Engine Electrical System
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Ignition coil | Rated voltage | 12V | ||
| Firing order | 1-3-4-2 | |||
| Spark plug | Type | NGK: IZFR6K-11 DENSO: SKJ20DR-M11 | ||
| Gap | 1.0 - 1.1 mm (0.039-0.043 in.) | 1.3 mm (0.051 in.) | ||
| Ignition timing | At idle (check the red mark) | M/T (in neutral): 8± 2° BTDC at idle | ||
| A/T (in N or P position): 8± 2° BTDC at idle | ||||
| Alternator | Output | At 13.5 V and normal engine temperature | 90A | |
| Coil (rotor) resistance | At 68°F(20°C) | 1.84-2.10 ohms | ||
| Slip ring O.D. | 22.7 mm (0.89 in.) | 21.7 mm (0.85 in.) | ||
| Brush length | 19.0 mm (0.75 in.) | 5.0 mm (0.20 in.) | ||
| Brush spring tension | 3.3-4.1 N (0.34-0.42 kgf, 0.7-0.9 lbf) | |||
| Starter | Output | 1.6 kW | ||
| Commutator mica depth | 0.4-0.5 mm (0.016-0.020 in.) | 0.15 mm (0.006 in.) | ||
| Commutator runout | 0.02 mm (0.001 in.) max. | 0.05 mm (0.002 in.) | ||
| Commutator O.D. | 28.0-28.1 mm (1.102-1.106 in.) | 27.5 mm (1.083 in.) | ||
| Brush length | 11.1-11.5 mm (0.44-0.45 in.) | 4.3 mm (0.17 in.) | ||
Engine Electrical Specification Table
Cylinder Head
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Head | Warpage | 0.05 mm (0.002 in.) | ||
| Height | 103.95-104.05 mm (4.093-4.096 in.) | |||
| Camshaft | End play | 0.05-0.20 mm (0.002-0.008 in.) | 0.4 mm (0.02 in.) | |
| Camshaft-to-holder oil clearance | No. 1 journal | 0.030-0.069 mm (0.001-0.003 in.) | 0.15 mm (0.006 in.) | |
| No. 2, 3, 4, 5 journals | 0.060-0.099 mm (0.002-0.004 in.) | 0.15 mm (0.006 in.) | ||
| Total runout | 0.03 mm (0.001 in.) max. | 0.04 mm (0.002 in.) | ||
| Cam lobe height | Intake, primary | 33.925 mm (1.3356 in.) | ||
| Intake, secondary | 29.638 mm (1.1668 in.) | |||
| Exhaust | 34.092 mm (1.3422 in.) | |||
| Valve | Clearance (cold) | Intake | 0.21-0.25 mm (0.008-0.010 in.) | |
| Exhaust | 0.28-0.32 mm (0.011-0.013 in.) | |||
| Stem O.D. | Intake | 5.475-5.485 mm (0.2156-0.2159 in.) | 5.445 mm (0.214 in.) | |
| Exhaust | 5.450-5.460 mm (0.2146-0.2150 in.) | 5.42 mm (0.213 in.) | ||
| Stem-to-guide clearance | Intake | 0.0300.055 mm (0.0012 0.0022 in.) | 0.08 mm (0.003 in.) | |
| Exhaust | 0.055-0.080 mm (0.0022-0.0031 in.) | 0.11 mm (0.004 in.) | ||
| Valve seat | Width | Intake | 1.25-1.55 mm (0.049-0.061 in.) | 2.00 mm (0.079 in.) |
| Exhaust | 1.25-1.55 mm (0.049-0.061 in.) | 2.00 mm (0.079 in.) | ||
| Stem installed height | Intake | 44.0-44.6 mm (1.73-1.76 in.) | ||
| Exhaust | 44.0-44.6 mm (1.73-1.76 in.) | |||
| Valve spring | Free length | Intake | 47.61 mm (1.874 in.) | |
| Exhaust | 49.64 mm (1.954 in.) NIPPON HATSUJO 49.63 mm (1.954 in.) CHUO HATSUJO | |||
| Valve guide | I.D. | Intake | 5.515-5.530 mm (0.2171-0.2177 in.) | 5.55 mm (0.219 in.) |
| Exhaust | 5.515-5.530 mm (0.2171-0.2177 in.) | 5.55 mm (0.219 in.) | ||
| Installed height | Intake | 15.2-16.2 mm (0.598-0.638 in.) | ||
| Exhaust | 15.5-16.5 mm (0.610-0.650 in.) | |||
| Rocker arm | Arm-to-shaft clearance | Intake | 0.025-0.052 mm (0.0010-0.0020 in.) | 0.08 mm (0.003 in.) |
| Exhaust | 0.018-0.056 mm (0.0007-0.0022 in.) | 0.08 mm (0.003 in.) |
Cylinder Head Specification Table
Engine Block
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Block | Warpage of deck | 0.07 mm (0.003 in.) max. | 0.10 mm (0.004 in.) | |
| Bore diameter | A or I | 87.010-87.020 mm (3.4256-3.4260 in.) | 87.070 mm (3.4279 in.) | |
| B or II | 87.000-87.010 mm (3.4252-3.4256 in.) | 87.070 mm (3.4279 in.) | ||
| Bore taper | 0.05 mm (0.002 in.) | |||
| Reboring limit | 0.25 mm (0.01 in.) | |||
| Piston | Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt | No letter or A | 86.980-86.990 mm (3.4244-3.4248 in.) | 86.930 mm (3.4224 in.) |
| Letter B | 86.970-86.980 mm (3.4240-3.4244 in.) | 86.920 mm (3.4220 in.) | ||
| Clearance in cylinder | 0.020-0.040 mm (0.0008-0.0016 in.) | 0.05 mm (0.002 in.) | ||
