Contents Section: Mechanical - Hydraulic All sections

Engine Controls - Specifications: Other Honda S2000 AP2 рестайлинг

Engine Electrical System

ItemMeasurementQualificationStandard or NewService Limit
Ignition coilRated voltage12 V
Firing order1-3-4-2
Spark plugTypeNGK: PFR7G11S DENSO: PK22PR-L11S
Gap1.0-1.1 mm (0.039-0.043 in.)
Ignition timingAt idle Check the red markIn neutral5+/-2° BTDC
Drive beltTensionAuto tensioner
AlternatorOutputAt 13.5 V and normal engine temperature105 A
Brush length10.5 mm (0.41 in.)1.5 mm (0.06 in.)
StarterOutput2000-2003 models1.0 kW
2004-2009 models1.1 kW
Commutator mica depth0.4-0.5 mm (0.016-0.020 in.)0.15 mm (0.006 in.)
Commutator runout0.02 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 length15.8-16.2 mm (0.62-0.64 in.)11.0 mm (0.43 in.)
Brush spring tension (new)15.7-17.7 N (1.60-1.80 kgf, 3.53-3.97 lbf)

ENGINE ELECTRICAL STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Cylinder Head

ItemMeasurementQualificationStandard or NewService Limit
HeadWarpage0.05 mm (0.002 in.)
Height104.95-105.05 mm (4.132-4.136 in.)
CamshaftEnd play0.05-0.15 mm (0.002-0.006 in.)0.30 mm (0.012 in.)
Camshaft-to-holder oil clearance0.060-0.099 mm (0.002-0.004 in.)0.15 mm (0.006 in.)
Total runout0.03 mm (0.001 in.) max.0.04 mm (0.002 in.)
Cam lobe height (2000-2003 models)Intake, primary33.677 mm (1.326 in.)
Intake, mid36.533 mm (1.438 in.)
Intake, secondary33.961 mm (1.337 in.)
Exhaust, primary33.716 mm (1.327 in.)
Exhaust, mid35.928 mm (1.414 in.)
Exhaust, secondary33.994 mm (1.338 in.)
Cam lobe height (2004-2009 models)Intake, primary33.961 mm (1.337 in.)
Intake, mid36.421 mm (1.434 in.)
Intake, secondary33.961 mm (1.337 in.)
Exhaust, primary33.716 mm (1.327 in.)
Exhaust, mid35.660 mm (1.404 in.)
Exhaust, secondary33.716 mm (1.327 in.)
ValveClearance (cold)Intake0.21-0.25 mm (0.008-0.010 in.)
Exhaust0.25-0.29 mm (0.010-0.011 in.)
Stem O.D.Intake5.48-5.49 mm (0.2157-0.2162 in.)5.45 mm (0.215 in.)
Exhaust5.45-5.46 mm (0.2146-0.2150 in.)5.42 mm (0.213 in.)
Stem-to-guide clearanceIntake0.02-0.05 mm (0.001-0.002 in.)0.08 mm (0.003 in.)
Exhaust0.05-0.08 mm (0.002-0.003 in.)0.11 mm (0.004 in.)
Valve seatWidthIntake1.05-1.35 mm (0.041-0.053 in.)1.80 mm (0.071 in.)
Exhaust1 25-1.55 mm (0.049-0.061 in.)2.00 mm (0.079 in.)
Stem installed heightIntake44.1-44.4 mm (1.736-1.748 in.)44.7 mm (1.760 in.)
Exhaust44.2-44.5 mm (1.740-1.752 in.)44.8 mm (1.764 in.)
Valve springFree length2000-2003 models Intake49.77 mm (1.959 in.)
2004-2009 models Intake49.76 mm (1.959 in)
Exhaust50.39 mm (1.984 in.)
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 heightIntake15.2-16.2 mm (0.598-0.638 in.)
Exhaust16 0-17.0 mm (0.630-0.669 in.)
Rocker armArm-to-shaft clearanceIntake0.021-0.041 mm (0.0008-0.0016 in.)0.07 mm (0.003 in.)
Exhaust0.021-0.041 mm (0.0008-0.0016 in.)0.07 mm (0.003 in.)

