Introduction Introduction The 1993integra 3

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1993 ACURA U'.7J'EGRA INTRODUCTION INTRODUCTION The 1993Integra 3-door and 4-door sports sedans are sophisticated, technologically advanced, aerodynamically styled and designed around the driver. They have the first-class accommodations and high quality that have become synonymous with Acura, yet continue to project the sporty and youthful image associated with the Integra name. The starting point for the Honda R&D designers who created the secondgeneration Integra was to build on the considerable strengths of the original design, concentrating on every area from styling to performance. CONCEPTS AND GOALS The 1993Integra sports sedans were designed to achieve: . Spirited engine performance, with excellent acceleration, sporty, free-revving response, and top-level smoothness and flexibility. . Crisp, precise handling with good driver feedback and accurate steering. . Sporty, aerodynamic styling witb low wind noise and high efficiency. . A rigid structure for accurate handling, impressive long-term durability, excellent corrosion protection and high occupant safety. . An ergonomic, low-stress driving environment. 1 1993 ACURA INfEGRA INTRODUCTION OVERVIE'" The 1993Integra sports sedans are subtly refined developments of the secondgeneration Integra models originally introduced for the 1990model year. Compared to their first-generation predecessors, they are longer, lower,wider and have more cargo space. With the exception of the GS-R, all Integra models feature a 140-hp,1.8liter, DOHC engine, 4-wheel independent double-wishbone suspension and advanced technology like the available Anti-Lock Braking System (ABS). The GS-R, with its 160-hp, 1.7-liter,VfEC-equipped engine offers even more performance. They are true performance cars for serious drivers. The 1993Integracomesin twobodystyles,3-doorand 4-doorsedan.The 3-door is a sports-oriented hatchback designed to appeal to people who enjoy spirited driving. The 4-door is in the European sports sedan tradition in that it offers performance, clean stylish looks and family style versatility. Both Integra body configurations are fully equipped with a broad range of standard features which include speed-sensitive, variable power-assisted, rack-andpinion steering, 4-wheel disc brakes, tinted glass, and numerous comfort and convenience items. Three distinct trim levels are available, in both the 3-door and 4-door body styles: RS, LS and GS. The GS-R and LS Special are only available in a 3-door configuration. The LS Special features leather-trimmed seats, cast aluminum alloy wheels, Michelin XGT-V4 tires, body-colored side mouldings,a rear spoiler and a special emblem as standard equipment.GS 3- and 4-door models and GS-Rmodels include such standard features as an Anti-Lock Braking System (ABS), alloy wheels, audiophile sound system, a power moonroof and, in the 3-door sedan, a rear spoiler. 2 1993 ACURA INTEGRA POWERTRAIN OVERVIEW The goal of the engineers who designed the engine for the 1993Integra was to provide more power and increased torque, while retaining the strengths and basic design of the 1.8-liter,second-generation Integra powerplant. The engine received a 10-hp increase in the 1992modelyear,raisingit to 140hp. It is an all-aluminum, transverse-mounted,4-cylinder,dualoverheadearn,16-valvedesign. . A standard 5-speed manual transmission, and an optional electronically controlled 4-speed automatic, with driver-selectable Sport Mode are available. The GS-R 5-speed manual transmission features shorter (numerically taller) gear ratios to fully exploit the added horsepower. No automatic is available in the GS-R. The Integra uses equal-length halfshafts to virtually eliminate torque steer. CYLINDER HEAD AND INDUCTION SYSTEM The Integra's cylinder head is a compact, aluminum die casting with pent-roof combustion chambers and centrally located spark plugs. With multiple valves and carefully tuned intake and exhaust ports, the cylinder head is able to "breathe" efficiently. This combustion chamber shape is widely accepted as the best configuration for a 4-valve-per-cylinderinternal combustion engine. Its layout is nearly identical to the design of Honda's championship-winningFormula One engines. To further improve volumetric efficiency and boost low-end power, a new high-efficiencyintake manifold was developed. PROGRAMMED FUEL INJECTION (PGM-FI) Precise control of fuel induction is essential for instant throttle response, smooth acceleration and engine efficiency. To provide such control, the Integra engine's PGM-FI uses a sixteen-bit microprocessor. It directs the system so that the correct amount of fuel is injected into each intake port at the proper moment. 