| Ring groove width | Top | 1.230-1.240 mm (0.0484-0.0488 in.) | 1.26 mm (0.0450 in.) | |
| Second | 1.240-1.250 mm (0.0488-0.0492 in.) | 1.270 mm (0.050 in.) | ||
| Oil | 2.005-2.025 mm (0.0789-0.0797 in.) | 2.05 mm (0.081 in.) | ||
| Piston ring | Ring-to-groove clearance | Top | 0.045-0.070 mm (0.0018-0.0028 in.) | 0.13 mm (0.005 in.) |
| Second | 0.050-0.075 mm (0.0020-0.0030 in.) | 0.13 mm (0.005 in.) | ||
| Ring end gap | Top | 0.20-0.35 mm (0.008-0.014 in.) | 0.60 mm (0.024 in.) | |
| Second | 0.40-0.55 mm (0.016-0.022 in.) | 0.70 mm (0.028 in.) | ||
| Oil | 0.20-0.70 mm (0.008-0.028 in.) | 0.80 mm (0.031 in.) | ||
| Piston pin | O.D. | 21.961 21.965 mm (0.8646-0.8648 in.) | 21.953 mm (0.8643 in.) | |
| Pin-to-piston clearance | 0.005- ± 0.002 mm (-0.00020- ± 0.00008 in.) | 0.005 mm (0.0002 in.) | ||
| Connecting rod | Pin-to-rod clearance | 0.005-0.015 mm (0.0002-0.0006 in.) | 0.02 mm (0.0008 in.) | |
| Small-end bore diameter | 21.970-21.976 mm (0.8650-0.8652 in.) | |||
| Large-end bore diameter (Normal) | 51.0 mm (2.01 in.) | |||
| End play installed on crankshaft | 0.15-0.30 mm (0.006-0.012 in.) | 0.40 mm (0.016 in.) | ||
| Crankshaft | Main journal diameter | No. 1 journal No. 2 journal No. 4 journal No. 5 journal | 54.984-55.008 mm (2.1648-2.1657 in.) | |
| No. 3 journal | 54.976-55.000 mm (2.1644-2.1654 in.) | |||
| Rod journal diameter | 47.976-48.000 mm (1.8888-1.8898 in.) | |||
| Rod/main journal taper | 0.005 mm (0.0002 in.) max. | 0.010 mm (0.0004 in.) | ||
| Rod/main journal out-of-round | 0.005 mm (0.0002 in.) max. | 0.010 mm (0.0004 in.) | ||
| End play | 0.10-0.35 mm (0.004-0.014 in.) | 0.45 mm (0.018 in.) | ||
| Runout | 0.03 mm (0.0012 in.) max. | 0.04 mm (0.0016 in.) | ||
| Crankshaft bearing | Main bearing-to-journal oil clearance | No. 1 journal No. 2 journal No. 4 journal No. 5 journal | 0.017-0.041 mm (0.0007-0.0016 in.) | 0.050 mm (0.0020 in.) |
| No. 3 journal | 0.025-0.049 mm (0.0010-0.0019 in.) | 0.055 mm (0.0022 in.) | ||
| Rod bearing clearance | 0.020-0.050 mm (0.0008-0.0020 in.) | 0.060 mm (0.0024 in.) |
Engine Block Specification Table
Engine Cooling System
| Item | Measurement | Qualification | |
|---|---|---|---|
| Radiator | Coolant capacity (includes engine, heater, hoses, and reservoir) | M/T at engine overhaul | 7.2 l (7.6 US qt) |
| M/T at coolant change | 5.5 l (5.8 US qt) | ||
| A/T at engine overhaul | 7.1 l (7.5 US qt) | ||
| A/T at coolant change | 5.4 l (5.7 US qt) | ||
| Reservoir | Coolant capacity | 0.55 l (0.58 US qt) | |
| Radiator cap | Opening pressure | 93-123 kPa (0.95-1.25 kgf/cm 2 , 14-18 psi) | |
| Thermostat | Opening temperature | Begins to open | 169 -176°F (76-80°C) |
| Fully open | 194°F(90°C) | ||
| Valve lift at fully open | 8.0 mm (0.31 in.) min. | ||
| Radiator fan switch | Switching temperature | Turns ON | 196-203°F(91-95°C) |
| Turns OFF | Subtract 5-15°F (3-8°C) from actual ON temperature | ||
Cooling Specification Table
Fuel System and Emission System
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Fuel pressure regulator | Pressure with fuel pressure gauge connected | 320-370 kPa (3.3-3.8 kgf/cm 2 , 47-54 psi) | |
| Fuel tank | Capacity | 58 l (15 US gal) | |
| Engine idle | Idle speed without load | M/Tin neutral | 650 ±50 rpm |
| A/T in N or P position | 650±50 rpm | ||
| Idle speed with high electric load (with HVAC on) | M/T in neutral | 700±50 rpm | |
| A/T in N or P position | 700 ±50 rpm |
Fuel & Emissions Specification Table
Clutch System
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Clutch pedal | Height from floor | 200 mm (7.87 in.) | ||
| Stroke | 125-135 mm (4.92-5.31 in.) | |||
| Play | 6-17 mm (0.24-0.67 in.) | |||
| Disengagement height from floor | 112 mm (4.41 in.) min. | |||
| Flywheel | Runout on clutch mating surface | 0.05 mm (0.002 in.) max. | 0.15 mm (0.006 in.) | |