CYLINDER HEAD STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Engine Block

ItemMeasurementQualificationStandard or NewService Limit
BlockWarpage of deck0.07 mm (0.003 in.) max.0.10 mm (0.004 in.)
Bore diameterA or I87.010-87.020 mm (3.4256-3.4260 in.)87.070 mm (3.4279 in.)
B or II87.000-87.010 mm (3.4252-3.4256 in.)87.070 mm (3.4279 in.)
Bore taper0.05 mm (0.002 in.)
Reboring limit0.25 mm (0.01 in.)
PistonSkirtNo letter86.993-87.006 mm (3.4249-3.4254 in.)86.980 mm (3.4244 in.)
Letter B86.983-86.996 mm (3.4245-3.4250 in.)86.970 mm (3.4240 in.)
Clearance in cylinder0.004-0.027 mm (0.0002-0.0011 in.)0.04 mm (0.002 in.)
Ring groove widthTop1.235-1.265 mm (0.0486-0.0498 in.)1.285 mm (0.0506 in.)
Second1.230-1.245 mm (0.0484-0.0490 in.)1.265 mm (0.0498 in.)
Oil2.005-2.025 mm (0.0789-0.0797 in.)2.05 mm (0.081 in.)
Piston ringRing-to-groove clearanceTop0.045-0.090 mm (0.0018-0.0035 in.)0.135 mm (0.005 in.)
Second0.040-0.070 mm (0.0016-0.0028 in.)0.13 mm (0.005 in.)
Ring end gapTop0.25-0.35 mm (0.010-0.014 in.)0.60 mm (0.024 in.)
Second0.60-0.75 mm (0.024-0.030 in.)0.90 mm (0.035 in.)
Oil0.20-0.70 mm (0.008-0.028 in.)0.80 mm (0.031 in.)
Piston pinO.D.22.961-22.965 mm (0.9040-0.9041 in.)22.953 mm (0.9037 in.)
Pin-to-piston clearance0.0020 to +0.0050 mm (-0.00008 to +0.00020 in.)0.010 mm (0.0004 in.)
Connecting rodPin-to-rod clearance0.018-0.035 mm (0.0007-0.0014 in.)0.04 mm (0.0016 in.)
Small-end bore diameter22.983-22.996 mm (0.9048-0.9053 in.)
Large-end bore diameter (Normal)51.0 mm (2.01 in.)
End play installed on crankshaft0.15-0.30 mm (0.006-0.012 in.)0.40 mm (0.016 in.)
CrankshaftMain journal diameter54.976-55.000 mm (2.1644-2.1654 in.)
Rod journal diameter47.976-48.000 mm (1.8888-1.8898 in.)
Rod/main journal taper0.005 mm (0.0002 in.) max.0.006 mm (0.0002 in.)
Rod/main journal out-of-round0.004 mm (0.0002 in.) max.0.006 mm (0.0002 in.)
End play0.10-0.35 mm (0.004-0.014 in.)0.45 mm (0.018 in.)
Runout0.02 mm (0.0008 in.) max.0.04 mm (0.0016 in.)
Crankshaft bearingMain bearing-to-journal oil clearance0.017-0.041 mm (0.0007-0.0016 in.)0.050 mm (0.0020 in.)
Rod bearing clearance0.030-0.054 mm (0.0012-0.0021 in.)0.060 mm (0.0024 in.)

ENGINE BLOCK STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Engine Cooling System

ItemMeasurementQualificationStandard or New
RadiatorCoolant capacities (includes engine, heater, hoses, and reservoir) Use Honda Long Life Antifreeze/Coolant Type 2Engine overhaul7.6 L (2.01 US gal)
Coolant change6.5 L (1.72 US gal)
ReservoirCoolant capacity0.6 L (0.16 US gal)
Radiator capOpening pressure93-123 kPa (0.95-1.25 kgf/cm 2 , 14-18 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.
Radiator fan switch (2000-2005 models)Thermoswitch "ON" temperature196-203°F (91-95°C)
Thermoswitch "OFF" temperatureSubtract 5-15°F (3-8°C) from actual "ON" temperature

COOLING STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Engine Fuel System and Engine Emissions System