3 1993 ACURA I1'.l'fEGRA POWERTRAIN MANUAL TRANSMISSION The manualtransmission'sgear ratioswererevisedin the 1992modelyearto match the power and torque curves of the engine. Due to increased engine output, it was possible to use slightly taller ratios for first, second, third and fourth gears; the final drive ratio has been shortened slightly.The gear ratios of the GS-R 5-speed manual transmission are numerically higher than those of the rest of the Integra line to fully optimize the performance of the 160-hpengine. AUTOMATIC TRANSMISSION The automatic transmission has a programmed lockup torque converter that's operational in second, third and fourth gear when accelerating, and third and fourth gear when decelerating. There's also a driver-selectable Sport Mode which permits the driver to choose a shift pattern more appropriate to spirited driving. When the driver selects the "S3" Mode, the transmission shifts at higher rpm points, at partial throttle openings, from first to second and second to third gears. To shift to fourth gear in the Sport Mode, the driver presses the "S4" button. Using the Sport Mode increases responsiveness and is useful on long grades or mountain roads to keep the transmission from "hunting" for gear ratios. 4 1993 ACURA ~1]"EGRA GS-R POWERTRAIN OVERVIE'" The GS-R engine is a development of the 1.6-literVTEC engine used in the Japanese-market Integra. Using this engine as a starting point, the engineers increased displacement to 1.7 liters by lengthening the stroke from 77.4 mm to 81.4 mm. The stroke of the GS-R engine is 7.6 mm shorter than that of the standard 1.8-liter Integra engine; this was necessary to achieve the high revving capability required for the VTEC engine. The GS-R engine is a 1678cc, all-aluminum, transverse-mounted, 4-cylinder design with pent-roof combustion chambers and 4 valves per cylinder.Valve actuation is by dual overhead camshafts, driven by a toothed, rubber-composite belt. The GS-R engine produces 160horsepower at 7600 rpm, and 16.1kilogram/meters (117Ibs-ft) of torque at 7000 rpm. Engine redline is 8000rpm; fuel cutoff is set for 8100rpm. The 8000-rpm redline makes the GS-R engine the highest-revving 4-cylinder production powerplant sold in the U.S. Its redline equals that of the manual transmission equipped NSX. ENGINE BLOCK, CRANKSHAFf AND CYLINDER HEAD The cast-aluminum engine block is a deep-skirt design, with the walls of the block extending downward a significant distance below the centerline of the crankshaft. This stiffens the block, helping to reduce vibration and maintain bearing alignment at very high rpm levels. Steel cylinder liners are cast into the aluminum of the block. The crankshaft of the GS-R is a steel forging, and the journals are polished to much closer tolerances than is customary in production engines. This expensive micro-finish polishing process is used in the NSX and in hand-built race engines, such as the Honda Formula One engines. The roughness of the bearing journals is decreased from 0.8 microns to 0.4 microns, compared to the conventional lapping process, and the allowable variation in the roundness of the journals is reduced from 7 microns to 4 microns. The extremely precise finishing of the crankshaft improves durability at extremely high engine speeds, and reduces overall friction significantly. The cylinderhead is a low-pressurealuminum casting.The combustionchambers are of a pent-roof design,with a generous squish area outboard of the valveseats to enhance mixture turbulence and increase combustion efficiency.The compression ratio is 9.7:1.The spark plugs are centrally located for optimum flame propagation. 5 1993 ACURA INTEGRA ENGINE BLOCK, CRANKSHAFf GS-R PO\VERTRAIN AND CYLINDER HEAD (Cont.) Because of the high rpm potential of the engine, special measures were taken to ensure adequate cooling.The pistons are cooled by jets of pressurized oil directed at the underside of the piston crowns,a technique also used in the Honda Formula One V-6turbo and V-lOnormally aspirated engines.The resultinglower piston temperatures allowed the pistons to be made lighter,reducing reciprocatingweight and improving throttle response. VARIABLE VALVE TIMING AND LIFf ELECfRONIC CONTROL (VTEC) Without question, the Variable ValveTiming and Lift Electronic Control (VTEC) system is a breakthrough in engine technology that eliminates the traditional tradeoffs between low-end torque and high-end power. The VTEC system used in the GS-R is essentially identical to that used in the NSX. The heart of the VTEC system is a unique camshaft and rocker arm system. For each cylinder's set of two intake (and exhaust) valves there are three corresponding lobes on the camshaft. The two outboard lobes each have a profile suited for ]ow- to mid-rpm operation. The third, or center, cam