Contents Section: Cooling System (Mechanical) All sections

Specifications: Other Honda Pilot I рестайлинг

Cooling System (Mechanical) 1 illustration ~118 words

Engine Electrical

ItemMeasurementQualificationStandard or NewService Limit
Ignition coilRated voltage12 V
Firing order1-4-2-5-3-6
Spark plugTypeNGK: IZFR5K11 DENSO: SKJ16DR-M11
Gap1.0-1.1 mm (0.039-0.043 in.)
Ignition timingAt idle Check the red markIn N or P position10+/-2°BTDC
Drive beltTensionAuto tensioner
AlternatorOutputAt 13.5 V and normal engine temperature130 A
Coil (rotor) resistanceAt 68°F (20°C)2.5 ohms
Slip ring O.D.14.4 mm (0.57 in.)14.0 mm (0.55 in.)
Brush length10.5 mm (0.41 in.)1.5 mm (0.06 in.)
Brush spring tension3.2 N (0.33 kgf, 0.72 lbf)
StarterOutput1.6 kW
Commutator mica depth0.4-0.5 mm (0.016-0.020 in.)0.15 mm (0.006 in.)
Commutator runout0.02 mm (0.0008 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 length15.8-16.2 mm (0.622-0.638 in.)11 mm (0.433 in.)
Brush spring tension (new)15.7-17.7 N (1.60-1.80 kgf, 3.53-3.98 lbf)

ENGINE ELECTRICAL STANDARDS AND SERVICE LIMITS

Cylinder Head

ItemMeasurementQualificationStandard or NewService Limit
HeadWarpage0.05 mm (0.002 in.)
Height120.95-121.05 mm (4.762-4.766 in.)
CamshaftEnd play0.05-0.20 mm (0.002-0.008 in.)0.20 mm (0.008 in.)
Camshaft-to-holder oil clearance0.050-0.089 mm (0.0020-0.0035 in.)0.15 mm (0.006 in.)
Total runout0.03 mm (0.001 in.) max.0.04 mm (0.002 in.)
Cam lobe heightJ35A9 engineIntake, primary35.041 mm (1.3796 in.)
Intake, mid36.445 mm (1.4348 in.)
Intake, secondary35.284 mm (1.3891 in.)
J35Z1 engineIntake, front side36.140 mm (1.4228 in.)
Intake, rear side35.096 mm (1.3817 in.)
J35A9 engineExhaust36.326 mm (1.4302 in.)
J35Z1 engineExhaust, front side35.864 mm (1.4120 in.)
Exhaust, rear side36.509 mm (1.4374 in.)
ValveClearance (cold)Intake0.20-0.24 mm (0.008-0.009 in.)
Exhaust0.28-0.32 mm (0.011-0.013 in.)
Stem O.D.Intake5.475-5.485 mm (0.2156-0.2159 in.)5.445 mm (0.2143 in.)
Exhaust5.475-5.485 mm (0.2156-0.2159 in.)5.445 mm (0.2143 in.)
Stem-to-guide clearanceIntake0.020-0.045 mm (0.0008-0.0018 in.)0.08 mm (0.003 in.)
Exhaust0.055-0.080 mm (0.0022-0.0031 in.)0.11 mm (0.004 in.)
Valve seatWidthIntake1.25-1.55 mm (0.049-0.061 in.)2.00 mm (0.079 in.)
Exhaust1.25-1.55 mm (0.049-0.061 in.)2.00 mm (0.079 in.)
Stem installed heightIntake46.75-47.55 mm (1.841 - 1.872 in.)47.80 mm (1.882 in.)
Exhaust46.68-47.48 mm (1.838-1.869 in.)47.73 mm (1.879 in.)
Valve springFree lengthJ35A9 engineIntake51.54 mm (2.029 in.)
J35Z1 engineIntake, front side
Intake, rear side
J35A9 engineExhaust51.06 mm (2.010 in.)
J35Z1 engineExhaust, front side52.55 mm (2.069 in.)
Exhaust, rear side
Valve guideI.D.Intake5.510-5.530 mm (0.2169-0.2177 in.)5.55 mm (0.219 in.)
Exhaust5.510-5.530 mm (0.2169-0.2177 in.)5.55 mm (0.219 in.)
Installed heightIntake21.20-22.20 mm (0.835-0.874 in.)
Exhaust20.63-21.63 mm (0.812-0.852 in.)
Rocker armArm-to-shaft clearanceJ35A9 engineIntake0.026-0.067 mm (0.0010-0.0026 in.)
J35Z1 engineIntake, front side0.019-0.067 mm (0.0007-0.0026 in.)
Intake, rear side0.015-0.046 mm (0.0006-0.0018 in.)
J35A9 engineExhaust0.026-0.077 mm (0.0010-0.0030 in.)
J35Z1 engineExhaust, front side0.019-0.058 mm (0.0007-0.0023 in.)
Exhaust, rear side0.015-0.046 mm (0.0006-0.0018 in.)

