Engine Electrical
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Ignition coil | Rated voltage | 12V | ||
| Firing order | 1-3-4-2 | |||
| Spark plug | Type | NGK: IZFR6K11 | ||
| DENSO: SKJ20DR-M11 | ||||
| Gap | 1.0-1.1 mm (0.039-0.043 in.) | |||
| Ignition timing | At idle Check the red mark | M/T (in neutral) | 8 ± 2° BTDC | |
| A/T (in N or P position) | 8 ± 2° BTDC | |||
| Drive belt | Tension | Auto-tensioner | ||
| Alternator | Output | At 13.5 V and normal engine temperature | 105A | |
| Coil (rotor) resistance | At 68°F (20°C) | 2.5 ohms | ||
| Slip ring O.D. | 14.4 mm (0.57 in.) | 14.0 mm (0.55 in.) | ||
| Brush length | 10.5 mm (0.41 in.) | 1.5 mm (0.06 in.) | ||
| Brush spring tension | 3.2 N (0.33 kgf, 0.7 lbf) | |||
| Starter | Output | 1.6 kW | ||
| Commutator mica depth | 0.40-0.50 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 | 34.263 mm (1.3489 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 | 0.030-0.055 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 | 44.0-44.5 mm (1.73-1.75 in.) | ||
| Exhaust | 44.1-44.6 mm (1.74-1.76 in.) | |||
| Valve spring | Free length | Intake | 47.57 mm (1.873 in.) | |
| Exhaust | 49.64 mm (1.954 in.) | |||
| 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
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 | 0.050-0.075 mm (0.0020-0.0030 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 | 0.20-0.50 mm (0.008-0.020 in.) | 0.80 mm (0.031 in.) | ||
| Piston pin | O.D. | 21.962-21.965 mm (0.8646-0.8648 in.) | 21.953 mm (0.8643 in.) | |
| Pin-to-piston clearance | 0.005 to +0.001 mm (-0.00020 to +0.00004 in.) | 0.005 mm (0.0002 in.) | ||
| Connecting rod | Pin-to-rod clearance | 0.005-0.014 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 | 51.0 mm (2.01 in.) | |||
| End play installed on crankshaft | 0.15-0.35 mm (0.006-0.014 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 ('07-08 model) | 0.005 mm (0.0002 in.) max. | 0.010 mm (0.0004 in.) | ||
| Rod/main journal out-of-round ('09-10 model) | 0.004 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
Cooling System
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Radiator | Coolant capacities (including engine, heater, hoses, and reservoir) Use Honda Long Life Antifreeze/Coolant Type 2 | M/T: engine overhaul | 7.3 L (1.93 US gal) |
| M/T: coolant change | 5.2 L (1.37 US gal) | ||
| A/T: engine overhaul | 7.2 L (1.90 US gal) | ||
| A/T: coolant change | 5.1 L (1.35 US gal) | ||
| Coolant reservoir | Coolant capacity | 0.6 L (0.16 US gal) | |
| 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. |
COOLING SYSTEM SPECIFICATION TABLE
Fuel and Emissions
| 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 | 60 L (15.9 US gal) | |
| Engine idle | Idle speed without load | M/T (in neutral) | 700 ± 50 rpm |
| A/T (in N or P position) | 700 ± 50 rpm | ||
| Idle speed with high electrical load (A/C switch ON, temperature set to max cool, blower fan on High, rear window defogger ON, and headlights on high beam) | M/T (in neutral) | 720 ± 50 rpm | |
| A/T (in N or P position) | 720 ± 50 rpm |
FUEL AND EMISSIONS SPECIFICATION TABLE
Clutch
| 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 | 8.6-9.2 mm (0.34-0.36 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 AND M/T DIFFERENTIAL SPECIFICATION Item Measurement Qualification Standard or New Service Limit Manual transmission fluid Capacity Use Honda MTF Fluid change 1.90 L (2.0 US qt) 2WD: overhaul 2.15 L (2.3 US qt) 4WD: overhaul 2.25 L (2.4 US qt) Mainshaft End play - 0.11-0.17 mm (0.004-0.007 in.) Adjust Diameter of bushing contact area - 20.80-20.85 mm (0.8189-0.8209 in.) 20.75 mm (0.817 in.) Diameter of distance collar contact area - 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.) 