| Clutch disc | Rivet head depth | 1.65-2.25 mm (0.065-0.089 in.) | 0.7 mm (0.03 in.) | |
| Thickness | 8.7-9.3 mm (0.34-0.37 in.) | 6.0 mm (0.24 in.) | ||
| Pressure plate | Warpage | 0.03 mm (0.001 in.) max. | 0.15 mm (0.006 in.) | |
| Height of diaphragm spring fingers measured with special tool and feeler gauge | 0.6 mm (0.02 in.) max. | 0.8 mm (0.03 in.) |
Clutch Specification Table
Manual Transmission and M/T Differential
Manual Transmission & M/T Differential Specifications Table Item Measurement Qualification Standard or New Service Limit Transmission fluid Capacity Fluid change 1.9 l (2.0 US qt) Use Honda MTF Overhaul 2.3 l (2.4 US qt) Mainshaft End play 0.11-0.17 mm (0.004-0.007 in.) Adjust Diameter of bushing surface 20.80-20.85 mm (0.8189-0.8209 in.) 20.75 mm (0.817 in.) Diameter of distance collar 31.984-32.000 mm (1.2594-1.2598 in. 31.93 mm (1.257 in.) Diameter of ball bearing contact area (clutch housing side) 27.977-27.990 mm (1.1015-1.1020 in.) 27.94 mm (1.100 in.) Diameter of needle bearing contact area 38.984-39.000 mm (1.5348-1.5354 in.) 38.93 mm (1.533 in.) Diameter of ball bearing contact area (transmission housing side) 27.987-28.000 mm (1.1019-1.1024 in.) 27.94 mm (1.100 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) Mainshaft 3rd, 4th and 5th gear I.D. 44.009-44.025 mm (1.7326-1.7333 in.) 44.08 mm (1.735 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 23.92-23.97 mm (0.941 -0.944 in.) 23.80 mm (0.937 in.) Countershaft Diameter of needle bearing contact area (clutch housing side) 35.000-35.015 mm (1.3780-1.3785 in.) 34.95 mm (1.376 in.) Diameter of distance collar contact area 39.937-39.950 mm (1.5723-1.5728 in.) 39.88 mm (1.570 in.) Diameter of ball bearing contact area (transmission housing side) 30.020-30.033 mm (1.1819-1.1824 in.) 29.97 mm (1.180 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 35 mm shim-to-bearing inner race clearance 0.04-0.10 mm (0.0016-0.0039 in.) Adjust Countershaft 1st gear I.D. 52.010-52.029 mm (2.0476-2.0484 in.) 52.08 mm (2.050 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 22.92-22.97 mm (0.902-0.904 in.) 22.87 mm (0.900 in.) Countershaft 2nd gear I.D. 52.010-52.029 mm (2.0476-2.0484 in.) 52.08 mm (2.050 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 27.92-27.97 mm (1.099-1.101 in.) 27.87 mm (1.097 in.) Countershaft 1st gear distance collar I.D. 39.95-39.96 mm (1.5728-1.5732 in.) 39.97 mm (1.574 in.) O.D. 46.989-47.000 mm (1.8499-1.8504 in.) 46.94 mm (1.848 in.) Length 23.03-23.08 mm (0.907-0.909 in.) - Countershaft 2nd gear distance collar I.D. 39.95-39.96 mm (1.5728-1.5732 in.) 39.97 mm (1.574 in.) O.D. 46.989-47.000 mm (1.8499-1.8504 in.) 46.94 mm (1.848 in.) Length 28.03-28.08 mm (1.104-1.106 in.) - Mainshaft 4th and 5th gear distance collar I.D. 32.00-32.01 mm (1.2598-1.2602 in.) 32.02 mm (1.261 in.) O.D. 38.989-39.000 mm (1.5350-1.5354 in.) 38.94 mm (1.533 in.) Length A 51.95-52.05 mm (2.045-2.049 in.) - B 24.03-24.08 mm (0.946-0.947 in.) - MBS distance collar I.D. 28.00-28.01 mm (1.102-1.103 in.) 28.02 mm (1.103 in.) Length 23.95-24.05 mm (0.943-0.947 in.) - Reverse idler gear I.D. 20.016-20.043 mm (0.7880-0.7891 in.) 20.90 mm (0.832 in.) Gear-to-reverse gear shaft clearance 0.036-0.084 mm (0.0014-0.0033 in.) 0.16 mm (0.006 in.) Synchro ring Ring-to-gear clearance Ring pushed against gear 0.70-1.49 mm (0.028 0.059 in.) 0.4 mm (0.016 in.) Double cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) Triple cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) Outer synchro ring-to-gear cone clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) Shift fork Finger thickness 7.4-7.6 mm (0.29-0.30 in.) - Fork-to-synchro sleeve clearance 0.35-0.65 mm (0.014-0.026 in.) 1.0 mm (0.039 in.) Reverse shift fork Finger thickness 13.4-13.7 mm (0.527-0.539 in.) - Fork-to-reverse idler gear clearance 