CYLINDER HEAD STANDARDS AND SERVICE LIMITS

Engine Block

ItemMeasurementQualificationStandard or NewService Limit
BlockWarpage of deck0.07 mm (0.003 in.) max.0.10 mm (0.004 in.)
Bore diameter89.000-89.015 mm (3.5039-3.5045 in.)89.065 mm (3.5065 in.)
Bore taper0.05 mm (0.002 in.)
Reboring limit0.25 mm (0.01 in.)
PistonSkirt O.D. at 16.0 mm (0.63 in.) from bottom of skirt88.975-88.985 mm (3.5029-3.5033 in.)
Clearance in cylinder0.015-0.040 mm (0.0006-0.0016 in.)0.08 mm (0.003 in.)
Ring groove widthTop1.240-1.250 mm (0.0488-0.0492 in.)1.27 mm (0.050 in.)
Second1.220-1.230 mm (0.0480-0.0484 in.)1.25 mm (0.049 in.)
Oil2.805-2.825 mm (0.1104-0.1112 in.)2.85 mm (0.112 in.)
Piston ringRing-to-groove clearanceTop0.055-0.080 mm (0.0022-0.0031 in.)0.15 mm (0.006 in.)
Second0.030-0.055 mm (0.0012-0.0022 in.)0.13 mm (0.005 in.)
Ring end gapTop0.20-0.35 mm (0.008-0.014 in.)0.60 mm (0.024 in.)
Second0.40-0.55 mm (0.016-0.022 in.)0.70 mm (0.028 in.)
Oil0.20-0.70 mm (0.008-0.028 in.)0.80 mm (0.031 in.)
Piston pinO.D.21.962-21.965 mm (0.8646-0.8648 in.)21.954 mm (0.8643 in.)
Pin-to-piston clearance0.0050 to +0.0010 mm (-0.00020 to +0.00004 in.)0.004 mm (0.0002 in.)
Connecting rodPin-to-rod clearance0.005-0.014 mm (0.0002-0.0006 in.)0.019 mm (0.0007 in.)
Small-end bore diameter21.970-21.976 mm (0.8650-0.8652 in.)
Large-end bore diameter58.0 mm (2.28 in.)
End play installed on crankshaft0.15-0.35 mm (0.006-0.014 in.)0.45 mm (0.018 in.)
CrankshaftMain journal diameter71.976-72.000 mm (2.8337-2.8346 in.)
Rod journal diameter71.976-72.000 mm (2.8337-2.8346 in.)
Rod/main journal taper0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)
Rod/main journal out-of-round0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)
End play320.10-0.35 mm (0.004-0.014 in.)0.45 mm (0.018 in.)
RunoutNo. 1, 4 journals0.020 mm (0.0008 in.) max.0.03 mm (0.0012 in.)
No. 2, 3 journals0.025 mm (0.0010 in.) max.0.03 mm (0.0012 in.)
Crankshaft bearingMain bearing-to-journal oil clearance0.020-0.044 mm (0.0008-0.0017 in.)0.050 mm (0.0020 in.)
Rod bearing clearance0.020-0.044 mm (0.0008-0.0017 in.)0.050 mm (0.0020 in.)

ENGINE BLOCK STANDARDS AND SERVICE LIMITS

Cooling

ItemMeasurementQualificationStandard or New
RadiatorCoolant capacities (including engine, heater, hoses, and reservoir) Use Honda Long Life Anti-freeze/ Coolant Type 2Engine overhaul9.7 L (2.56 US gal)
Coolant change7.0 L (1.85 US gal)
ReservoirCoolant capacity0.72 L (0.19 US gal)
Radiator capOpening pressure93-123 kPa (0.95-1.25 kgf/cm 2 , 13-18 psi)
ThermostatOpening temperatureBegins to open169-176°F (76-80 °C)
Fully open194°F (90°C)
Valve lift at fully open10.0 mm (0.39 in.) min.

COOLING STANDARDS AND SERVICE LIMITS

Fuel and Emissions

ItemMeasurementQualificationStandard or New
Fuel pressure regulatorPressure with fuel pressure gauge connected380-430 kPa (3.9-4.4 kgf/cm 2 , 55-63 psi)
Fuel tankCapacity77.0 L (20.34 US gal)
Engine idleIdle speed without loadIn N or P position (J35Z1 engine)650+/-50 rpm
In N or P position (J35A9 engine)730+/-50 rpm
Idle speed with high electric load (A/C switch ON, temperature set to Max Cool, blower fan on High, rear window defogger ON, and headlights on high beam)In N or P position (J35Z1 engine)700+/-50 rpm
In N or P position (J35A9 engine)730+/-50 rpm