lobe has a dramatically different profile designed for longer duration and higher lift-this lobe profile is designed to optimize breathing and horsepower production at high engine speeds. At part throttle, and in low-load situations, this third lobe is inactive. During high-speed operation, the VTEC computer sends a signal to a spool valve, which in turn delivers engine oil to small pistons in the rocker arms. Oil pressure causes the pistons to slide between the rocker arms, locking all three rocker arms together. Once locked together, the rocker arms are forced to follow the center cam lobe, with its higher lift and increased duration. The crossover from low lift to high lift occurs in 0.1 second and is virtually undetectable to the driver. To promote swirlin the combustion chamber and improve combustionefficiency, the two individualintake (and exhaust) valvesfor"each cylinder operate with different timing and lift specificationsduring low-speedoperation. Once the VfEC system engages, the intake (and exhaust) valvepairs for each cylinder operate together. 6 ~------ 1993 ACURA INTEGRA GS.R PO\VERTRAIN VARIABLE VALVE TIMING AND LIFf ELECTRONIC CONTROL (VTEC) (Cont.) VTEC uses a dedicated CPU which monitors a number of engine operating parameters and activates the system only when certain conditions are met. It's designedto engageat approximately5500rpm,and willnot engageunder a "no load" situation, such as when the transmission is in neutral or when the clutch is disengaged. To further improve intake efficiency,the GS.R intake valves are 33 mm in diameter, 2 mm larger than those of the 1.8-literIntegra engine. The exhaust valves are 28 mm in diameter, the same diameter as those of the 1.8-literengine. INDUCTION SYSTEM The GS-R engine uses a "high response" intake manifold for improved engine breathing at high engine speeds. The diameter and length of the aluminum manifold runners are tuned for maximum inertia effect, and to optimize resonance effects which help to increase the volume of air moving into each cylinder.To smooth airflow as much as possible at high rpm, the intake tract is nearly straight from the intake plenum chamber all the way to the intake port. PROGRAMMED FUEL INJECTION (PGM.FI) Precise control of fuel induction is essential for instant throttle response, smooth acceleration and engine efficiency.To provide such control, the Integra engine's Programmed Fuel Injection (PGM-FI) system uses a 16-bit microprocessor, which ensures that the correct amount of fuel is injected into each intake port at the proper moment. 7 1993 ACURA ThlEGRA GS-R POWERTRAIN COOLING To meet the increased cooling requirements of the more powerful GS-R engine, a new radiator was used, similar in design to the radiator of the NSX. The core of the radiator is aluminum, for reduced weight and improved heat dissipation. The radiator top and bottom sections are molded of high-temperature resin, for reduced weight. The GS-R engine also uses a specialliquid-cooled oil cooler in which engine oil is routed through a heat exchanger that uses coolant from the radiator to extract heat. TRANSMISSION The GS-R is equipped with a special5-speed manual transmission. All forward ratios, and the final drive ratio, are shorter (numerically higher) than in the standard Integra transmission, complementing the higher power peak and redline of the GS-R. Dualcone synchronizers are used for second gear, and even reverse gear is synchronized. The synchronizers for second, third, fourth and fifth gears are larger in diameter than in the standard Integra 5-speed,to accommodate the greater power output of the GS-R engIne. The GS-R is fitted with a special lightweight flywheelwith 14% less rotational inertia, for quicker revving and enhanced throttle response. ~-~; 1993ACURA INTEGRA -- STRUCTURE OVERVIEW The main design consideration of the Integra body is to provide a high degree of structural integrity.This achieves the followingobjectives:it provides a stable platform for suspension and driveline components, and it helps reduce vibration and noise. The unit body is also designed to help ensure occupant safety,with specificimpactabsorption zones, front and rear, and a high overall level of passenger cabin integrity. The Integra body design is aerodynamically efficient with a sloping hood, nearly flush outside surfaces, sashless doors, a low belt line and a large greenhouse. The styling emphasizes its wedge shape, yet softens it with smooth, rounded contours. With sharply raked front and rear glass, the Integra has a look that's aggressive and sporty, yet elegant and contemporary. AERODYNAMICS The Integra shape is aerodynamically efficient, with a drag coefficient of only 0.32 for the 3-door and 0.34 for the 4-door. This means better fuel efficiency and a