September 10, 1996 YEAR MODEL VIN APPLICATION BULLETIN NO. 1992 93 INTEGRA See VEHICLES AFFECTED 96-015 Product Update Campaign: 1992 93 Integra Distributor (Supersedes 96-015, dated June 11, 1996) BACKGROUND The bearing may develop excessive clearance. If this happens, the engine will not start. This product update campaign is being conducted to help eliminate any possibility of the customer s car not starting. VEHICLES AFFECTED 1992 Integra: ALL 1993 Integra: 2-door RS, LS, GS Thru VIN JH4DA9...PS021690 4-door RS, LS, GS Thru VIN JH4DB1...PS003558 2-door GSR Thru VIN JH4DB2...PS000804 GENERAL INFORMATION This product update campaign is being conducted in two regions: Region A and Region B (see map on page 2). Depending on mileage, the repair procedure is different for vehicles in Region A. There is only one repair procedure in Region B. Refer to the maps and zip code information in this service bulletin to determine which region you are in, then follow the appropriate CORRECTIVE ACTION. Owners who live outside Regions A and B are not included in this campaign. They will be notified that the warranty on the assembly has been extended to 6 years or 100,000 miles. Refer to service bulletin 96-022, Warranty Extension: 1992 93 Integra Distributor, for details. PROCEDURE GUIDE Is the car within this VIN range? 1992 Integra: ALL 1993 Integra: 2-door RS, LS, GS Thru VIN JH4DA9...PS021690 4-door RS, LS, GS Thru VIN JH4DB1...PS003558 2-door GSR Thru VIN JH4DB2...PS000804 Does the customer live in Region A or B? Region A YES NO NO Region B This car is not affected by this campaign. See service bulletin 96-022, Warranty Extension: 1992 93 Integra Distributor. State Zip Code Alabama.... First two digits are 36 Florida..................... All Georgia..... First two digits are 31 Hawaii..................... All Louisiana... First two digits are 70 Mississippi.. First two digits are 39 Puerto Rico................. All Texas.. First two digits are 77 or 78 State Zip Code Alabama.... First two digits are 35 Arkansas.... First two digits are 71 California.................. All Georgia..... First two digits are 30 Louisiana... First two digits are 71 Mississippi.. First two digits are 38 South Carolina............. All Tennessee...First two digits are 38 Texas......... All except 77 or 78 YES Go to the Region A Corrective Action on page 3. YES Go to the Region B Corrective Action on page 6. 1996 American Honda Motor Co., Inc. All Rights Reserved BTB 17880-18232 (9609) 1 of 9 CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by do-it-yourselfers, and you should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an authorized Acura automobile dealer.
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Product Update Information: Region A PUERTO RICO The shaded area in the above map is Region A. This region includes these zip codes: Alabama.................. First two digits are 36 Florida.................................... ALL Georgia................... First two digits are 31 Hawaii.................................... ALL Louisiana................. First two digits are 70 Mississippi................ First two digits are 39 Puerto Rico................................ ALL Texas................ First two digits are 77 or 78 CUSTOMER NOTIFICATION Owners of affected vehicles who live in the above zip codes will be contacted by mail and asked to take the car to a dealership for repair. The text of the customer letter is at the end of this service bulletin. 2. Remove the two connectors from the bracket behind the. 3. Unplug the 2-P and 8-P connectors. 4. Disconnect the spark plug wires from the cap. 5. Place a shop towel under the to catch any oil that drips. Remove the three hold-down bolts. Remove the from the car. 2-P CONNECTOR 8-P CONNECTOR CORRECTIVE ACTION FOR REGION A Vehicle has more than 30,000 miles: Replace the housing assembly (see PARTS INFORMATION). Vehicle has less than 30,000 miles: Pack grease in the shaft bearing, check the bearing, and replace components with the components from the cap kit listed under PARTS INFORMATION. Repair Procedure 1. Make sure the ignition is off. HOLD-DOWN BOLTS 6. Remove the cap. If the vehicle has more than 30,000 miles, keep the cap for later installation. 96-015 3 of 9