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 (0.946-0.948 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.) - 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.) - 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 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 clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) Shift fork Fork 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 width - 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.) Detent ball spring Free length 1st/2nd, 3rd/4th, 5th 22.1 mm (0.870 in) When worn or damaged Steel ball Ball size 7.94 mm (0.3126 in) When worn or damaged Shift arm I.D. - 13.973-14.000 mm (0.5501-0.5512 in.) - Shift arm thickness at contact area - 16.9-17.0 mm (0.665-0.669 in.) - Shift arm-to-shift fork 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 Change-to-select lever clearance - 0.05-0.25 mm (0.002-0.010 in.) 0.5 mm (0.020 in.) Groove width (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 - 0-0.10 mm (0-0.0039 in.) Adjust Transfer assembly 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 - 2.16-3.57 N.m (22.0-36.4 kgf.cm, 19.1-31.6 lbf.in.) Adjust
Automatic Transmission and A/T Differential
| Item | Measurement | Qualification | Standard or New | Service Limit | |
|---|---|---|---|---|---|
| Automatic transmission fluid | Capacity Use Honda ATF-Z1 | 4WD | Fluid change | 2.5 L (2.6 US qt) | |
| Overhaul | 7.2 L (7.6 US qt) | ||||
| 2WD | Fluid change | 2.6 L (2.7 US qt) | |||
| Overhaul | 7.0 L (7.4 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 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 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 D3 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) | ||
| 5th clutch pressure | At 2,000 rpm in 5th 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 | 2,400 rpm | 2,250-2,550 rpm | ||
| Clutch | Clutch end-plate-to-top disc clearance | 1st | 1.38-1.58 mm (0.054-0.062 in.) | ||
| 2nd | 1.14-1.34 mm (0.045-0.053 in.) | ||||
| 3rd | 1.23-1.43 mm (0.048-0.056 in.) | ||||
| 4th, 5th | 0.93-1.13 mm (0.037-0.044 in.) | ||||
| Clutch return spring free length | 1st, 2nd, 3rd | 45.1 mm (1.78 in.) | 48.8 mm (1.92 in.) | ||
| 4th, 5th | 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, 3rd | 1.6 mm (0.063 in.) | When discolored | ||
| 2nd | 2.0 mm (0.079 in.) | When discolored | |||
| 4th, 5th | 2.0 mm (0.079 in.) | When discolored | |||
| Clutch wave-plate phase difference | 0.07-0.20 mm (0.003-0.008 in.) | 0.05 mm (0.002 in.) | |||
| 1st 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 | |||
| 2nd clutch end-plate thickness | Mark 1 | 2.4 mm (0.095 in.) | When discolored | ||
| Mark 2 | 2.5 mm (0.098 in.) | When discolored | |||
| Mark 3 | 2.6 mm (0.102 in.) | When discolored | |||
| Mark 4 | 2.7 mm (0.106 in.) | When discolored | |||
| Mark 5 | 2.8 mm (0.110 in.) | When discolored | |||
| Mark 6 | 2.9 mm (0.114 in.) | When discolored | |||
| Mark 7 | 3.0 mm (0.118 in.) | When discolored | |||
| Mark 8 | 3.1 mm (0.122 in.) | When discolored | |||
| Mark 9 | 3.2 mm (0.126 in.) | When discolored | |||
| 3rd, 4th, 5th clutch end-plate thickness | Mark 1 | 2.1 mm (0.083 in.) | When discolored | ||
| Mark 2 | 2.2 mm (0.087 in.) | When discolored | |||
| Mark 3 | 2.3 mm (0.091 in.) | When discolored | |||
| Mark 4 | 2.4 mm (0.095 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 5th 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 | 5th 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 | 5th gear | 0.04-0.10 mm (0.002-0.004 in.) | |||
| 4th gear | 0.1-0.22 mm (0.004-0.009 in.) | ||||
| 41 x 68 mm thrust washer thickness | No. 1 | 4.450 mm (0.1752 in.) | When worn or damaged | ||
| No. 2 | 4.475 mm (0.1762 in.) | When worn or damaged | |||
| No. 3 | 4.500 mm (0.1772 in.) | When worn or damaged | |||
| No. 4 | 4.525 mm (0.1781 in.) | When worn or damaged | |||
| No. 5 | 4.550 mm (0.1791 in.) | When worn or damaged | |||
| No. 6 | 4.575 mm (0.1801 in.) | When worn or damaged | |||