0.20-0.59 mm (0.007-0.024 in.) 1.2 mm (0.047 in.) Shift arm I.D. 13.973-14.000 mm (0.5501-0.5512 in.) - Shift fork diameter at contact area 16.9-17.0 mm (0.665-0.669 in.) - Shift arm-to-shift lever clearance 0.2-0.5 mm (0.008-0.020 in.) 0.6 mm (0.023 in.) Select lever Finger width 14.85-14.95 mm (0.585-0.589 in.) - Change lever Shaft-to-select lever clearance 0.05-0.25 mm (0.002-0.010 in.) 0.5 mm (0.020 in.) Groove (to select lever) 15.00-15.10 mm (0.591-0.594 in.) - Shaft-to-shift arm clearance 0.013-0.07 mm (0.0005-0.003 in.) 0.1 mm (0.004 in.) M/T differential carrier Pinion shaft contact area I.D. 18.010-18.028 mm (0.7091-0.7098 in.) - Carrier-to-pinion shaft clearance 0.027-0.057 mm (0.0011-0.0022 in.) 0.1 mm (0.004 in.) Driveshaft contact area I.D. 28.025-28.045 mm (1.1033-1.1041 in.) - M/T differential pinion gear Backlash 0.05-0.15 mm (0.002 0.006 in.) - I.D. 18.042-18.066 mm (0.7103-0.7113 in.) - Pinion gear-to-pinion shaft clearance 0.059-0.095 mm (0.0023-0.0037 in.) 0.15 mm (0.006 in.) 80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing 0-0.1 mm (0-0.0039 in.) Adjust Transfer Diameter of tapered roller bearing contact area (transfer shaft) 24.975-24.990 mm (0.9833-0.9838 in.) 24.92 mm (0.9811 in.) Diameter of tapered roller bearing contact area (transfer drive gear) 40.002-40.018 mm (1.5749-1.5755 in.) 38.95 mm (1.5335 in.) Diameter of tapered roller bearing contact area (driven gear side) 35.002-35.018 mm (1.3780-1.3786 in.) 34.95 mm (1.3760 in.) Diameter of tapered roller bearing contact area (splined side) 26.975-26.988 mm (1.0620-1.0625 in.) 26.92 mm (1.0598 in.) Transfer gear backlash 0.06-0.16 mm (0.0024-0.0063 in.) Adjust Total starting torque 2.24-3.71 N.m (22.0 36.4 kgf.cm, 19.1-31.6 lbf.in.) Adjust
Scheme 2
Automatic Transmission and A/T Differential
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| ATF (Automatic Transmission Fluid) | Capacity Use Honda ATF-Z1 | 4WD at fluid change | 3.1 l (3.3 US qt) | |
| 4WD at overhaul | 7.2 l (7.6 US qt) | |||
| 2WD at fluid change | 2.9 l (3.1 US qt) | |||
| 2WD at overhaul | 6.5 l (6.9 US qt) | |||
| ATF pressure | Line pressure | At 2,000 rpm in N or P position | 900-960 kPa (9.2-9.8 kgf/cm 2 , 130-140 psi) | 850 kPa (8.7 kgf/cm 2 , 120 psi) |
| 1st clutch pressure | At 2,000 rpm in 1st gear in 1 position | 890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi) | 840 kPa (8.6 kgf/cm 2 , 120 psi) | |
| 2nd clutch pressure | At 2,000 rpm in 2nd gear in 2 position | 890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi) | 840 kPa (8.6 kgf/cm 2 , 120 psi) | |
| 3rd clutch pressure | At 2,000 rpm in 3rd gear in D position | 890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi) | 840 kPa (8.6 kgf/cm 2 , 120 psi) | |
| 4th clutch pressure | At 2,000 rpm in 4th gear in D position | 890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi) | 840 kPa (8.6 kgf/cm 2 , 120 psi) | |
| Torque converter | Stall speed Check with vehicle on level ground | 2,100 rpm | 1,950-2,250 rpm | |
| Clutch | Clutch end-plate-to-top-disc clearance | 1st | 1.28-1.48 mm (0.050-0.058 in.) | |
| 2nd | 0.85-1.05 mm (0.033-0.041 in.) | |||
| 3rd and 4th | 0.73-0.93 mm (0.029-0.037 in.) | |||
| Clutch return spring free length | 1st, 2nd, and 3rd | 50.8 mm (2.00 in.) | 48.8 mm (1.92 in.) | |
| 4th | 33.5 mm (1.32 in.) | 31.5 mm (1.24 in.) | ||
| Clutch disc thickness | 1.94 mm (0.076 in.) | |||
| Clutch plate thickness | 1st | 1.6 mm (0.063 in.) | When discolored | |
| 2nd, 3rd, and 4th | 2.00 mm (0.079 in.) | When discolored | ||
| Clutch waved-plate phase difference | 0.07-0.20 mm (0.003-0.008 in.) | 0.05 mm (0.002 in.) | ||
| 1st and 2nd clutch end plate thickness | Mark 1 | 2.6 mm (0.102 in.) | When discolored | |
| Mark 2 | 2.7 mm (0.106 in.) | When discolored | ||
| Mark 3 | 2.8 mm (0.110 in.) | When discolored | ||