7. Remove the retaining screw, then remove the rotor. Remove the leak cover. Remove the to-cylinder head O-ring. Do not discard the leak cover and rotor. They will be needed for reassembly. RETAINING SCREW ROTOR LEAK COVER 9. Remove the ignition coil and igniter mounting screws. Remove the coil and igniter from the. If the vehicle has less than 30,000 miles, continue to step 10 to pack grease in the bearing. If the vehicle has more than 30,000 miles, go to step 18 to replace the housing. IGNITER IGNITION COIL O-RING 8. Use a Phillips screwdriver to disconnect the BLK/YEL wire from the ignition coil. Disconnect all four wires from the igniter. Take care that you do not damage the wire connectors or lose the screw, you will need to reuse them. SCREW (Retain.) 10. Use a two-jaw puller to remove the cylinder sensor rotor from the shaft. Make sure the jaws are placed under the inner part of the rotor and not on the projection. Watch the roll pin on the inside of the rotor next to the shaft. It should slide off with the rotor; if it does not, do not let it fall inside the housing. Do not place jaw here. ROLL PIN 11. Use a small punch to remove the roll pin from the cylinder sensor rotor. Discard the roll pin. 12. Cut the corner off the bag of grease that came in the cap kit. Fill the well above the shaft bearing with this grease; distribute it evenly. 4 of 9 96-015
13. Use a piece of hose to pack the grease into the bearing. The hose should have an inner diameter of 1/2 inch (12.5 mm) and an outside diameter of 13/16 inch (20.5 mm). A piece of heater bypass hose, P/N 19508-PA6-010, will work. Make sure the end is cut perfectly square. 18. Install the original ignition coil and igniter in the housing with the original screws. 19. Reconnect the wires to the igniter and ignition coil terminals. YEL/GRN BLK/YEL WHT/BLU BLU HEATER HOSE 14. Inspect the shaft and bearing to verify that all the grease has been forced into the bearing. If not, repeat step 13. 15. Rotate the shaft 10 to 15 revolutions to distribute the grease. 16. Place the housing near your ear and listen as you rotate the shaft. If you can hear the bearing making a scraping noise, replace the housing (see PARTS INFORMATION) and go to step 18. If the bearing is quiet and the shaft turns freely, continue to step 17. (Because of the CKP sensor magnet, you will feel some drag when you rotate the shaft slowly. If you have any doubt about the bearing, compare it to a known-good.) 17. Install the cylinder sensor rotor on the shaft. Use a small punch to drive the new roll pin into the rotor. Verify that the rotor is lined up with the pickup and that the roll pin is flush with the top of the rotor. 20. Install the original leak cover. If the vehicle has less than 30,000 miles, install the rotor, cap, cap seal, and O-ring from the cap kit. If the vehicle has more than 30,000 miles, install the original rotor, cap, and cap seal. 21. Apply a small amount of clean engine oil to the O-ring that goes between the and the head. Install the on the head. 22. Install the spark plug wires. Reconnect the 2-P and 8-P connectors. Install the two electrical connectors on the bracket. No. 3 No. 4 CYLINDER SENSOR ROTOR PICKUP ROLL PIN No. 1 No. 2 23. Set the ignition timing according to the procedure in the service manual. 24. Center-punch a completion mark above the first character of the engine compartment VIN. Center-punch here. PICKUP ROLL PIN CYLINDER SENSOR ROTOR 96-015 5 of 9
Product Update Information: Region B É É ÉÉ É É ÉÉ ÉÉ É ÉÉ É ÉÉ ÉÉ É ÉÉ The lined area in the above map is Region B. This region includes these zip codes. Alabama.................. First two digits are 35 Arkansas.................. First two digits are 71 California.................................. ALL Georgia................... First two digits are 30 Louisiana................. First two digits are 71 Mississippi................ First two digits are 38 South Carolina............................. ALL Tennessee................ First two digits are 38 Texas...................... All except 77 and 78 4. Disconnect the spark plug wires from the cap. 5. Place a shop towel under the to catch any oil that drips. Remove the three hold-down bolts. Remove the from the car. 2-P CONNECTOR 8-P CONNECTOR CUSTOMER NOTIFICATION Owners of affected vehicles who live in the above zip codes will be contacted by mail and asked to take the car to a dealership for repair. The text of the customer letter is at the end of this service bulletin. CORRECTIVE ACTION FOR REGION B Pack grease in the shaft bearing, check the bearing, and replace components with the components from the cap kit listed under PARTS INFORMATION. Replace the housing only if the bearing is still noisy after being greased. 1. Make sure the ignition is off. 2. Remove the two connectors from the bracket behind the. 3. Unplug the 2-P and 8-P connectors. MOUNTING BOLTS 6. Remove and discard the cap. 6 of 9 96-015
7. Remove the retaining screw, then remove the rotor. Remove the leak cover. Remove the to-cylinder head O-ring. Do not discard the leak cover. It will be needed for reassembly. 9. Remove the ignition coil and igniter mounting screws. Remove the coil and igniter from the. ROTOR IGNITION COIL RETAINING SCREW LEAK COVER IGNITER O-RING 8. Use a Phillips screwdriver to disconnect the BLK/YEL wire from the ignition coil. Disconnect all four wires from the igniter. Take care that you do not damage the wire connectors or lose the screw, you will need to reuse them. SCREW (Retain.) 10. Use a two-jaw puller to remove the cylinder sensor rotor from the shaft. Make sure the jaws are placed under the inner part of the rotor and not on the projection. Watch the roll pin on the inside of the rotor next to the shaft. It should slide off with the rotor; if it does not, do not let it fall inside the housing. Do not place jaw here. ROLL PIN 11. Use a small punch to remove the roll pin from the cylinder sensor rotor. Discard the roll pin. 96-015 7 of 9