FUEL AND EMISSIONS STANDARDS AND SERVICE LIMITS

Automatic Transmission and A/T Differential

ItemMeasurementQualificationStandard or NewService Limit
ATF (Automatic Transmission Fluid)4WD model: Capacity Use Honda ATF-Z1Fluid change3.3L (3.5 US qt)
Overhaul7.9 L (8.3 US qt)
2WD model: Capacity Use Honda ATF-Z1Fluid change3.8 L (4.0 US qt)
Overhaul8.4 L (8.9 US qt)
ATF pressureLine pressureAt 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 2120 psi)
5th clutch pressureAt 2,000 rpm in D position890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi)840 kPa (8.6 kgf/cm 2 , 120 psi)
4th clutch pressureAt 2,000 rpm in D position890-970 kPa (9.1-9.9 kgf/cm 2130-140 psi) 840 kPa (8.6 kgf/cm 2 , 120 psi)
3rd clutch pressureAt 2,000 rpm in D3 position890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi)840 kPa (8.6 kgf/cm 2 , 120 psi)
2nd clutch pressureAt 2,000 rpm in 2 position890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi)840 kPa (8.6 kgf/cm 2 , 120 psi)
1st clutch pressureAt 2,000 rpm in 1 position890-970 kPa (9.1-9.9 kgf/cm 2 , 130-140 psi)840 kPa (8.6 kgf/cm 2 , 120 psi)
1st-hold clutch pressureAt 2,000 rpm in 1 position760-830 kPa (7.7-8.5 kgf/cm 2 , 110-120 psi)710 kPa (7.2 kgf/cm 2 , 100 psi)
Torque converterStall speed Check with vehicle on level ground1,950 rpm1,800-2,100 rpm
ClutchClutch end-plate-to-top-disc clearance1st1.15-1.35 mm (0.045-0.053 in.)
2nd1.05-1.25 mm (0.041-0.049 in.)
3rd0.8-1.0 mm (0.031-0.039 in.)
4th0.7-0.9 mm (0.028-0.035 in.)
5th0.75-0.95 mm (0.030-0.037 in.)
1st-hold0.6-1.0 mm (0.024-0.039 in.)
Clutch return spring free length1st68.3 mm (2.69 in.)66.3 mm (2.61 in.)
2nd48.3 mm (1.90 in.)46.3 mm (1.82 in.)
3rd52.0 mm (2.05 in.)50.0 mm (1.97 in.)
4th37.7 mm (1.48 in.)35.7 mm (1.41 in.)
5th37.4 mm (1.47 in.)35.4 mm (1.39 in.)
Clutch disc thickness1.94 mm (0.076 in.)
Clutch plate thickness1st1.6 mm (0.06 in.)When discolored
2nd1.8 mm (0.07 in.)When discolored
3rd2.0 mm (0.079 in.)When discolored
4th1.8 mm (0.071 in.)When discolored
5th1.6 mm (0.063 in.)When discolored
1st-hold1.8 mm (0.07 in.)When discolored
1st clutch end plate thicknessMark 13.1 mm (0.122 in.)When discolored
Mark 23.2 mm (0.126 in.)When discolored
Mark 33.3 mm (0.130 in.)When discolored
Mark 43.4 mm (0.134 in.)When discolored
Mark 53.5 mm (0.138 in.)When discolored
Mark 63.6 mm (0.142 in.)When discolored
Mark 73.7 mm (0.146 in.)When discolored
Mark 83.8 mm (0.150 in.)When discolored
Mark 93.9 mm (0.154 in.)When discolored
1st-hold clutch plate B thickness5.0 mm (0.197 in.)When discolored
2nd, 3rd, 4th, and 5th clutch end plate thicknessMark 12.1 mm (0.083 in.)When discolored
Mark 22.2 mm (0.087 in.)When discolored
Mark 32.3 mm (0.091 in.)When discolored
Mark 42.4 mm (0.094 in.)When discolored
Mark 52.5 mm (0.098 in.)When discolored
Mark 62.6 mm (0.102 in.)When discolored
Mark 72.7 mm (0.106 in.)When discolored
Mark 82.8 mm (0.110 in.)When discolored
Mark 92.9 mm (0.114 in.)When discolored
Stator shaftI.D. at needle bearing contact areaTorque converter side27.000-27.021 mm (1.063-1.064 in.)When worn or damaged
ATF pump side31.000-31.025 mm (1.220-1.221 in.)
I.D. at mainshaft sealing ring contact area31.000-31.025 mm (1.220-1.221 in.)31.05 mm (1.222 in.)
ATF pumpGear-to-body thrust clearance0.03-0.06 mm (0.001-0.002 in.)0.07 mm (0.003 in.)
Gear-to-body clearanceDrive gear0.210-0.265 mm (0.008-0.010 in.)
Driven gear0.070-0.125 mm (0.003-0.005 in.)
Driven gear I.D.14.016-14.034 mm (0.5518-0.5525 in.)When worn or damaged
Driven gear shaft O.D.13.980-13.990 mm (0.5504-0.5508 in.)When worn or damaged
Reverse shift forkFork finger thickness5.90-6.00 mm (0.220-0.236 in.)5.4 mm (0.213 in.)
Park gear and pawlWhen worn or damaged
Regulator valve bodyShift fork shaft bore I.D.14.000-14.010 mm (0.5512-0.5516 in.)
Shift fork shaft/servo valve bore I.D.37.000-37.039 mm (1.4567-1.4582 in.)37.045 mm (1.4585 in.)
Mainshaft sealing ring contact I.D.31.000-31.025 mm (1.220-1.221 in.)31.05 mm (1.222 in.)
Main valve bodyThird shaft sealing ring contact I.D.35.000-35.025 mm (1.3780-1.3789 in.)35.05 mm (1.3799 in.)
ATF guide collarSecondary shaft sealing ring contact I.D.29.000-29.021 mm (1.1417-1.1426 in.)29.05 mm (1.1437 in.)
MainshaftDiameter at stator shaft needle bearing contact area22.984-23.000 mm (0.9049-0.9055 in.)When worn or damaged
5th gear collar diameter at needle bearing contact area39.975-39.991 mm (1.5738-1.5744 in.)When worn or damaged
5th gear collar length48.7-48.8 mm (1.917-1.921 in.)
5th gear collar flange thickness5.15-5.30 mm (0.203-0.209 in.)When worn or damaged
5th gear I.D.46.000-46.016 mm (1.8110-1.8116 in.)When worn or damaged
5th gear axial clearance0.10-0.22 mm (0.004-0.009 in.)
Sealing ring thickness1.90-1.96 mm (0.074-0.077 in.)1.85 mm (0.073 in.)
Sealing ring groove width2.025-2.060 mm (0.080-0.081 in.)2.08 mm (0.082 in.)
CountershaftDiameter at bearing contact areaTorque converter housing bearing40.505-40.515 mm (1.5947-1.5951 in.)When worn or damaged
5th gear34.975-34.991 mm (1.3770-1.3776 in.)When worn or damaged
Diameter of 2nd gear at needle bearing contact area56.975-56.991 mm (2.2431-2.2437 in.)When worn or damaged
Reverse gear collar O.D.39.979-40.000 mm (1.5740-1.5748 in.)When worn or damaged
Reverse selector hub O.D.55.885-55.900 mm (2.200-2.201 in.)When worn or damaged
Cotter thickness1.99-2.02 mm (0.078-0.080 in.)
I.D. of gears5th gear41.000-41.016 mm (1.6142-1.6148 in.)When worn or damaged
Idler gear65.000-65.019 mm (2.5590-2.5598 in.)When worn or damaged
Reverse gear46.000-46.016 mm (1.8110-1.8116 in.)When worn or damaged
Axial clearance of gears2nd gear0.005-0.040 mm (0.0002-0.0016 in.)
5th gear0.12-0.27 mm (0.0047-0.0106 in.)
Idler gear0.005-0.040 mm (0.0002-0.0016 in.)
Reverse gear0.10-0.25 mm (0.0039-0.0098 in.)
56 mm washer thicknessA1.525 mm (0.0600 in.)When worn or damaged
B1.505 mm (0.0593 in.)When worn or damaged
C1.485 mm (0.0585 in.)When worn or damaged
D1.465 mm (0.0577 in.)When worn or damaged
E1.445 mm (0.0569 in.)When worn or damaged
F1.425 mm (0.0561 in.)When worn or damaged
G1.405 mm (0.0553 in.)When worn or damaged
50.2 mm washer thicknessA3.95 mm (0.1555 in.)When worn or damaged
B3.97 mm (0.1563 in.)When worn or damaged
C3.99 mm (0.1571 in.)When worn or damaged