| Mark 4 | 2.9 mm (0.114 in.) | When discolored | ||
| Mark 5 | 3.0 mm (0.118 in.) | When discolored | ||
| Mark 6 | 3.1 mm (0.122 in.) | When discolored | ||
| Mark 7 | 3.2 mm (0.126 in.) | When discolored | ||
| Mark 8 | 3.3 mm (0.130 in.) | When discolored | ||
| Mark 9 | 3.4 mm (0.134 in.) | When discolored | ||
| 3rd and 4th clutch end plate thickness | Mark 1 | 2.1 mm (0.122 in.) | When discolored | |
| Mark 2 | 2.2 mm (0.126 in.) | When discolored | ||
| Mark 3 | 2.3 mm (0.091 in.) | When discolored | ||
| Mark 4 | 2.4 mm (0.094 in.) | When discolored | ||
| Mark 5 | 2.5 mm (0.098 in.) | When discolored | ||
| Mark 6 | 2.6 mm (0.102 in.) | When discolored | ||
| Mark 7 | 2.7 mm (0.106 in.) | When discolored | ||
| Mark 8 | 2.8 mm (0.110 in.) | When discolored | ||
| Mark 9 | 2.9 mm (0.114 in.) | When discolored | ||
| Mainshaft | Diameter of needle bearing contact area | At stator shaft | 22.984-23.000 mm (0.905-0.906 in.) | When worn or damaged |
| At 3rd gear | 51.975-51.991 mm (2.046-2.047 in.) | When worn or damaged | ||
| At 4th gear collar | 33.975-33.991 mm (1.3376-1.3382 in.) | When worn or damaged | ||
| I.D. of gears | 3rd gear | 57.000-57.019 mm (2.2441-2.2448 in.) | When worn or damaged | |
| 4th gear | 40.000-40.016 mm (1.5748-1.5754 in.) | When worn or damaged | ||
| End play of gears | 3rd gear | 0.03-0.31 mm (0.001-0.012 in.) | ||
| 4th gear | 0.1-0.212 mm (0.004-0.008 in.) | |||
| 41 x 68 mm thrust washer thickness | No. 1 | 6.35 mm (0.250 in.) | When worn or damaged | |
| No. 2 | 6.40 mm (0.252 in.) | When worn or damaged | ||
| No. 3 | 6.45 mm (0.254 in.) | When worn or damaged | ||
| No. 4 | 6.50 mm (0.256 in.) | When worn or damaged | ||
| No. 5 | 6.55 mm (0.258 in.) | When worn or damaged | ||
| No. 6 | 6.60 mm (0.260 in.) | When worn or damaged | ||
| 4th gear collar length | 66.3-66.4 mm (2.610-2.614 in.) | |||
| Length of 4th gear collar flange from end | 19.15-19.30 mm (0.754-0.760 in.) | When worn or damaged | ||
| Sealing ring thickness | 1.91-1.97 mm (0.0752-0.0776 in.) | 1.86 mm (0.0732 in.) | ||
| Width of sealing ring groove | 2.025-2.060 mm (0.0797-0.0811 in.) | 2.080 mm (0.0819 in.) | ||
| Clutch feed pipe O.D. | 7.97-7.98 mm (0.3138-0.3142 in.) | 7.95 mm (0.313 in.) | ||
| Clutch feed pipe bushing I.D. | 8.000-8.015 mm (0.3150-0.3156 in.) | 8.030 mm (0.3161 in.) | ||
| Countershaft | Diameter of needle bearing contact area | At torque converter housing | 36.005-36.015 mm (1.4175-1.4179 in.) | When worn or damaged |
| At 4th gear | 34.982-34.998 mm (1.3772-1.3778 in.) | When worn or damaged | ||
| At reverse gear collar | 39.979-40.000 mm (1.5740-1.5748 in.) | When worn or damaged | ||
| I.D. of gears | 4th gear | 41.000 - 41.016 mm (1.6141 - 1.6148 in.) | When worn or damaged | |
| Reverse gear | 46.000-46.016 mm (1.8110-1.8116 in.) | When worn or damaged | ||
| End play of gears | 1st gear | 0-0.43 mm (0.000-0.017 in.) | ||
| 2nd gear | 0-0.43 mm (0.000-0.017 in.) | |||
| 3rd gear | 0-0.43 mm (0.000-0.017 in.) | |||
| 4th gear | 0.04-0.27 mm (0.001-0.010 in.) | |||
| Reverse gear | 0.10-0.25 mm (0.004-0.010 in.) | |||
| Distance collar length | 82.75-82.80 mm (3.258-3.259 in.) | |||
| Reverse selector hub width | 25.45-25.65 mm (1.002-1.010 in.) | |||
| Reverse selector hub O.D. | 55.87-55.90 mm (2.200-2.201 in.) | When worn or damaged | ||
| Secondary shaft | Diameter of needle bearing contact area | At 1st gear | 39.986-39.999 mm (1.5742-1.5748 in.) | When worn or damaged |
| At 2nd gear | 39.986-39.999 mm (1.5742-1.5748 in.) | When worn or damaged | ||
| I.D. of gears | 1st gear | 47.000-47.016 mm (1.8504-1.8510 in.) | When worn or damaged | |
| 2nd gear | 46.000-46.016 mm (1.8110-1.8116 in.) | When worn or damaged | ||
| End play of gears | 1st and 2nd gear | 0.04-0.12 mm (0.002-0.005 in.) | ||
| 37 x 58 mm thrust washer thickness | No. 1 | 3.900 mm (0.154 in.) | When worn or damaged | |