12. Cut the corner off the bag of grease that came in the cap kit. Fill the well above the shaft bearing with this grease; distribute it evenly. 13. Use a piece of hose to pack the grease into the bearing. The hose should have an inner diameter of 1/2 inch (12.5 mm) and an outside diameter of 13/16 inch (20.5 mm). A piece of heater bypass hose, P/N 19508-PA6-010, will work. Make sure the end is cut perfectly square. 17. Install the cylinder sensor rotor on the shaft. Use a small punch to drive the new roll pin into the rotor. Verify that the rotor is lined up with the pickup and that the roll pin is flush with the top of the rotor. PICKUP CYLINDER SENSOR ROTOR ROLL PIN HEATER HOSE 14. Inspect the shaft and bearing to verify that all the grease has been forced into the bearing. If not, repeat step 13. 15. Rotate the shaft 10 to 15 revolutions to distribute the grease. 16. Place the housing near your ear and listen as you rotate the shaft. If you can hear the bearing making a scraping noise, replace the housing (see PARTS INFORMATION) and go to step 18. If the bearing is quiet and the shaft turns freely, continue to step 17. (Because of the CKP sensor magnet, you will feel some drag when you rotate the shaft slowly. If you have any doubt about the bearing, compare it to a known-good.) PICKUP ROLL PIN CYLINDER SENSOR ROTOR 18. Install the original ignition coil and igniter in the housing with the original screws. 19. Reconnect the wires to the igniter and ignition coil terminals. YEL/GRN BLK/YEL WHT/BLU BLU 20. Install the original leak cover. Install the rotor, cap, cap seal, and O-ring from the cap kit. 21. Apply a small amount of clean engine oil to the O-ring that goes between the and the head. Install the on the head. 8 of 9 96-015
22. Install the spark plug wires. Reconnect the 2-P and 8-P connectors. Install the two electrical connectors on the bracket. No. 3 No. 1 No. 2 No. 4 23. Set the ignition timing according to the procedure in the service manual. 24. Center-punch a completion mark above the first character of the engine compartment VIN. Center-punch here. PARTS INFORMATION Distributor cap kit: P/N 06303-P30-A01 Distributor housing assembly: RS, LS, GS P/N 06301-PR4-A01 GSR P/N 06301-P30-A01 WARRANTY CLAIM INFORMATION OPERATION NUMBER DESCRIPTION 117171 Grease shaft bearing, install cap kit 117136 Replace housing RS, LS, GS 117136 Replace housing GSR 117138 Replace housing after greasing and inspecting bearing, install cap kit RS, LS, GS 117138 Replace housing after greasing and inspecting bearing, install cap kit GSR FLAT RATE TIME Failed P/N: 30102-PT2-016 Defect code: 721 Contention code: K08 TEMPLATE ID 0.6 hour 96-015A 0.5 hour 96-015B 0.5 hour 96-015C 0.9 hour 96-015D 0.9 hour 96-015E Example of customer letter June 1996 Product Update Campaign: 1992 93 Integra Ignition System Dear Integra Owner: We are writing to notify you of a potential problem with your Integra. What is the problem? The bearing, a part in your car s ignition system, does not meet Acura s standards for durability. If it should fail, your car s engine may be difficult to start, or may not start at all. What should you do? Call your local Acura dealer and schedule an appointment to have your car updated. This update will be done free of charge. Please plan to leave your car at the dealer for at least half a day to allow him flexibility in scheduling. You should have this update done even though you may have had the assembly repaired or replaced previously. Please make an appointment with the dealer. In addition, you are eligible for reimbursement if you paid for a previous assembly repair or replacement. Reimbursement is subject to the eligibility requirements given on the enclosed Request for Reimbursement form included for your convenience. What to do if our information is incorrect. This letter was mailed to you according to the most current information we have available. If you no longer own this car, or some information in this notice is incorrect, please fill out and return the included, postage-paid Information Change Card. This will help us update our records. If you have questions If you need assistance with locating an Acura dealer, or you have questions about this notice, please call Acura Customer Relations at (800) 382-2238. Thank you for your cooperation. We apologize for any inconvenience this update may cause you. Sincerely, AMERICAN HONDA MOTOR CO., INC Acura Automobile Division 96-015 9 of 9