaft-to-holder

the head

check

lf warpage
head

lf warpage

(0.008
Maximum

on a

is less than 0.05

resurfacing

is between

in). resurface cylinder

resurface

height of

132.0 mm

oil clearances

specification,

oil clearances

for warpage.

mm

is not required.

0.05 mm
head.

limit is 0.2

(5.20

in).

PRECISION

STRAIGHT

(see

head cannot

the

within specifica-

are

(0.002

in) cylinder

(0.002

in) and 0.2

(0.008

mm

EDGE

page

6

be

mm

in) based

lnstallation

Install the
NOTE:

.

Always use

.

Cylinder

.

to

.
.

Clean the

.
L Cylinder

cylinder

a new head

head

clean.

"UP"

p.
Do not use the
ing removed

lation.
Replace

must be aligned.

.

.

on the camshaft

mark

items.

middle cover

the washer

head dowel

hand'ing a metal

When

not to

taken

gasket.

of the
Clean the oil control

head in the

and cYlinder

middle cover

when damaged

fold it or damage the

reverse order

gasket.

block surface

pulleys

and lower

and lower

pins

and the

gasket,

when installing,

orifice

CYLINDER

LAYERS OF

{3

removal:

of

must be

should

cover before

or deteriorated

oil control

be at the

cover for stor-

orifice

care should
contact surface

HEAD GASKET

METAL)

instal-

be

Measure along

Cylinder
Standard lNewl:

Head Height:

edges, and 3 ways across

131.95 - 132.05 mm

-

(5.195

5.199 inl

center.

DOWEL

Tighten
tirst step

N.m

lhe same

NOTE:

.

.

CYLINDER

the cylinder

tighten all bolts,

(3.0

kgf.m,22

sequence to 85

Apply engine oil to the
the washers.

the longer bolts at

Use
as snown,

HEAD BOLTS TOROUE SEOUENCE

lbf.ft); in

CONTROL

OIL
ORIFICE

head bolts in two steps.

in sequence, to

final step. tighten

the

(8.7

N.m

positions No. 1

kgnm,63

cylinder

about 29

lbf.ft).

head bolts and

and

In the

in

No. 2

\

.l

Put

longer bolts here.

tNOTE:

6.30

t

-

\-

Install

the intake
cflsscross pattern
inner

nuts.

CAUTION:

face

ol

the

damaged.

INTAKE
MANIFOLD

manifold

in 2

Check lor

gasket.

GASKET

Replace.

and

tighten the nuts

or 3 steps.

folds

or scratches

Replace with

beginning with

on the sur-

gasket

a new

in a

the

CAUTION:
.

Make

sure that

tacing

up and No.

tTDCt.

.

Replacethe

il

6. Place

the rocker

valve stems.

the keyways

rocker

arms in

arms

piston

1

on the

on the

is at

their original

camshafts

top dead

pivot

cenier

positions.

bolts and

are

the

7.8.Install

",', r, ^-'-"-!,1,,,';-

21N.m

l2.1kglm,

L

4. Tighten
Install

5.

self-locking
steps,

.

Use

1 .25 mm

8x

N.m

24

{2.4

rbrftt

17

17lbf.ftl

the intake

the exhaust

beginning

new self-locking

kg{.m,

\

q

manifold

maniiold

nuts

in a

with the inner

EXHAUST
MANIFOLD

bracket

and

crisscross

nuts.

SELF.LOCKING
8 x 1.25 mm
31 N.m

Replace.

pattern

nuts.

(3.2

(2.3

23 N.m

17 tbf.ftr

bolts.

tighten the new

kgt m,23 lbf.ft)

NUT

ksf.m,

in 2

or 3

GASKET

Replace.

the camshafts,

with

the open side

Apply
the No.
them,

NOTE:

"l"

.

holders.

.

Do not
camshaft

.

Apply liquid gasket

.

The
should

.

Clean
before

gasket

liquid

1 and No.

along with No.2,3,

"E'

or

marks

apply

seals.

arrows marked

point

to the timing

and dry

applying liquid gasket.