ItemMeasurementQualificationStandard or New
Fuel pressure regulatorPressure with regulator vacuum hose disconnected2000-2005 models320-370 kPa (3.3-3.8 kgf/cm 2 , 47-54 psi)
2006-2009 models380-430 kPa (3.9-4.4 kgf/cm 2 , 55-63 psi)
Fuel tankCapacity50 L (13.2 US gal)
Engine idleIdle speed without loadIn neutral (2000-2005 models)800+/-50 RPM
In neutral (2006-08 model)900+/-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 (if applicable), and head lights on high beam)In neutral900+/-50 RPM

FUEL AND EMISSIONS STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Clutch Disc & Clutch Pressure Plate

ItemMeasurementQualificationStandard or NewService Limit
Clutch pedalHeightFrom the floor189 mm (7.44 in.)
Stroke115-125 mm (4.53-4.92 in.)
Play9-17 mm (0.4-0.7 in.)
FlywheelRunout on clutch mating surface0.05 mm (0.002 in.) max.0.15 mm (0.006 in.)
Clutch discRivet head depth1.2-1.7 mm (0.047-0.067 in.)0.2 mm (0.008 in.)
Rivet head thickness8.2-8.9 mm (0.32-0.35 in.)6.0 mm (0.24 in.)
Pressure plateWarpage0.03 mm (0.001 in.) max.0.15 mm (0.006 in.)
Height of diaphragm spring fingersMeasure with feeler gauge and special tool0.4 mm (0.016 in.) max.0.6 mm (0.024 in.)

CLUTCH STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Manual Transmission