D4.01 mm (0.1579 in.)When worn or damaged
E4.03 mm (0.1587 in.)When worn or damaged
F4.05 mm (0.1594 in.)When worn or damaged
G4.07 mm (0.1602 in.)When worn or damaged
H4.09 mm (0.1610 in.)When worn or damaged
I4.11 mm (0.1618 in.)When worn or damaged
J4.13 mm (0.1626 in.)When worn or damaged
K4.15 mm (0.1634 in.)When worn or damaged
L4.17 mm (0.1642 in.)When worn or damaged
M4.19 mm (0.1650 in.)When worn or damaged
N4.21 mm (0.1657 in.)When worn or damaged
O4.23 mm (0.1665 in.)When worn or damaged
P4.25 mm (0.1673 in.)When worn or damaged
Q4.27 mm (0.1681 in.)When worn or damaged
R4.29 mm (0.1689 in.)When worn or damaged
S4.31 mm (0.1697 in.)When worn or damaged
T4.33 mm (0.1705 in.)When worn or damaged
U4.35 mm (0.1713 in.)When worn or damaged
35 x 47 mm thrust washer thickness5.97-6.00 mm (0.2350-0.2362 in.)When worn or damaged
Secondary shaftDiameter at bearing contact area2nd gear43.986-43.999 mm (1.7317-1.7322 in.)When worn or damaged
Torque converter housing bearing32.002-32.015 mm (1.2599-1.2604 in.)When worn or damaged
Torque converter housing bearing (shaft end side)28.592-28.608 mm (1.1257-1.1263 in.)When worn or damaged
Diameter of 1st gear collar at needle bearing contact area38.975-38.991 mm (1.5344-1.5351 in.)When worn or damaged
I.D. of gears1st gear44.000-44.016 mm (1.7323-1.7329 in.)When worn or damaged
2nd gear50.00-50.02 mm (1.9685-1.9693 in.)When worn or damaged
Axial clearance of gears1st gear0.085-0.130 mm (0.0033-0.0051 in.)
2nd gear0.06-0.23 mm (0.0024-0.0091 in.)
52 mm thrust washer thicknessA2.405 mm (0.095 in.)When worn or damaged
B2.430 mm (0.096 in.)When worn or damaged
C2.455 mm (0.097 in.)When worn or damaged
D2.480 mm (0.098 in.)When worn or damaged
E2.505 mm (0.099 in.)When worn or damaged
F2.530 mm (0.100 in.)When worn or damaged
G2.555 mm (0.101 in.)When worn or damaged
H2.580 mm (0.102 in.)When worn or damaged
I2.605 mm (0.103 in.)When worn or damaged
J2.630 mm (0.104 in.)When worn or damaged
K2.655 mm (0.105 in.)When worn or damaged
L2.680 mm (0.106 in.)When worn or damaged
M2.705 mm (0.106 in.)When worn or damaged
1st gear collar length63.3-63.4 mm (2.4921-2.4961 in.)
Sealing ring thickness1.91 -1.97 mm (0.075-0.078 in.)1.86 mm (0.073 in.)
Sealing ring groove width2.025-2.060 mm (0.080-0.081 in.)2.08 mm (0.082 in.)
ATF feed pipe O.D.1st clutch11.47-11.48 mm (0.4516-0.4520 in.)11.45 mm (0.4508 in.)
1st-hold clutch5.97-5.98 mm (0.2350-0.2354 in.)5.95 mm (0.2343 in.)
Feed pipe bushing I.D.1st clutch11.518-11.530 mm (0.4535-0.4539 in.)11.545 mm (0.4545 in.)
1st-hold clutch6.018-6.030 mm (0.2369-0.2374 in.)6.045 mm (0.2380 in.)
65 mm thrust shim thickness0A0.80 mm (0.031 in.)When worn or damaged
A0.84 mm (0.033 in.)When worn or damaged
B0.88 mm (0.035 in.)When worn or damaged
C0.92 mm (0.036 in.)When worn or damaged
D0.96 mm (0.038 in.)When worn or damaged
E1.00 mm (0.039 in.)When worn or damaged
F1.04 mm (0.041 in.)When worn or damaged
G1.08 mm (0.043 in.)When worn or damaged
H1.12 mm (0.044 in.)When worn or damaged
I1.16 mm (0.046 in.)When worn or damaged
J1.20 mm (0.047 in.)When worn or damaged
K1.24 mm (0.049 in.)When worn or damaged
L1.28 mm (0.050 in.)When worn or damaged
M1.32 mm (0.052 in.)When worn or damaged
N1.36 mm (0.054 in.)When worn or damaged
O1.40 mm (0.055 in.)When worn or damaged
P1.44 mm (0.057 in.)When worn or damaged
Q1.48 mm (0.058 in.)When worn or damaged
R1.52 mm (0.060 in.)When worn or damaged
S1.56 mm (0.061 in.)When worn or damaged
T1.60 mm (0.063 in.)When worn or damaged
U1.64 mm (0.065 in.)When worn or damaged
V1.68 mm (0.066 in.)When worn or damaged
W1.72 mm (0.068 in.)When worn or damaged
X1.76 mm (0.069 in.)When worn or damaged
Y1.80 mm (0.071 in.)When worn or damaged
Z1.84 mm (0.072 in.)When worn or damaged
AA1.88 mm (0.074 in.)When worn or damaged
AB1.92 mm (0.076 in.)When worn or damaged
AC1.96 mm (0.077 in.)When worn or damaged
AD2.00 mm (0.079 in.)When worn or damaged
AE2.04 mm (0.080 in.)When worn or damaged
AF2.08 mm (0.082 in.)When worn or damaged
AG2.12 mm (0.083 in.)When worn or damaged
AH2.16 mm (0.085 in.)When worn or damaged
AI2.20 mm (0.087 in.)When worn or damaged
AJ2.24 mm (0.088 in.)When worn or damaged
AK2.28 mm (0.090 in.)When worn or damaged
AL2.32 mm (0.091 in.)When worn or damaged
Intermediary shaftI.D. of 3rd gear36.000-36.016 mm (1.4173-1.4179 in.)When worn or damaged
Axial clearance of 3rd gear0.005-0.045 mm (0.0002-0.0018 in.)
Cotter thickness2.99-3.02 mm (0.1177-0.1189 in.)
Sealing ring thickness1.89-1.95 mm (0.0744-0.0768 in.)1.84 mm (0.0724 in.)
Sealing ring groove width2.025-2.060 mm (0.080-0.081 in.)2.08 mm (0.082 in.)
53 mm splined washer thicknessA3.995 mm (0.1573 in.)When worn or damaged
B4.015 mm (0.1581 in.)When worn or damaged
C4.035 mm (0.1589 in.)When worn or damaged
D4.055 mm (0.1596 in.)When worn or damaged
E4.075 mm (0.1604 in.)When worn or damaged
F4.095 mm (0.1612 in.)When worn or damaged
G4.115 mm (0.1620 in.)When worn or damaged
H4.135 mm (0.1628 in.)When worn or damaged
I4.155 mm (0.1636 in.)When worn or damaged
J4.175 mm (0.1644 in.)When worn or damaged
K4.195 mm (0.1652 in.)When worn or damaged
L4.215 mm (0.1659 in.)When worn or damaged
M4.235 mm (0.1667 in.)When worn or damaged
N4.255 mm (0.1675 in.)When worn or damaged
26.5 mm washer thicknessA1.05 mm (0.041 in.)When worn or damaged
B1.13 mm (0.044 in.)When worn or damaged
C1.21 mm (0.048 in.)When worn or damaged
D1.29 mm (0.051 in.)When worn or damaged
E1.37 mm (0.054 in.)When worn or damaged
F1.45 mm (0.057 in.)When worn or damaged
G1.53 mm (0.060 in.)When worn or damaged
H1.61 mm (0.063 in.)When worn or damaged
I1.69 mm (0.067 in.)When worn or damaged
J1.77 mm (0.070 in.)When worn or damaged
K1.85 mm (0.073 in.)When worn or damaged
L1.93 mm (0.076 in.)When worn or damaged
M2.01 mm (0.079 in.)When worn or damaged
N2.09 mm (0.082 in.)When worn or damaged
Reverse idler gearGear shaft O.D.13.99-14.00 mm (0.5508-0.5512 in.)When worn or damaged
I.D. of transmission housing of gear shaft contact area14.006-14.024 mm (0.5514-0.5521 in.)
I.D.18.007-18.020 mm (0.7089-0.7094 in.)When worn or damaged
Axial clearance0.07-0.38 mm (0.003-0.015 in.)
Thrust washer thicknessTransmission housing0.97-1.05 mm (0.038-0.041 in.)
Holder side0.97-1.05 mm (0.038-0.041 in.)

AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL STANDARDS AND SERVICE LIMITS (1 OF 3)

ItemMeasurementQualificationStandard or New
Wire DiameterO.DFree LengthNo. of Coil
Main valve body spring (see MAIN VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY )Cooler check valve spring0.6 mm (0.024 in.)5.8 mm (0.228 in.)14.5 mm (0.571 in.)6.8
Lock-up timing valve spring0.65 mm (0.026 in.)6.6 mm (0.260 in.)34.8 mm (1.370 in.)15.6
Shift valve D spring0.7 mm (0.028 in.)6.6 mm (0.260 in.)32.2 mm (1.268 in.)13.4
Shift valve B spring0.8 mm (0.031 in.)6.6 mm (0.260 in.)49.1 mm (1.933 in.)21.7
Shift valve A spring0.8 mm (0.031 in.)6.6 mm (0.260 in.)49.1 mm (1.933 in.)21.7
Modulator valve spring1.6 mm (0.063 in.)10.4 mm (0.409 in.)33.5 mm (1.319 in.)9.8
CPC valve C spring0.7 mm (0.028 in.)6.1 mm (0.240 in.)17.8 mm (0.701 in.)7.9
Shift valve E spring0.8 mm (0.031 in.)7.1 mm (0.280 in.)49.0 mm (1.929 in.)17.2
Torque converter check valve spring1.1 mm (0.043 in.)8.6 mm (0.339 in.)35.0 mm (1.378 in.)12.6
Relief valve spring1.1 mm (0.043 in.)8.6 mm (0.339 in.)32.1 mm (1.264 in.)11.2
Lubrication control valve spring0.7 mm (0.028 in.)7.7 mm (0.303 in.)28.8 mm (1.134 in.)10.4
Lock-up shift valve spring0.9 mm (0.035 in.)7.6 mm (0.299 in.)63.0 mm (2.480 in.)22.4
Secondary valve body spring (see SECONDARY VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY )Reverse CPC valve spring0.7 mm (0.028 in.)6.1 mm (0.240 in.)17.8 mm (0.701 in.)7.9
Servo control valve spring0.7 mm (0.028 in.)6.6 mm (0.260 in.)35.7 mm (1.406 in.)17.2
Shift valve C spring0.8 mm (0.031 in.)6.6 mm (0.260 in.)49.1 mm (1.933 in.)21.7
CPC valve A spring0.7 mm (0.028 in.)6.1 mm (0.240 in.)17.8 mm (0.701 in.)7.9
Kick-down valve spring0.8 mm (0.031 in.)6.6 mm (0.260 in.)49.1 mm (1.933 in.)21.7
CPC valve A spring0.7 mm (0.028 in.)6.1 mm (0.240 in.)17.8 mm (0.701 in.)7.9
Regulator valve body spring (see REGULATOR VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY )3rd accumulator spring3.1 mm (0.122 in.)19.6 mm (0.772 in.)41.4 mm (1.630 in.)5.5
Lock-up control valve spring0.7 mm (0.028 in.)6.6 mm (0.260 in.)42.9 mm (1.689 in.)14.2
0.8 mm (0.031 in.)6.6 mm (0.260 in.)44.3 mm (1.744 in.)25.5
Regulator valve spring B1.4 mm (0.055 in.)8.8 mm (0.346 in.)44.0 mm (1.732 in.)12.0
Regulator valve spring A1.85 mm (0.073 in.)14.7 mm (0.579 in.)86.9 mm (3.421 in.)16.2
Stator reaction spring5.5 mm (0.217 in.)37.4 mm (1.472 in.)30.3 mm (1.193 in.)2.1
Accumulator body spring (see ACCUMULATOR BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY )1st-hold accumulator spring2.0 mm (0.079 in.)13.1 mm (0.516 in.)42.9 mm (1.689 in.)9.8
4th accumulator spring3.0 mm (0.118 in.)19.6 mm (0.772 in.)45.3 mm (1.783 in.)6.4
1st accumulator spring A2.2 mm (0.087 in.)17.7 mm (0.697 in.)77.6 mm (3.055 in.)12.1
1st accumulator spring B2.0 mm (0.079 in.)11.1 mm (0.437 in.)49.0 mm (1.929 in.)10.0
2nd accumulator spring3.1 mm (0.122 in.)19.6 mm (0.772 in.)53.4 mm (2.102 in.)7.5
5th accumulator spring A2.2 mm (0.087 in.)16.4 mm (0.646 in.)75.7 mm (2.980 in.)14.2
5th accumulator spring B2.0 mm (0.079 in.)10.0 mm (0.394 in.)45.5 mm (1.791 in.)11.6

AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL STANDARDS AND SERVICE LIMITS (2 OF 3)

ItemMeasurementQualificationStandard or NewService Limit
A/T differential carrierPinion shaft contact area I.D.18.000-18.025 mm (0.7087-0.7096 in.)
Carrier-to-pinion shaft clearance0.013-0.054 mm (0.0005-0.0021 in.)0.1 mm (0.004 in.)
Driveshaft contact area I.D.30.025-30.055 mm (1.182-1.183 in.)
Carrier-to-driveshaft clearance0.045-0.096 mm (0.002-0.004 in.)0.13 mm (0.005 in.)
Carrier-to-intermediate shaft clearance0.080-0.126 mm (0.003-0.005 in.)
Tapered roller bearing starting torque (preload)For new bearing3.9-5.1 N.m (40-52 kgf.cm, 35-45 lbf.in.)Adjust
For used bearing3.6-4.8 N.m (37-49 kgf.cm, 32-43 lbf.in.)Adjust
A/T differential pinion gearBacklash0.05-0.15 mm (0.002-0.006 in.)
I.D.18.042-18.066 mm (0.7103-0.7113 in.)
Pinion gear-to-pinion shaft clearance0.055-0.095 mm (0.0022-0.0037 in.)0.12 mm (0.005 in.)
Transfer output shaftDiameter at bearing contact areaTransmission housing side21.977-21.990 mm (0.8652-0.8657 in.21.92 mm (0.8630 in.)
Torque converter housing side40.002-40.018 mm (1.5749-1.5755 in.)39.95 mm (1.5728 in.)
Axial clearance0-0.39 mm (0-0.015 in.)
28.5 mm thrust washer thicknessA1.82 mm (0.0717 in.)When worn or damaged
B1.84 mm (0.0724 in.)When worn or damaged
C1.86 mm (0.0732 in.)When worn or damaged
D1.88 mm (0.0740 in.)When worn or damaged
E1.90 mm (0.0748 in.)When worn or damaged
F1.92 mm (0.0756 in.)When worn or damaged
G1.94 mm (0.0764 in.)When worn or damaged
H1.96 mm (0.0772 in.)When worn or damaged
I1.98 mm (0.0780 in.)When worn or damaged
J2.00 mm (0.0787 in.)When worn or damaged
K2.02 mm (0.0795 in.)When worn or damaged
L2.04 mm (0.0803 in.)When worn or damaged
M2.06 mm (0.0811 in.)When worn or damaged
N2.08 mm (0.0819 in.)When worn or damaged
O2.10 mm (0.0827 in.)When worn or damaged
P2.12 mm (0.0835 in.)When worn or damaged
Q2.14 mm (0.0843 in.)When worn or damaged
R2.16 mm (0.0850 in.)When worn or damaged
S2.18 mm (0.0858 in.)When worn or damaged
T2.20 mm (0.0866 in.)When worn or damaged
U2.22 mm (0.0874 in.)When worn or damaged
V2.24 mm (0.0882 in.)When worn or damaged
W2.26 mm (0.0890 in.)When worn or damaged
X2.28 mm (0.0898 in.)When worn or damaged
Y2.30 mm (0.0906 in.)When worn or damaged
Z2.32 mm (0.0913 in.)When worn or damaged
AA2.34 mm (0.0921 in.)When worn or damaged
Transfer assembly fluidCapacityFluid change0.43 L (0.45 us qt)
Overhaul0.45 L (0.48 us qt)
Transfer assemblyDiameter of transfer hypoid drive gear/shaft assembly at tapered roller bearing contact areaTransfer cover side50.002-50.018 mm (1.9686-1.9692 in.)49.95 mm (1.9665 in.)
Transfer gear side24.987-25.000 mm (0.9837-0.9843 in.)24.93 mm (0.9815 in.)
Diameter of transfer output shaft (hypoid gear) at tapered roller bearing contact areaTransfer gear side40.002-40.018 mm (1.5749-1.5755 in.)39.95 mm (1.5728 in.)
Companion flange side27.975-27.990 mm (1.1014-1.1020 in.)27.92 mm (1.0992 in.)
Transfer gear backlash0.06-0.17 mm (0.002-0.007 in.)Adjust
Tapered roller bearing total starting torque (preload)3.20-4.16 N.m (32.6-42.4 kgf.cm, 28.3-36.8 lbf.in.)Adjust

AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL SPECIFICATIONS (3 OF 3)

Rear Differential

ItemMeasurementQualificationStandard or New
Rear differential fluidCapacity Use Honda VTM-4 Differential FluidFluid replacement2.64 L (2.79 US qt)

REAR DIFFERENTIAL STANDARDS AND SERVICE LIMITS

Steering

ItemMeasurementQualificationStandard or NewService Limit
Steering wheelRotational play measured at outside edgeWith engine running0-10 mm (0-0.39 in.)
Starting load measured at outside edgeWith engine running29 N (3.0 kgf, 6.5 lbf)If higher, check gearbox and pump
GearboxAngle of rack guide screw loosened from locked position20° max. Tighten lock nut to 25 N.m (2.5 kgf.m, 18 lbf.ft)
PumpOutput pressure with shut-off valve closed8,300-8,800 kPa (85-90 kgf/cm 2 , 1,210-1,280 psi)
Power steering fluidCapacity Use Honda power steering fluidReservoir capacity0.4 L (0.42 US qt)
System capacityWith accessory power steering cooler: 1.26 L (1.33 US qt) Without accessory power steering cooler: 1.22 L (1.29 US qt)

STEERING STANDARDS AND SERVICE LIMITS

Suspension

ItemMeasurementQualificationStandard or NewService Limit
Wheel alignmentCamber4WDFront0° 30'+/-1°
Rear0° 30 '+/-45'
2WDFront0° 40'+/-1°
Rear0° 40'+/-45'
Caster4WDFront1° 53'+/-1°
2WDFront1° 59'+/-1°
Total Toe-in4WDFront0+/-2 mm (0+/-1/16 in.)
Rear0+/-2 mm (0+/-1/16 in.)
2WDFront0+/-2 mm (0+/-1/16 in.)
Rear2+/-2 mm (1/16+/-1/16 in.)
Front wheel turning angle4WDInside wheel38° 08'
Outside wheel30° 19' (Reference)
2WDInside wheel37° 52'
Outside wheel30° 10' (Reference)
WheelRunoutAxial0-7.0 mm (0-0.03 in.)2.0 mm (0.08 in.)
Radial0-7.0 mm (0-0.03 in.)1.5mm (0.06 in.)
Wheel bearingEnd playFront0-0.05 mm (0-0.002 in.)
Rear0-0.05 mm (0-0.002 in.)

SUSPENSION STANDARDS AND SERVICE LIMITS

Brakes

ItemMeasurementQualificationStandard or NewService Limit
Parking brake pedalNumber of clicks when pressed with 294 N (30 kgf, 66 lbf) of force4 to 6 clicks
Drum I.D209.9-210.0 mm (8.264-8.267 in.)211.0 mm (8.307 in.)
Shoe lining thickness4.0 mm (0.16 in.)1.0 mm (0.04 in.)
Brake pedalPedal height (carpet removed)155 mm (6 1/32 in.)
Free play1-5 mm (1/16-3/16 in.)
Brake discThicknessFront27.9-28.1 mm (1.10-1.11 in.)26.0 mm (1.02 in.)
Rear10.9-11.1 mm (0.43-0.44 in.)9 mm (0.35 in.)
Runout0.4 mm (0.0016 in.)
Parallelism0.015 mm (0.0006 in.)
Brake padThicknessFront10.5-11.5 mm (0.41-0.45 in.)1.6 mm (0.06 in.)
Rear9.5-10.5 mm (0.37-0.41 in.)1.6 mm (0.06 in.)

BRAKES STANDARDS AND SERVICE LIMITS

Air Conditioning

ItemMeasurementQualificationStandard or New
RefrigerantTypeHFC-134a (R-134a)
Capacity of systemDual700-750 g (24.7-26.5 oz.)
Refrigerant oilTypeND-OIL 8 (P/N 38897--PR7--A01AH or 38899--PR7--A01)
Capacity of componentsCondenser35 mL (1 1/6 fl oz)
Evaporator (front)40 mL (1 1/3 fl oz)
Evaporator (rear)30 mL (1 fl oz)
Each line and hose10 mL (1/3 fl oz)
Compressor180-195 mL (6-6 3/5 fl oz)
Compressor (DENSO)Starter coil resistanceAt 68°F (20°C)3.9-4.3 ohms
Pulley-to-pressure plate clearance0.35-0.60 mm (0.014-0.024 in.)