| No. 2 | 3.925 mm (0.155 in.) | When worn or damaged | ||
| No. 3 | 3.950 mm (0.156 in.) | When worn or damaged | ||
| No. 4 | 3.975 mm (0.156 in.) | When worn or damaged | ||
| No. 5 | 4.000 mm (0.157 in.) | When worn or damaged | ||
| No. 6 | 4,025 mm (0.158 in.) | When worn or damaged | ||
| No. 7 | 4.050 mm (0.159 in.) | When worn or damaged | ||
| No. 8 | 4.075 mm (0.160 in.) | When worn or damaged | ||
| No. 9 | 4.100 mm (0.161 in.) | When worn or damaged | ||
| No. 10 | 4.125 mm (0.162 in.) | When worn or damaged | ||
| No. 11 | 4.150 mm (0.163 in.) | When worn or damaged | ||
| No. 12 | 4.175 mm (0.164 in.) | When worn or damaged | ||
| No. 13 | 4.200 mm (0.165 in.) | When worn or damaged | ||
| No. 14 | 4.225 mm (0.166 in.) | When worn or damaged | ||
| No. 15 | 4.250 mm (0.167 in.) | When worn or damaged | ||
| No. 16 | 4.275 mm (0.168 in.) | When worn or damaged | ||
| No. 17 | 4.300 mm (0.169 in.) | When worn or damaged | ||
| No. 18 | 4.325 mm (0.170 in.) | When worn or damaged | ||
| No. 19 | 4.350 mm (0.171 in.) | When worn or damaged | ||
| No. 20 | 4.375 mm (0.172 in.) | When worn or damaged | ||
| 40 x 51.5 mm thrust washer thickness | No. 1 | 4.80 mm (0.189 in.) | When worn or damaged | |
| No. 2 | 4.85 mm (0.191 in.) | When worn or damaged | ||
| No. 3 | 4.90 mm (0.193 in.) | When worn or damaged | ||
| No. 4 | 4.95 mm (0.195 in.) | When worn or damaged | ||
| No. 5 | 5.00 mm (0.197 in.) | When worn or damaged | ||
| No. 6 | 5.05 mm (0.199 in.) | When worn or damaged | ||
| 27 x 45 x 44 mm gear collar length | 43.9-44.0 mm (1.728-1.732 in.) | |||
| Sealing ring thickness | 1.91-1.97 mm (0.0752-0.0776 in.) | 1.86 mm (0.0732 in.) | ||
| Width of sealing ring groove | 2.025-2.060 mm (0.0797-0.0811 in.) | 2.080 mm (0.0819 in.) | ||
| Clutch feed pipe O.D. | 11.47-11.48 mm (0.4516-0.4520 in.) | 11.45 mm (0.4508 in.) | ||
| Clutch feed pipe bushing O.D. | 11.500-11.518 mm (0.4527-0.4534 in.) | 11.530 mm (0.4539 in.) | ||
| ATF guide of sealing ring contact I.D. | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | ||
| Idler gear shaft | Diameter of needle bearing contact area | End cover side | 32.003-32.013 mm (1.2600-1.2604 in.) | When worn or damaged |
| Thickness of cotters | 1.39-1.42 mm (0.0547-0.0559 in.) | |||
| Reverse idler gear | Reverse idler gear shaft diameter at needle bearing contact area | 14.99-15.00 mm (0.5902-0.5906 in.) | When worn or damaged | |
| I.D. | 20.007-20.020 mm (0.7877-0.7882 in.) | When worn or damaged | ||
| I.D. of reverse idler gear shaft contact area on transmission housing | 14.800-14.818 mm (0.5827-0.5834 in.) | |||
| I.D. of reverse idler gear shaft holder | 14.800-14.824 mm (0.5827-0.5836 in.) | When worn or damaged | ||
| ATF pump | ATF pump thrust clearance | 0.03-0.05 mm (0.001-0.002 in.) | 0.07 mm (0.003 in.) | |
| ATF pump gear-to-body clearance | Drive gear | 0.210-0.265 mm (0.08-0.010 in.) | ||
| Driven gear | 0.070-0.125 mm (0.003-0.005 in.) | |||
| ATF pump driven gear I.D. | 14.016-14.034 mm (0.5518-0.5525 in.) | When worn or damaged | ||
| ATF pump driven gear shaft O.D. | 13.980-13.990 mm (0.5504-0.5508 in.) | When worn or damaged | ||
| Stator shaft | Needle bearing contact I.D. | Torque converter side | 27.000-27.021 mm (1.063-1.064 in.) | When worn or damaged |
| ATF pump side | 29.000-29.021 mm (1.1417-1.1426 in.) | |||
| Sealing ring contact area I.D. | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | ||
| Reverse shift fork | Fork finger thickness | 5.90-6.00 mm (0.232-0.236 in.) | 5.40 mm (0.213 in.) | |
| Park gear and pawl | When worn or damaged | |||
| Servo body | Shift fork shaft bore I.D. | 14.000-14.010 mm (0.5512-0.5516 in.) | ||
| Shift fork shaft valve bore I.D. | 37.000-37.039 mm (1.4567-1.4582 in.) | 37.045 mm (1.4585 in.) | ||