| No. 7 | 4.600 mm (0.1811 in.) | When worn or damaged | |||
| No. 8 | 4.625 mm (0.1821 in.) | When worn or damaged | |||
| No. 9 | 4.650 mm (0.1831 in.) | When worn or damaged | |||
| No. 10 | 4.675 mm (0.1841 in.) | When worn or damaged | |||
| No. 11 | 4.700 mm (0.1850 in.) | When worn or damaged | |||
| No. 12 | 4.725 mm (0.1860 in.) | When worn or damaged | |||
| No. 13 | 4.750 mm (0.1870 in.) | When worn or damaged | |||
| No. 14 | 4.775 mm (0.1880 in.) | When worn or damaged | |||
| No. 15 | 4.800 mm (0.1890 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 (1.3772-1.3779 in.) | When worn or damaged | |||
| At reverse gear | 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 (1.6142-1.6148 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 | 5th gear | 0.00-0.48 mm (0.000-0.019 in.) | |||
| 4th gear | 0.04-0.27 mm (0.002-0.011 in.) | ||||
| Reverse gear | 0.10-0.25 mm (0.004-0.010 in.) | ||||
| Collar, 35 x 47 x 7.8 mm thickness | 7.8 mm (0.31 in.) | ||||
| Collar, 37 x 41 x 54.3 mm length | 54.25-54.30 mm (2.136-2.138 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 | |||
| At 3rd gear collar | 36.975-36.991 mm (1.4557-1.4563 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 | |||
| 3rd gear | 43.000-43.016 mm (1.6929-1.6935 in.) | When worn or damaged | |||
| End play of gears | 1st gear | 0.04-0.12 mm (0.002-0.005 in.) | |||
| 2nd gear | 0.04-0.12 mm (0.002-0.005 in.) | ||||
| 3rd gear | 0.10-0.22 mm (0.004-0.009 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 | |||
| 3rd gear collar length | 43.9-44.0 mm (1.728-1.732 in.) | ||||
| Length of 3rd gear collar flange from end | 5.25-5.40 mm (0.207-0.213 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. | 3rd clutch feed pipe | 11.47-11.48 mm (0.4516-0.4520 in.) | 11.45 mm (0.4508 in.) | ||
| 1st clutch feed pipe | 6.97-6.98 mm (0.2744-0.2748 in.) | 6.95 mm (0.2736 in.) | |||
| Clutch feed pipe bushing O.D. | 3rd clutch feed pipe | 11.500-11.518 mm (0.4528-0.4553 in.) | 11.530 mm (0.4539 in.) | ||
| 1st clutch feed pipe | 7.018-7.030 mm (0.2763-0.2768 in.) | 7.045 mm (0.2774 in.) | |||
| ATF guide collar 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 | 0.03-0.06 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 (0.008-0.010 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.) | ||
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | |||
|---|---|---|---|---|---|---|
| Wire Diameter | O.D. | Free Length | No. of Coils | |||
| Main valve body spring (see MAIN VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY ) | 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 B 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 | 0.85 mm (0.033 in.) | 6.6 mm (0.260 in.) | 27.0 mm (1.063 in.) | 11.3 | ||
| 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 (see REGULATOR VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY ) | 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 | ||
| 3rd accumulator spring | 2.5 mm (0.098 in.) | 14.6 mm (0.575 in.) | 29.9 mm (1.177 in.) | 4.9 | ||
| 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 (see SERVO BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY ) | Shift valve D spring | 0.8 mm (0.031 in.) | 5.6 mm (0.220 in.) | 28.1 mm (1.106 in.) | 15.9 | |
| 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 | 2.1 mm (0.083 in.) | 10.8 mm (0.425 in.) | 34.0 mm (1.339 in.) | 8.2 | ||
| 2nd accumulator spring A | 2.1 mm (0.083 in.) | 16.6 mm (0.654 in.) | 48.7 mm (1.917 in.) | 8.4 | ||
| 5th accumulator spring | 2.5 mm (0.098 in.) | 14.6 mm (0.575 in.) | 29.9 mm (1.177 in.) | 4.9 | ||
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| A/T differential carrier | Pinion shaft contact area I.D. | 18.000-18.025 mm (0.709-0.719 in.) | ||
| Carrier-to-pinion shaft clearance | 0.017-0.109 mm (0.001-0.004 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 (0.002-0.003 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 used bearing | 2.5-3.6 N.m (25-37 kgf.cm, 22-32 lbf.in.) | Adjust | ||
