| | CYLINDER BORING/HONING CAUTION FOR 2.3L ENGINES | Cylinder Boring/Honing Caution For
1992-96 Honda 2.3L Engines
The AERA Technical Committee offers the following information on a cylinder boring/honing caution for 1992-96 Honda 2.3L engines. This engine is used in their Prelude vehicles and uses a fiber-reinforced metal (FRM) in the cylinder bores. Those bores are also a nonferrous metal and require special attention during the oversize operations.
During manufacturing, a rigid hone using a GC-600-J or finer stone designed for nonferrous metal was used to finish hone the cylinder bores. Honing pressure should be adjusted to 29-43 psi (200-300 kpa), while the hone head is rotating at 45-50 rpm. The desired crosshatch pattern is 60° for a proper piston ring seal. To prevent stone loading and debris build-up, cleaning the stones every five cycles is recommended.
After the bores have been honed to final size, the block should be cleaned with hot, soapy water and then dried. A cleaning solvent is not advised as it has a tendency to only redistribute honing grit.
Aftermarket honing stone suppliers have found using a silicon carbide, 400 grit stone provides the desired finish and crosshatch required for this cylinder block.
The AERA Technical Committee | | BALANCE SHAFT SEAL CAUTION | Balance Shaft Seal Caution For
1990-99 Honda 1.5, 1.6, 2.2 & 2.3L Engines
The AERA Technical Company offers the following information on a balance shaft seal caution for 1990-99 Honda 1.5, 1.6, 2.2 & 2.3L engines. This caution is expressed as the oil seal used for the front of the balance shaft may become dislodged, creating engine oil loss. In severe situations, engine damage has resulted before a leak was noticed.
Apparently, the seal retention is questionable on these engines and the seal may move within its housing at an undetermined time. To resolve this situation, Honda suggests installing a retaining clip within the seal housing to prevent the seal from moving. The repair involves removing the front timing belt cover and installing the clip. As the result of these seals moving Honda published a service bulletin describing the use of a new seal installer, Part #TN 07XAF-PT00100. This installer positions the seal deeper within the timing cover to allow room for the clip.
AERA is aware of another source for components regarding a similar repair of this condition, it involves bolting on a retaining plate as shown below.
The AERA Technical Committee | | FLYWHEEL SPECIFICATIONS | Flywheel Specifications
The following flywheel specifications may be used as reference
when surfacing flywheels.
Type of
Manufacturer flywh. Specs. Comments
BMW Step .013 - .015
Datsun Step .003 - .005 No groove
Flat With groove
Datsun 240Z Step .010 With groove
Fiat Spider 1600 Step .018
Ford Falcon Cup .018 6 Cylinder engines
Ford Courier Cup .285
Cup .310
Ford Ranger Cup .003 V6 Cylinder engines
GM Cup .125
GM - Buick Cup .125 V6 Cylinder engines
GM - Spirit Cup .195
Honda Cup .030 Small cup
Cup .100 - .104
Cup .785 Long alignment pins
Cup .900 Short alignment pins
Honda Accord Cup .615
Mazda Cup .062 Rotary engines
Subaru Cup .785
Toyota Step .018 - .022 Large alignment pins
Cup .055 Small cup
Cup .965 - .970 Tercel, large cup
Step .040 Tercel, step
Step .020 Land Cruiser
VW Cup .945 Air cooled, 6 Volt
Cup .830 Scirocco
Cup .835 Rabbit/Golf
Cup .982 Air cooled bus engine
Cup .830 Air cooled engine
Cup .885 Air cooled engine
Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface. Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear
surface.
The AERA Technical Committee
February 1988 - SB 153
##END## | | CYLINDER HEAD INSTALLATION CAUTION | Cylinder Head Installation Caution For
1992-95 Honda 1.6L D16DZ Engines
The AERA Technical Committee offers the following information regarding a cylinder head installation caution for 1992-95 Honda 1.6L D16DZ engines. This caution is expressed for engines that have had either machining of the block or head surfaces. It has been reported that interference between the intake manifold and the cylinder block may prevent the head from properly clamping the block.