ItemMeasurementQualificationStandard or NewService Limit
Transmission fluidCapacity Use Honda MTFFluid change1.48 L (1.56 US qt)
Overhaul1.62 L (1.71 US qt)
MainshaftEnd play0.14-0.21 mm (0.006-0.008 in.)Adjust
Diameter of transmission housing ball bearing contact area27.987-28.000 mm (1.1018-1.1024 in.)27.94 mm (1.100 in.)
Diameter of 4th/5th gears contact area34.987-35.000 mm (1.3774-1.3780 in.)34.94 mm (1.376 in.)
Diameter of 6th gear contact area38.984-39.000 mm (1.5348-1.5354 in.)38.94 mm (1.533 in.)
Diameter of clutch housing ball bearing contact area28.002-28.015 mm (1.1024-1.1030 in.)27.95 mm (1.100 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Mainshaft 3rd gearI.D.40.009-40.025 mm (1.5752-1.5758 in.)
Thickness35.09-35.17 mm (1.381-1.385 in.)34.97 mm (1.377 in.)
End play0.06-0.19 mm (0.002-0.007 in.)0.3 mm (0.012 in.)
Mainshaft 3rd gear distance collarI.D.28.002-28.012 mm (1.1024-1.1028 in.)
O.D.34.989-35.000 mm (1.3775-1.3780 in.)
Length35.23-35.28 mm (1.387-1.389 in.)
Mainshaft 4th and 5th gearsI.D.47.009-47.025 mm (1.8507-1.8514 in.)
Thickness31.89-31.97 mm (1.256-1.259 in.)31.77 mm (1.251 in.)
End play0.06-0.19 mm (0.002-0.007 in.)0.3 mm (0.012 in.)
Mainshaft 4th and 5th gears distance collarI.D.35.002-35.012 mm (1.3780-1.3784 in.)
O.D.41.989-42.000 mm (1.6531-1.6535 in.)
Length32.03-32.08 mm (1.261-1.263 in.)
Mainshaft 6th gearI.D.44.009-44.025 mm (1.7326-1.7333 in.)
Thickness28.89-28.97 mm (1.137-1.141 in.)28.77 mm (1.133 in.)
End play0.06-0.19 mm (0.002-0.007 in.)0.3 mm (0.012 in.)
CountershaftDiameter of rear side cover needle bearing contact area30.020-30.029 mm (1.1819-1.1822 in.)29.97 mm (1.180 in.)
Diameter of transmission housing side needle bearing contact area34.002-34.018 mm (1.3387-1.3393 in.)33.95 mm (1.337 in.)
Diameter of 2nd gear contact area43.984-44.000 mm (1.7317-1.7323 in.)43.93 mm (1.730 in.)
Diameter of clutch housing side ball bearing contact area28.002-28.015 mm (1.1024-1.1030 in.)27.95 mm (1.100 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Countershaft 1st gearI.D.57.010-57.029 mm (2.2445-2.2452 in.)
Thickness2000-2003 models31.18-31.26 mm (1.228-1.231 in.)31.06 mm (1.223 in.)
2004-2009 models27.88-27.96 mm (1.098-1.101 in.)27.76 mm (1.093 in.)
End play2000-2003 models0.04-0.22 mm (0.002-0.009 in.)0.3 mm (0.012 in.)
2004-2009 models0.04-0.17 mm (0.002-0.007 in.)
Countershaft 1st gear distance collarO.D.50.987-51.000 mm (2.0074-2.0079 in.)
Length28.03-28.08 mm (1.104-1.106 in.)
Countershaft 2nd gearI.D.43.984-44.000 mm (1.7317-1.7323 in.)
Thickness32.88-32.96 mm (1.294-1.298 in.)32.76 mm (1.290 in.)
End play0.04-0.17 mm (0.002-0.007 in.)0.3 mm (0.012 in.)
Countershaft reverse gearI.D.50.009-50.025 mm (1.9689-1.9695 in.)
Thickness26.38-26.46 mm (1.039-1.042 in.)26.26 mm (1.034 in.)
End play0.04-0.22 mm (0.002-0.009 in.)0.3 mm (0.012 in.)
Countershaft reverse gear distance collarO.D.37.989-38.000 mm (1.4956-1.4961 in.)
Length25.53-25.58 mm (1.005-1.007 in.)
Secondary shaftDiameter of ball bearing contact area31.002-31.013 mm (1.2205-1.2210 in.)30.95 mm (1.219 in.)
Diameter of propeller shaft side tapered roller bearing contact area41.002-41.018 mm (1.6142-1.6149 in.)40.95 mm (1.612 in.)
Diameter of transmission housing side tapered roller bearing contact area35.009-35.025 mm (1.3783-1.3790 in.)34.96 mm (1.376 in.)
Runout0.02 mm (0.001 in.) max.0.05 mm (0.002 in.)
Starting torque (preload)1.86-2.84 N.m (19.0-29.0 kgf.cm, 16.5-25.2 lbf.in.)Adjust
Shift forkFinger thickness1-2 shift fork7 4-7.6 mm (0.29-0.30 in.)
3-4 shift fork6.2-6 4 mm (0.24-0.25 in.)
5-6 shift fork6.2-6.4 mm (0 24-0.25 in.)
Reverse shift fork6.2-6.4 mm (0.24-0.25 in.)
Fork-to-synchro sleeve clearance0.35-0.65 mm (0.014-0.026 in.)1.00 mm (0.039 in.)
GrooveTo 1-2 shift lever17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
To shift arm A17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
Shift arm AI.D.16.000-16.027 mm (0.6299-0.6310 in.)
Finger width16.8-17.0 mm (0.661-0.669 in.)16.7 mm (0.657 in.)
Shift arm A-to-shift forks0.2-0.6 mm (0.008-0.024 in.)0.7 mm (0.028 in.)
1-2 shift leverFinger width17.0-17.2 mm (0.669-0.677 in.)16.9 mm (0.665 in.)
Lever-to-shift forks and pieces clearance0-0.4 mm (0-0.016 in.)0.5 mm (0.020 in.)
1-2 shift pieceGrooveTo shift arm A17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
3-4 shift pieceGrooveTo shift arm A17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
Reverse shift pieceGrooveTo 1-2 shift arm A17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
To shift arm A17.2-17.4 mm (0.677-0.685 in.)17.1 mm (0.673 in.)
Synchro ringRing-to-gear clearance (ring pushed against gear)2000-2003 models 5th and 6th gears0.75-1.00 mm (0.030-0.039 in.)0.4 mm (0.016 in.)
2004-2008 models 3rd, 4th, 5th, and 6th gears0.85-1.10 mm (0.033-0.043 in.)0.4 mm (0.016 in.)
Reverse gear0.85-1.10 mm (0.033-0.043 in.)0.4 mm (0.016 in.)
Double cone synchroOuter syncro ring-to-synchro cone clearance (ring pushed against gear)2000-2003 models 1st and 2nd gears0.70-1.09 mm (0.028-0.043 in.)0.3 mm (0.012 in.)
2004-2009 models 1st and 2nd gears0.58-1.09 mm (0.023-0.043 in.)0.3 mm (0.012 in.)
2000-2003 models 3rd and 4th gears0.90-1.39 mm (0.035-0.055 in.)0.3 mm (0.012 in.)
Synchro cone-to-gear clearance (ring pushed against gear)2000-2003 models 1st, 3rd, and 4th gears0.50-1.04 mm (0.020-0.041 in.)0.3 mm (0.012 in.)
2004 model 1st gear0.33-1.04 mm (0.013-0.041 in.)0.3 mm (0.012 in.)
2000-2003 models 2nd gear0.65-1.78 mm (0.026-0.070 in.)0.3 mm (0.012 in.)
2004-2009 models 2nd gear0.33-1.04 mm (0.013-0.041 in.)0.3 mm (0.012 in.)
Outer synchro ring-to-gear clearance (ring pushed against gear)2000-2003 models 1st, 3rd, and 4th gears0.95-1.68 mm (0.037-0.066 in.)0.6 mm (0.024 in.)
2004-2009 models 1st gear0.95-1.35 mm (0.037-0.053 in.)0.6 mm (0.024 in.)
2000-2003 models 2nd gear0.70-1.82 mm (0.028-0.072 in.)0.6 mm (0.024 in.)
2004-2009 models 2nd gear0.95-1.35 mm (0.037-0.053 in.)0.6 mm (0.024 in.)
Oil pumpInner rotor-to-outer rotor radial clearance1.14 mm (0.006 in.) max.0.20 mm (0.008 in.)
Rotor-to-transmission housing clearanceRadial clearance0.1-0.2 mm (0.004-0.008 in.)0.22 mm (0.009 in.)
Axial clearance0.03-0.07 mm (0.001-0.003 in.)Adjust