| Regulator valve body | Sealing ring contact I.D. | 29.000-29.021 mm (1.1417-1.1426 in.) | 29.05 mm (1.144 in.) | |
| A/T differential carrier | Pinion shaft contact area I.D. | 18.000-18.025 mm (0.709-0.710 in.) | ||
| Carrier-to-pinion shaft clearance | 0.013-0.054 mm (0.001-0.002 in.) | 0.1 mm (0.004 in.) | ||
| Driveshaft contact area I.D. | 28.015-28.045 mm (1.103-1.104 in.) | |||
| Carrier-to-driveshaft clearance | 0.035-0.086 mm (0.001 0.003 in.) | 0.12 mm (0.005 in.) | ||
| Intermediate shaft contact I.D. | 28.015-28.045 mm (1.103-1.104 in.) | |||
| Carrier-to-intermediate shaft clearance | 0.065-0.111 mm (0.003-0.004 in.) | 0.12 mm (0.005 in.) | ||
| Carrier bearing starting torque (preload) | For new bearing | 2.7-3.9 N.m (28-40 kgf.cm, 24-35 lbf.in.) | Adjust | |
| For bearing reused | 2.5-3.6 N.m (25-37 kgf.cm, 22-32 lbf.in.) | Adjust | ||
| Final driven gear backlash | (References) | 0.087-0.146 mm (0.003-0.006 in.) | 0.2 mm (0.008 in.) | |
| A/T differential pinion gear | Backlash | 0.05-0.15 mm (0.002-0.006 in.) | ||
| I.D. | 18.042-18.066 mm (0.7103-0.7113 in.) | |||
| Pinion gear-to-pinion shaft clearance | 0.055-0.095 mm (0.0022-0.0037 in.) | 0.12 mm (0.005 in.) | ||
| Transfer assembly (4WD) | Diameter of transfer shaft on bearing contact area | At roller bearing | 38.485-38.500 mm (1.5152-1.5157 in.) | 38.43 mm (1.513 in.) |
| At tapered roller bearing | 24.975-24.990 mm (0.9833-0.9839 in.) | 24.92 mm (0.9811 in.) | ||
| Transfer drive gear diameter | At tapered roller bearing | 40.002-40.018 mm (1.5749-1.5755 in.) | 38.95 mm (1.533 in.) | |
| Diameter of transfer driven gear on tapered roller bearing contact area | At driven gear side | 35.002-35.018 mm (1.3780-1.3787 in.) | 34.95 mm (1.376 in.) | |
| At shaft splines side | 26.975-26.988 mm (1.0620-1.0625 in.) | 26.92 mm (1.060 in.) | ||
| Transfer gear backlash | 0.06-0.16 mm (0.002-0.006 in.) | Adjust | ||
| Total starting torque (preload) | 2.16-3.57 N.m (22.0-36.4 kgf.cm, 19.2-31.6 lbf.in.) | Adjust | ||
Automatic Transmission & A/T Differential Specifications
| Item | Measurement | Qualification | Standard or New | |||
|---|---|---|---|---|---|---|
| Wire Diameter | O.D. | Free Length | No. of Coil | |||
| Main valve body spring | Shift valve A spring | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | |
| Shift valve 8 spring | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | ||
| Shift valve C spring | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | ||
| Relief valve spring | 1.0 mm (0.039 in.) | 9.6 mm (0.378 in.) | 34.1 mm (1.343 in.) | 10.2 | ||
| Lock-up control valve spring | 0.65 mm (0.026 in.) | 7.1 mm (0.280 in.) | 23.1 mm (0.909 in.) | 12.7 | ||
| Cooler check valve spring | 0.9 mm (0.035 in.) | 6.6 mm (0.260 in.) | 26.5 mm (1.043 in.) | 12.6 | ||
| Servo control valve spring | 0.7 mm (0.028 in.) | 6.6 mm (0.260 in.) | 35.7 mm (1.406 in.) | 17.2 | ||
| Shift valve E spring | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | ||
| Regulator valve body spring | Stator reaction spring | 4.5 mm (0.177 in.) | 35.4 mm (1.394 in.) | 30.3 mm (1.193 in.) | 1.92 | |
| Regulator valve spring A | 1.9 mm (0.075 in.) | 14.7 mm (0.579 in.) | 80.6 mm (3.173 in.) | 16.1 | ||
| Regulator valve spring B | 1.6 mm (0.063 in.) | 9.2 mm (0.362 in.) | 44.0 mm (1.732 in.) | 12.5 | ||
| Torque converter check valve spring | 1.2 mm (0.047 in.) | 8.6 mm (0.339 in.) | 33.8 mm (1.331 in.) | 12.2 | ||
| Lock-up shift valve spring | 1.0 mm (0.039 in.) | 6.6 mm (0.260 in.) | 35.5 mm (1.398 in.) | 18.2 | ||
| 1st accumulator spring A | 2.4 mm (0.094 in.) | 18.6 mm (0,732 in.) | 49.0 mm (1.929 in.) | 7.1 | ||
| 1st accumulator spring B | 2.3 mm (0.091 in.) | 12.2 mm (0.480 in.) | 31.5 mm (1.240 in.) | 6.6 | ||
| Servo body spring | CPB valve spring | 0.7 mm (0.028 in.) | 9.1 mm (0,358 in.) | 32.3 mm (1.272 in.) | 8.6 | |
