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The following technical bulletins were published by AERA.

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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