INTAKE

CAMSHAFT HOLDERS

then install

(spring)

6 camshaft

oil to the holder

the cylinder

facing

to the head mating

holders,

4,

and 5.

are stamped

to the

shaded areas.

on

the camshaft

belt.

head mating

the

camshaft

in.

on the

mating

seals

surfaces

then install

surface

ot

camshaft

of

holders

surfaces

10 x 1.25 mm

4,{ N.rn

14.5

33 tbf.ftl

kgf.m,

4

8 x 1.25
24 N.m

'17

tbf.ft)

mm

{2.4

kgtm,

No.6

No.5

No.4 No.3 No.2

No.

1

{cont'd)

6-31

Cylinder

Head

Installation

Tighten the camshaft

9,

a

Make sure

positioned

on the

(cont'dl

holders temporarily.

that the

rocker arms

valve stems

are

properly

11. Align
cylinder

head

der

CYLINDEB
PLUG
Replace.

the marks on the

head upper surface,

plug

in the cylinder

HEAD

cylinder

then

head to

plug

head

install the

the end.

to the

\-

cylin-

Tighten each

10.
rockers do

NOTE:

1 and No. 6 camshaft

No.

6x1.0mm

N.m

9,8

11.0

bolt in two steps

not

bind

wipe off the

7.2 lbt'ftl

kgf m,

valves.

on the

excess of

holder with a shop

to ensure

gasket

liquid

that the

from

towel

lnstall

Install keys

13.
NOTE:

1
holes
pin

the back cover.

into camshaft

To set the camshafts

piston,

in No. 1 camshsft

punches

the holes

align

in

the

6x1.0mm

9.8 N.m

7.2 tbr.ft)

grooves.

at

in the camshafts

holders snd

holes.

KEYS

8
t7

kgt m.

{1.0

position

TDC

insert 5.0

x 1.25 mm

N.|rl

{3.8

for No.

with the

kst.m,27

mm

lbf.ftl

14.

camshaft

Push

retaining bolts

the

pulleys

onto camshafts,

to the torque

then tighten

specified.

15.

Install

16.

Adjust

17.

lnstall
head
camshaft

the

NOTE:
.

.

the timing

the valve

the rubber

cover.

first,

outside

Before

clean
When
securely
gap.

installing

the

installing,

belt

clearance

seal in the

Seat

the seal in

then work

edges.

seal and

in

the corners

(see

page

(see

page

groove

the recesses

it into

the rubber

groove.

the
make

sure

of the recesses

6-12).

the

seal,

the

6-3).

of the

cylinder

for

groove

seal is

around

thoroughly

seated

with no

the

18. Apply
corners of

NOTE:
.

Use liquid

-

0003.

.

Check
before

.

Do
elapsed
reapply

.

After

filling

gasket

liquid

the recesses.

that

applying

not installthe parts

since

liquid gasket

assembly,

the engine

to the rubber

gasket,

Part No.

the mating

liquid

applying

wait

with

after removing

at least

oil.

seal

08718

surfaces

gasket.

if 5 minutes

are

liquid

30 minutes

gasket.

at the

-

OO01

or 08718

clean

and

or more

Instead,

old residue.

eight

dry

nave

before

RUEBER

SEAL

Apply

the

shaded

liquid

areas.

gasket

to

(cont'd)

6-33

Cylinder

Head

Installation

installing the

When

19.
seal in the

rubber

the camshaft

semicircles).
Once the
head, slide

rubber seal.

the

NOTE:
.

Before
the cylinder
shop towel.

.

Do not touch
applied.

holder

cylinder

the cover slightly

installing the cylinder

6x1.0mm

9.8 N.m
7

(cont'dl

cylinder

groove

contacting surfaces

head cover

head contacting surfaces

parts

the

{1.0

.2 tblltl

head cover.

placing

by

is on the cylinder

back

head cover, clean

where liquid

kgf.m,

your

and iorth to

hold the

fingers on

(top

of the

seat

using

gasket

was

final step,

9.8 N'm

to

In the

(1.0

kgim,

in 2 or 3 steps.

Tighten the
tighten ali

7.2 tbf.ft).

a

nuts

nuts, in sequence,

21.

After installing, check
nectors

are installed correctly.

that all tubes,

hoses and con-

\

6-34