AIR CONDITIONING STANDARDS AND SERVICE LIMITS

ItemMeasurementQualificationSpecification
DIMENSIONSOverall length4,775 mm (188.0 in.)
Overall widthLX, LX-VP1,963 mm (76.5 in.)
EX, EX-SE, EXL1,968 mm (77.5 in)
Overall height4WD1,793 mm (70.6 in.)
2WD1,780 mm (70.1 in)
Wheelbase2,700 mm (106.3 in.)
TrackFront (4WD)1,685 mm (66.3 in.)
Front (2WD)1,690 mm (66.5 in.)
Rear (4WD)1,690 mm (66.5 in)
Rear (2WD)1,694 mm (66.7 in)
Ground clearance4WD203 mm (8.0 in.)
2WD198 mm (7.8 in)
Seating capacityEight (8)
WEIGHTGross Vehicle Weight Rating (GVWR)4WD2,700 kg (5,950 lbs)
2WD2,650 kg (5,841 lbs)
ENGINETypeJ35A9Water-cooled, 4-stroke SOHC VTEC V6 gasoline engine
J35Z1Water-cooled, 4-stroke Variable Cylinder Management V6 gasoline engine
Cylinder arrangement60° V6-cylinder, transverse
Bore and stroke89.0 x 93.0 mm (3.50 x 3.66 in.)
Displacement3,471 cm 3 (mL) (211.8 cu in.)
Compression ratio10.0
Valve trainJ35A9Belt driven, SOHC VTEC 4 valves per cylinder
J35Z1Belt driven, SOHC i-VTEC 4 valves per cylinder
Lubrication systemForced, wet sump, with trochoid pump
Oil pump displacementAt 6,000 rpm58.4 L (61.7 US qt)/minute
Water pump displacementAt 6,000 rpm172 L (182 US qt)/minute
Fuel requiredNormal drivingRegular UNLEADED gasoline with 87 Pump Octane Number or higher
TowingPremium UNLEADED gasoline 91 Pump Octane Number or higher is recommended when towing load is more than 1,590 kg (3,500 lbs.)
STARTERTypeGear reduction
Normal output1.6 kW
Normal voltage12 V
Hour rating30 seconds
Direction of rotationClockwise as viewed from gear end
AUTOMATIC TRANSMISSIONTypeBVLA (2WD) BVGA (4WD)Electronically-controlled automatic, 5-speed forward, 1 reverse, 3-element torque converter with lock-up clutch
Primary reductionDirect 1:1
Gear ratio1st2.693
2nd1.565
3rd1.023
4th0.726
5th0.530
Reverse1.888
Final reductionTypeSingle helical gear
Gear ratio4.375
STEERINGTypeHydraulic power-assisted rack and pinion
Gear ratio42.3
Overall ratio16.9
Turns, lock-to-lock3.22
Steering wheel diameter386 mm (15.2 in.)
SUSPENSIONTypeFrontStrut with "L" arm
RearMulti-link with trailing arm
Shock absorberFrontTwin tube gas
RearTwin tube gas
TIRESSize of front and rear tiresP235/70R16 104S
Size of spare tireT155/90D16 110M
WHEEL ALIGNMENTCamberFront (4WD)0° 30'
Rear (4WD)0° 30'
Front (2WD)0° 40'
Rear (2WD)0° 40'
CasterFront (4WD)1° 53'
Front (2WD)1° 59'
Total Toe-inFront0 mm (0 in.)
Rear (4WD)0 mm (0 in.)
Rear (2WD)2 mm (1/16 in.)
SAI at camber (kingpin axis)11° 54'
BRAKESType of service brakeFrontPower-assisted self-adjusting ventilated disc
RearPower-assisted self-adjusting solid disc
Type of parking brakeFoot type mechanical actuating, rear wheels
Pad friction surface area (swept area)Front364.1 cm 2 (56.44 sq in.)
Rear325.1 cm 2 (50.39 sq in.)
AIR CONDITIONINGCooling capacityFront4,375 kcal/h (17,300 BTU/h)
Rear3,119 kcal/h (12,400 BTU/h)
CompressorType/ManufacturerSwash plate/DENSO
Number of cylinders10
Capacity215 mL/rev. (13.12 cu in./rev.)
Maximum speed7,600 rpm
Lubricant capacity180 mL (6 fl oz)
Lubricant typeDENSO ND-OIL 8
CondenserTypeCorrugated fin
EvaporatorTypeCorrugated fin
BlowerTypeSirocco fan
Motor input (front)228W/12 V
Motor input (rear)125W/12 V
Speed control (Front: Auto A/C)Infinite variable
Speed control (Front: Manual A/C)7-speed
Speed control (Rear: Auto A/C)Infinite variable
Speed control (Rear: Manual A/C)3-speed
Maximum capacity (front)490 m 3 /h (17,300 cu ft/h)
Maximum capacity (rear)310 m 3 /h (11,000 cu ft/h)
Temperature controlAir-mix type
Compressor clutchTypeDry, single plate, Poly-V belt drive
Electrical power consumption at 68°F (20°C)35 W maximum at 12 V
RefrigerantTypeHFC-134a (R-134a)
Quantity (dual)700-750 g (24.7-26.5 oz)
ELECTRICAL RATINGSBattery12 V-20 AH/5 hours
FusesUnder-hood fuse/relay box120 A, 50 A, 40 A, 30 A, 20 A, 15 A, 7.5 A
Driver's under-dash fuse/ relay box30 A, 15 A, 10 A, 7.5 A
Auxiliary under-hood fuse box40 A, 30 A, 20 A, 15 A, 7.5 A
Passenger's under-dash fuse/relay box20 A, 15 A, 10 A, 7.5 A
Light bulbsHeadlight high beam12V-60 W (HB3)
Headlight low beam12V-55 W (H11)
Front fog light12V-55 W
Front turn signal/hazard light12V-21 W
Front parking lights12V-5 W
Front side marker lights12V-5 W
Front side turn signal light12V-5 W
Rear turn signal/hazard/tail lights12V-21/5 W
Rear side marker lights12V-3CP
Brake/Taillights12V-21/5 W
High mount brake light12V-18 W
Back-up lights12V-21 CP
License plate light12V-5 W
Tailgate light12V-5 W
Vanity mirror lights12V-1.1 W
Front individual map lights12V-5 W
2nd and 3rd Roll Rear individual map lights12V-5 W
Courtesy light12V-3.8 W
Gauge lights12 V-LED Non-replaceable
Indicators12 V-LED Non-replaceable
Ambient light12 V-LED Non-replaceable
Heater control panel lights LX14V-5.9 W
Climate control unit lights EX14V-3.4 W, 10V-1.8 W
Rear heater control panel lights14V-1.4 W
Glove box light12V-3.4 W
Console box light12V-1.4 W

DESIGN SPECIFICATIONS

Scheme 1

Scheme 1: Body Specifications