In many instances, the intake manifold is attached to the cylinder head before that assembly is installed onto the block. If that is attempted, the intake manifold may contact the block in three areas while the head is tightened down. The areas are one at each end and one in the middle portion of the intake manifold and the interference may not occur until the head gasket is compressed.
Depending upon the amount of interference, the engine may start up and seem to run normally until the engine warms up completely. If the interference is excessive, coolant will flow out between the head and block when the cooling system is being filled. To repair this condition shops have used a portable grinder to remove manifold material until the additional clearance required is obtained.
The AERA Technical Committee | | SEIZED CAMSHAFTS ON 2.2L HONDA ENGINES | Seized Camshafts On
1990-99 Honda 2.2L Engines
The AERA Technical Committee offers information that may reduce the possibility of seized camshafts on 1990-99 Honda 2.2L engines. This engine uses a metered oil supply to the cylinder head by means of a restrictor located in the deck of the cylinder block.
Through time, the small hole in this restrictor may become partially blocked and limit the amount of oil flow to the cylinder head. Eventually, after many engine starts, a dry start condition may exist and cause a journal to score its camshaft bore.
Some AERA members are increasing the opening size of this oil restrictor anytime the cylinder head is removed from the block. Drilling the existing restrictor to .062 (1.575 mm) in size will increase the volume of oil to the cylinder head and camshaft. This should not overwhelm the cylinder head with oil, providing all other oil clearances are within specifications. This procedure has been done many times and should help prevent a seized camshaft journal in this head. Using heavier viscosity engine oil than called for cab also detrimental, as it does not flow quickly in colder ambient temperatures.
Figure 1. Oil Restrictor Removed
The AERA Technical Committee | | CRANKSHAFT IDENTIFICATION | Honda Crankshaft Identification
The AERA Technical Committee offers the following information on crankshaft identification for Honda four cylinder engines. Generally, there are no reliable casting numbers on Honda crankshaft and physical identification is required if the engine family is not known. In some instances, there may be a difference in crankshafts for the same engine family. Refer to the chart below to assist in
crankshaft identification, all dimensions are given in inches.
Total Length Flange Bolts
Nose Dia. Counterweights
Main Size Oil Pump Drive
Rod Size cc Displ.
Stroke Year Engine Model
---------------------------------------------------------------
16.5 .865 1.968 1.574 2.992 6 4 No 1169 1972-79 EB, EE
16.5 .865 1.968 1.574 2.992 6 4 No 1238 1972-79 EB, EE
16.6 .865 1.968 1.574 3.228 6 4 No 1300 1980-83 EJ, EN
16.6 .865 1.968 1.574 3.228 6 4 No 1335 1980-83 EJ, EN
16.6 .865 1.968 1.653 3.405 6 4 No 1488 1974-83 ED, EM
16.6 .865 1.968 1.653 3.396 6 8 No 1601 1980-83 EP
16.6 .865 1.968 1.653 3.661 6 8 No 1599 1976-78 EF
16.6 .865 1.968 1.653 3.700 6 8 No 1751 1980 EK, W/10mm Fly/Bolts
16.6 .865 1.969 1.653 3.700 6 8 No 1751 1981-83 EK, W/12mm Fly/Bolts
17.5 .865 1.771 1.495 3.326 6 4 Yes 1493 1988-92 D15B1, D15B2