| Final driven gear backlash | 0.085-0.144 mm (0.003-0.006 in.) | 0.2 mm (0.008 in.) | ||
| A/T differential pinion gear | Backlash | 1.1-1.6 mm (0.04-0.06 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.) | 0.12 mm (0.005 in.) | ||
| Transfer assembly | 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) | 1.96-3.14 N.m (20.0-32.0 kgf.cm, 17.4-27.8 lbf.in.) | Adjust |
AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATION
Rear Differential
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Rear differential fluid | Capacity Use Honda Dual Pump Fluid II | Fluid change | 1.0 L (1.1 US qt) |
| Overhaul | 1.21 (1.3 US qt) |
REAR DIFFERENTIAL SPECIFICATION TABLE
Steering
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Steering wheel | Rotational play measured at outside edge with engine running | 0-10 mm (0-0.39 in.) | ||
| Initial turning load measured at outside edge with engine running | 29 N (3.0 kgf, 6.6 lbf) | If higher, check gearbox and pump | ||
| 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 | 0.27 L (0.28 US qt) | |
| System capacity | 0.83 L (0.87 US qt) | |||
STEERING SPECIFICATION TABLE
Suspension
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Wheel alignment (LX, EX) | Camber | Front | 0°13' ± 45' | |
| Rear | 1°00' ± 45' | |||
| Caster | Front | 1°50' ± 1° | ||
| Total toe-in | Front | 0 ± 3 mm (0 ± 0.12 in.) | ||
| Rear | 2 +2 -1 mm (0.08 +0.08 -0.04 in.) | |||
| Front wheel turning angle | Inward | 40° 05' ± 2° | ||
| Outward | 32°16' (Reference) | |||
| Wheel alignment (SC) | Camber | Front | 0°24' ± 45' | |
| Rear | 1°06' ± 45' | |||
| Caster | Front | 1°50' ± 1° | ||
| Total toe-in | Front | 0 ± 3 mm (0 ± 0.12 in.) | ||
| Rear | 2 +2 -1 mm (0.08 +0.08 -00.4 in.) | |||
| Front wheel turning angle | Inward | 38° 24' ± 2° | ||
| Outward | 31° 24 '(Reference) | |||
| Wheel | Aluminum wheel runout | Axial | 0-0.6 mm (0-0.02 in.) | 2.0 mm (0.08 in.) |
| Radial | 0-0.6 mm (0-0.02 in.) | 1.5 mm (0.06 in.) | ||
| Steel wheel runout | Axial | 0-1.4 mm (0-0.06 in.) | 2.0 mm (0.08 in.) | |
| Radial | 0-1.4 mm (0-0.06 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
Brakes
| Item | Measurement | Qualification | Standard or New | Service Limit |
|---|---|---|---|---|
| Parking brake | Distance traveled when lever pulled with 196 N (20 kgf, 44 lbf) of force | LX, EX | 4 to 7 clicks | |
| SC | 8 to 10 clicks | |||
| Drum I.D. | 169.9-170.0 mm (6.689-6.693 in.) | 171 mm (6.732 in.) | ||
| Shoe lining thickness | 2.5 mm (0.098 in.) | 1.0 mm (0.04 in.) | ||
| Brake pedal | Pedal height (carpet removed) | M/T | 178 mm (7 in.) | |
| A/T | 180 mm (7 3/32 in.) | |||
| Free play | 1-5 mm (1/16-3/16 in.) | |||
| Master cylinder | Piston-to-pushrod clearance | 0-0.4 mm (0-0.02 in.) | ||
| Brake disc | Thickness | Front | 22.9-23.1 mm (0.90-0.91 in.) | 21.0 mm (0.83 in.) |
| Rear | 8.9-9.1 mm (0.35-0.36 in.) | 7.5 mm (0.30 in.) | ||
| Runout | Front | 0.04 mm (0.0016 in.) | ||
| Parallelism | 0.015 mm (0.0006 in.) | |||
| Brake pad | Thickness | Front | 10.6-11.2 mm (0.42-0.44 in.) | 1.6 mm (0.06 in.) |
| Rear | 8.6-9.7 mm (0.34-0.38 in.) | 1.6 mm (0.06 in.) | ||
BRAKES SPECIFICATION TABLE
Air Conditioning
| Item | Measurement | Qualification | Standard or New |
|---|---|---|---|
| Refrigerant | Type | HFC-134a (R-134a) | |
| Capacity of system | 500-550 g (17.6-19.4 oz) | ||
| Refrigerant oil | Type | DENSO ND-OIL 8 (P/N 38897-PR7-A01AH or 38899-PR7-A01) | |
| Capacity of components | Condenser | 25 mL (5/6 fl.oz) | |
| Evaporator | 45 mL (1 1/2 fl.oz) | ||
| Each line and hose | 10 mL (1/3 fl.oz) | ||
| Compressor | 160-175 mL (5 1/3-5 5/6 fl.oz) | ||
| Compressor | Field coil resistance | At 68°F (20°C) | 3.9-4.3 ohms |
| Pulley-to-pressure plate clearance | 0.35-0.6 mm (0.014-0.024 in.) |
AIR CONDITIONING SPECIFICATION TABLE