quieter ride as well as a more pleasing appearance. Extensive wind tunnel testing was used to refine the Integra's design. The body surface is smooth, with nearly flush metal-to-glass areas. Efficient engine and suspension packaging permits a very low hoodline that slopes sharply up to the cowl. The raked-back windshield blends the roof and large compound-curved rear glass. Integra 3-door GS models are equipped with a rear spoiler. STRUCTURAL DESIGN For passenger security and to provide a stable handling platform, the Integra body is a rigid unit structure designed to resist bending and torsional forces. ComputerAided Design (CAD) and NASTRAN, a stress analysis program written by NASA, were used throughout the development process to arrive at the final configuration of the Integra body architecture. To help assure the integrity of the passenger compartment, it is surrounded by box-section members. The A-pillars are braced at the cowl and have an extra V-shaped reinforcing member that runs through the center of their box section.The B-pillars are reinforced at their base, where they tie into the lower side members, which have a central support similar to that of the A-pillars. The rear pillars are anchored to the structure around the rear wheel housings with reinforcing members. Further bracing is provided by a bulkhead behind the rear seats in the 4-door models. 11 1993 ACURA INTEGRA STRUCTURAL DESIGN STRUCTURE (cont.) The pillars and side sills are tied together by the floorpan, front and rear crossmembers, and a box-section around the perimeter of the roof to form a cage around the passenger compartment. The resulting structure is much stronger in terms of bending rigidity and torsional rigidity than a conventional design. ANTI.CORROSION AND FINISH Resistance to corrosion is an inherent part of the Integra design. The metal panels that make up the Integra structure are carefully shaped to avoid indentations and depressions where moisture and road grime can accumulate and cause rust. Also, special materials and treatments are used throughout the Integra body to repel rust and resist corrosion. A zinc-phosphate coating is applied to the entire body. Doublesided zinc-dipped steel is used for the hood, front fenders, front wheel wells, engine compartment, floor pan and along the sills,and single-sidedzinc-galvanized steel is used on many exterior panels. For additional protection, the leading edges of the hood and front fenders are treated with a special primer that resists chipping. Antirust wax is sprayed inside box-sections and out-of-the-way places.The Integra surface finish begins with a thorough cleaning and then goes through a special three-coat, three-bake painting process. 12 1993ACURA I1'.7EGRA INTERIOR OVERVIEW The goal of the Integra's interior design is to assure the comfort and efficiencyof the driver. The instruments and controls are positioned so tbey fall into the driver's natural field of vision and reach; the seats conform to the body's shape and provide fatigue-reducing support; and the color, touch and texture of interior surfaces are designedto create a relaxing atmosphere. INSTRUMENTSAND CONTROLS The interior of the Integra follows a "soft touch" theme, with yielding surfaces and smoothly contoured corners throughout the passenger compartment. The analog instruments are grouped directly in the driver's field of vision, with a large speedometer and tachometer in the center. Switches and controls are designed to give tactile feedback so the driver can tell just by feel that a particular control has been activated. AUDIO SYSTEM A full-feature AMIFM stereo/cassette system is standard on LS and GS models, and optional on RS models. This unit has digital display and electronic tuning with a seek function. GS models include an automatic preset function that selects the 8 strongest AM and FM signals in an unfamiliar area. The cassette section has metal tape capability, Dolby@noise reduction, Permalloy@tape heads and full logiccontrols. Four 6.S-inch,dual-cone speakers are used for clear, clean sound. GS models have an 80-watt amplifier, while LS models have a 50-watt amplifier. A compact disc player is also available. PASSIVE RESTRAINT SEAT BELTS Front seat occupants are provided a motorized two-point passive shoulder belt, active lap belt and knee bolsters. The rear seat is equipped with 3-point seat belts in the outbQard positions. The fold-down rear seatbacks are split 60/40for more cargo carrying versatility. With both seatbacks folded down, luggage space is greatly increased; with one or the other down, both luggage and a passenger can be accommodated. LEATIlER-TRIMMED INTERIOR GranadaBlackPearl GS as wellasFrostWhitePearl and Isle Green Pearl LS Special modelsare availablewitha leather-trimmedinterior. 13