17.5 .865 1.771 1.574 3.070 6 4 Yes 1342 1984-87 D13A2, EV1
17.5 .865 1.77I 1.653 3.405 6 4 Yes 1488 1983-87 D15A1, EW1, EW3
17.5 .865 1.771 1.653 3.150 6 4 Yes ??? ??? EXPORT
17.5 .865 1.969 1.653 3.405 6 4 Yes 1488 1983-87 D15A1, EW1, EW3
17.5 .944 1.771 1.653 3.405 6 8 Yes 1488 1983-87 D15A1, EW1, EW3
17.6 .865 1.771 1.495 3.070 6 4 Yes 1342 1984-87 D13A2, EV1
17.6 .865 1.771 1.653 3.326 6 8 Yes 1493 1988-92 D15B1, D15B2, D15B6
17.6 .865 1.968 1.574 3.070 6 4 Yes 1342 1984-87 D13A2, EV 1
17.6 .865 2.165 1.771 3.543 6 8* Yes 1590 1988-93 D16 SERIES
17.6 .865 2.165 1.771 3.543 6 8**Yes 1590 1988-93 D16 SERIES
17.6 .944 1.771 1.495 3.326 6 4 Yes 1493 1988-92 D15B1, D15B2, D15B6
17.6 .944 1.771 1.653 3.326 6 8 Yes 1493 1988-92 D15B1, D15B2, D15B6
17.6 .944 2.165 1.771 3.543 6 8**Yes 1590 1988-93 D16 SERIES
17.6 .944 2.165 1.771 3.543 6 8* Yes 1590 1988-93 D16 SERIES
17.8 .984 1.968 1.771 3.582 8 8 No 1955^ 1986-89 BS, BT, A20A1, A20A3
17.8 .984 1.968 1.771 3.582 8 8 No 1955^^ 1986-89 BS, BT, A20A1, A20A3
18.5 1.102 2.165 1.771 3.740 8 8 Yes
18.7 1.181 1.969 1.771 3.543 7 8 Yes
19.9 1.102 2.165 1.771 3.503 8 8 Yes 1834 1985-88 B18A
18.9 1.102 2.165 1.889 3.740 8 8 Yes 2056 1990-91 B21A1
19.6 1.181 1.968 1.771 3.567 8 8 Yes 2259 1992-94 B23A1
19.6 1.181 1.968 1.989 3.740 8 8 Yes 2156 1993-95 H22A1
* All Counterweights Are 1.750 Long.
** Second Counterweight is 1.125 Long.
*** Oil Pump is Two Flat Areas Machined Between #1 Main and Pulley
Snout
^ Has 11.5mm Crankshaft Pulley Bolt 11.5mm.
^^ Has 14mm Crankshaft Pulley Bolt 14mm.
The AERA Technical Committee | | CAMSHAFT TIMING | Camshaft Timing On
1987 Honda 1.5L D15 Engines
The AERA Technical Committee suggests referring to the following information while setting the camshaft timing on 1987 Honda 1.5L D15 engines. This information applies to only those engines with multi-port fuel injection (CRX HF & SI, 4WD Wagon).
Through the years, Honda has used different methods for camshaft timing references, which has resulted in a camshaft sprocket with multiple identification marks. Only one of those marks is used for each timing method. Of course, the question always is: Which mark do we use?
The camshaft sprocket includes the word UP which applies, but is not specific enough to indicate the exact timing position. Refer to the illustration below and notice the small plastic pointer on the timing belt cover near the 7 o'clock position of the sprocket. Align the pointer with the mark on the sprocket while UP is at the top of the engine. Do not use the two timing marks that are near the 3 and 9 o'clock positions.
The AERA Technical Committee | | VALVE REUSE GUIDELINES | Valve Reuse Guidelines On
Honda Engines
The AERA Technical Committee is informing members of suggested valve reuse specifications on Honda engines. Unless service manuals provide specific measurements, the following guidelines for valve margin thickness should be considered:
Engines older than 1987: Discard the valve when the valve margin reaches .008 (.2mm) less than original thickness.
1987 and newer engines: The minimum valve margin is
.045 for intake and exhaust valves.
The valve stem and keeper grooves should also be inspected for wear when considering valve reuse.
AERA Technical Committee |
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