Campaign - 1992-93 INTEGRA Distributor (96-015)

CAMPAIGN - 1992-93 INTEGRA DISTRIBUTOR

TECHNICAL SERVICE BULLETIN

PRODUCT UPDATE CAMPAIGN: 1992-93 INTEGRA DISTRIBUTOR

Model(s): 1992-93 Acura Integra

Group: Electrical

Bulletin No.: 96-015

Date: September 10, 1996

VEHICLES AFFECTED

1992 Integra: All

1993 Integra: 2-door RS, LS, GS - thru VIN JH4DA9...PS021690

1993 Integra: 4-door RS, LS, GS - thru VIN JH4DB1...PS003558

1993 Integra: 2-door GSR - thru VIN JH4DB2...PS000804

See Procedure Guide at Fig 1 .

BACKGROUND

The distributor 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.

GENERAL INFORMATION

This product update campaign is being conducted in two regions: Region A and Region B. See Fig 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 FOR REGION A  or CORRECTIVE ACTION FOR REGION B  repairs.

Owners who live outside Regions A and B are not included in this campaign. They will be notified that the warranty on the distributor 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.

PRODUCT UPDATE INFORMATION FOR REGION A

The shaded area in the map is Region A. See Fig 2 . This region includes the following zip codes:

States	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

CUSTOMER NOTIFICATION FOR REGION A

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 A

See Fig 3 .

Vehicle has more than 30,000 miles: Replace the distributor housing assembly, see PARTS INFORMATION  .

Vehicle has less than 30,000 miles: Pack grease in the distributor shaft bearing, check the bearing, and replace distributor components with the components from the distributor cap kit listed under PARTS INFORMATION  .

REPAIR PROCEDURE FOR REGION A

1. Make sure the ignition is off.
2. Remove the two connectors from the bracket behind the distributor.
3. Unplug the distributor 2-P and 8-P connectors.
4. Disconnect the spark plug wires from the distributor cap.
5. Place a shop towel under the distributor to catch any oil that drips. Remove the three distributor hold-down bolts. Remove the distributor from the car. See Fig 4 .
6. Remove the distributor cap. If the vehicle has more Repair Procedure than 30,000 miles, keep the distributor cap for later installation.
7. Remove the retaining screw, then remove the rotor. Remove the leak cover. Remove the distributor-to-cylinder head O-ring. DO NOT discard the leak cover and rotor. They will be needed for reassembly. See Fig 5 .
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. See Fig 6 .
9. Remove the ignition coil and igniter mounting screws. Remove the coil and igniter from the distributor. See Fig 7 .
   1. If the vehicle has less than 30,000 miles, continue to step 10 to pack grease in the bearing.
   2. If the vehicle has more than 30,000 miles, go to step 18 to replace the distributor housing.
10. Use a two-jaw puller to remove the cylinder sensor rotor from the distributor 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 distributor housing. See Fig 8 .
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 distributor 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. See Fig 9 .
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 distributor housing near your ear and listen as you rotate the shaft.
    1. If you can hear the bearing making a scraping noise, replace the distributor housing (see PARTS INFORMATION  ) and go to step 18.
    2. 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 distributor.)
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. See Fig 10 .
18. Install the original ignition coil and igniter in the distributor housing with the original screws.
19. Reconnect the wires to the igniter and ignition coil terminals. See Fig 11 .
20. Install the original leak cover.
    1. If the vehicle has less than 30,000 miles, install the rotor, distributor cap, cap seal, and O-ring from the distributor cap kit.
    2. If the vehicle has more than 30,000 miles, install the original rotor, distributor cap, and cap seal.
21. Apply a small amount of clean engine oil to the O-ring that goes between the distributor and the head. Install the distributor 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. See Fig 12 .
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. See Fig 13 .

PRODUCT UPDATE INFORMATION FOR REGION B

The lined area in the map is Region B. See Fig 14 . This region includes the following zip codes.

States	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 and 78

CUSTOMER NOTIFICATION FOR REGION B

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 distributor shaft bearing, check the bearing, and replace distributor components with the components from the distributor cap kit listed under PARTS INFORMATION  . Replace the distributor 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 distributor.
3. Unplug the distributor 2-P and 8-P connectors.
4. Disconnect the spark plug wires from the distributor cap.
5. Place a shop towel under the distributor to catch any oil that drips. Remove the three distributor hold-down bolts. Remove the distributor from the car.
6. Remove and discard the distributor cap.
7. Remove the retaining screw, then remove the rotor. Remove the leak cover. Remove the distributor-to-cylinder head O-ring. DO NOT discard the leak cover. It will be needed for reassembly.
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.
9. Remove the ignition coil and igniter mounting screws. Remove the coil and igniter from the distributor.
10. Use a two-jaw puller to remove the cylinder sensor rotor from the distributor 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 distributor housing.
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 distributor 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.
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 distributor housing near your ear and listen as you rotate the shaft.
    1. If you can hear the bearing making a scraping noise, replace the distributor housing (see PARTS INFORMATION  ) and go to step 18.
    2. 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 distributor.)
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.
18. Install the original ignition coil and igniter in the distributor housing with the original screws.
19. Reconnect the wires to the igniter and ignition coil terminals.
20. Install the original leak cover. Install the rotor, distributor cap, cap seal, and O-ring from the distributor cap kit.
21. Apply a small amount of clean engine oil to the O-ring that goes between the distributor and the head. Install the distributor 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.
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.

PARTS INFORMATION

Description	Part Number
Distributor Cap Kit	06303-P30-A01

Description	Part Number
RS, LS, GS	06301-PR4-A01
GSR	06301-P30-A01

WARRANTY CLAIM INFORMATION

Operation Number	Description	Flat Rate Time	Template ID
117171	Grease distributor shaft bearing install cap	0.6 hr.	96-015A
117136	Replace distributor housing, RS, LS, GS	0.5 hr.	96-015B
117136	Replace distributor housing - GSR	0.5 hr.	96-015C
117138	Replace distributor housing after greasing and inspecting bearing, install cap kit - RS, LS, GS	0.9 hr.	96-015D
117138	Replace distributor housing after greasing and inspecting bearing, install cap kit - GSR	0.9 hr.	96-015E
NOTE: Failed P/N: 30102-PT2-016 Defect code: 721 Contention code: K08

CUSTOMER LETTER

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Dear Integra Owner:

We are writing to notify you of a potential problem with your Integra.

What is the problem?

The distributor 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 distributor 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 distributor 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

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