| 4th accumulator spring B | 2.3 mm (0.091 in.) | 12.2 mm (0.480 in.) | 31.5 mm (1.240 in.) | 6.6 | ||
| 4th accumulator spring A | 2.4 mm (0.094 in.) | 18.6 mm (0.732 in.) | 49.0 mm (1.929 in.) | 7.1 | ||
| 2nd accumulator spring B | 2.0 mm (0.079 in.) | 10.6 mm (0.417 in.) | 34.0 mm (1.339 in.) | 8.0 | ||
| 2nd accumulator spring A | 2.2 mm (0.087 in.) | 16.6 mm (0.654 in.) | 48.2 mm (1.898 in.) | 8.5 | ||
| 3rd accumulator spring | 2.5 mm (0.098 in.) | 14.6 mm (0.575 in.) | 29.9 mm (1.177 in.) | 4.9 | ||
Automatic Transmission Spring Specifications
Rear Differential
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Differential fluid | Capacity Use Honda Dual Pump Fluid | At fluid change | 1.0 l (1.1 US qt) |
| At overhaul | 1.2 l (1.3 US qt) |
Rear Differential Specification Table
Steering System
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Steering wheel | Rotational play measured at outside edge with engine running | 0-10 mm (0-0.39 in.) | |
| Starting load measured at outside edge with engine running | 29 N 13.0 kgf, 6.6 lbf) | ||
| Gearbox | Angle of rack guide screw loosened from locked position | 20° max. | |
| Pump | Output pressure with shut-off valve closed | 7,460-8,140 kPa (76-83 kgf/cm 2 , 1,080-1,180 psi) | |
| Power steering fluid | Capacity Use Honda Power Steering Fluid | Reservoir capacity | 0.26 l (0.27 US qt) |
| System overhaul | 0.75 l (0.79 US qt) | ||
| Drive belt | Auto tensioner |
Steering Specification Table
Suspension
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Wheel alignment | Camber | Front | 0°00' ±45' | |
| Rear | 1°00' ± 45' | |||
| Caster | Front | 1°45' ± 1° | ||
| Total Toe | Front | 0 ± 2 mm (0 ± 0.08 in.) | ||
| Rear | 2 +2 1 mm (0.08 +008 0.04 in.) | |||
| Front wheel turning angle | Inside wheel | 39°45' ± 2° | ||
| Outside wheel | 32°30' (Reference) | |||
| Wheel | Aluminum wheel runout | Axial | 0-0.7 mm (0-0.03 in.) | 2.0 mm (0.08 in.) |
| Radial | 0-0.7 mm (0-0.03 in.) | 1.5 mm (0.06 in.) | ||
| Steel wheel runout | Axial | 0-1.0 mm (0-0.04 in.) | 2.0 mm (0.08 in.) | |
| Radial | 0-1.0 mm (0-0.04 in.) | 1.5 mm (0.06 in.) | ||
| Wheel bearing | End play | Front | 0-0.05 mm (0-0.002 in.) | |
| Rear | 0-0.05 mm (0-0.002 in.) | |||
Suspension Specification Table
Brake System
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Parking brake lever | Distance traveled when lever pulled with 196 N (20 kgf, 44 lbf) of force | 5 to 9 clicks | ||
| Brake pedal | Pedal height (carpet removed) | 173 mm (6 13/16 in.) | ||
| Free play | 1-5 mm (0.04-0.2 in.) | |||
| Master cylinder | Piston-to-pushrod clearance | 0-0.4 mm (0-0.02 in.) | ||
| Brake disc | Thickness | Front | 23.0 mm (0.91 in.) | 21.0 mm (0.83 in.) |
| Rear | 9.0 mm (0.35 in.) | 7.0 mm (0.28 in.) | ||
| Runout | Front | 0.10 mm (0.004 in.) | ||
| Rear | 0.10 mm (0.004 in.) | |||
| Parallelism | Front and rear | 0.015 mm (0.0006 in.) | ||
| Brake pad | Thickness | Front | 11.0 mm (0.43 in.) | 1.6 mm (0.06 in.) |
| Rear | 9.0 mm (0.35 in.) | 1.0 mm (0.04 in.) | ||
| Paking brake | Brake drum I.D. | 170 mm (6.69 in.) | 171 mm (6.73 in.) | |
| Brake shoe lining thickness | 3.2 mm (0.13 in.) | 1.0 mm (0.04 in.) | ||
Brakes Specification Table
Air Conditioning System
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Refrigerant | Type | HFC-134a (R-134a) | |
| Capacity of system | 480-530 g (17.0-18.7 oz) | ||
| Refrigerant oil | Type | KEIHIN: SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01) | |
| Capacity of components | Condenser | 25 m l (5/6 fl oz) | |
| Evaporator | 40 m l (1 1/3 fl oz) | ||
| Each line and hose | 10 m l (1/3 fl oz) | ||
| Compressor | 130-150 m l (4 1/3-5 fl oz) | ||
| Compressor | Starter coil resistance | At 68°F (20°C) | 3.05-3.35 ohms |
| Pulley-to-pressure plate clearance | 0.35-0.6 mm (0.014-0.024 in.) | ||
| Drive belt | Tension | Auto tensioner |
Air Conditioning Specification Table