MANUAL TRANSMISSION STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Differential

ItemMeasurementQualificationStandard or NewService Limit
Differential oilCapacity Use Hypoid Gear OilOil change0.74 L (0.78 US qt)
Overhaul0.77 L (0.81 US qt)
Drive pinionStarting torque (preload) (Add additional value to actual starting torque measurement)Additional value0.88-1.37 N.m (9.0-14.0 kgf.cm, 7.81-12.15 lbf.in.)Adjust
Ring gearBacklash to drive pinion0.09-0.11 mm (0.0035-0.0043 in.)Adjust
DifferentialTotal starting torqueMeasured with push/pull gauge14-30 N (1.4-3.1 kgf, 3.1-6.8 lbf)Adjust

DIFFERENTIAL STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Steering System

ItemMeasurementQualificationStandard or New
Steering wheelRotational play measured at outside edgeWith engine running0-10 mm (0-0.39 in.)
Starting load measured at outside edgeWith engine running34 N (3.5 kgf, 7.7 lbf)
GearboxAngle of rack guide screw loosened from locked position10° to 20°

STEERING STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Suspension System

ItemMeasurementQualificationStandard or NewService Limit
Wheel alignmentCamberFront at inspection0° 30'+/-30'
Front at adjustment0° 30'+/-10'
Rear at inspection1° 30'+/-30'
Rear at adjustment1° 30'+/-10'
CasterFront at inspection6° 00'+/-15'
Front at adjustment6° 00'+/-15'
Total Toe-inFront0+/-2 mm (0+/-0.08 in.)
2000-2003 models Rear6+/-2 mm (0.25+/-0.08 in.)
2004-2009 models Rear3.7+/-2 mm (0.14+/-0.08 in.)
Front wheel turning angleInward34° 00'+/-2°
Outward29° 00' (Reference)
Aluminum wheelRunoutAxial0-0.7 mm (0-0.03 in.)2.0 mm (0.08 in.)
Radial0-0.7 mm (0-0.03 in.)1.5 mm (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 SPECIFICATIONS TABLE

Brakes System & Parking Brake System

ItemMeasurementQualificationStandard or NewService Limit
Parking brake leverDistance traveled when pulled with 196 N (20 kgf, 44 lbf) of force9 to 13 clicks
Brake pedalPedal height (carpet removed)179 mm (7 1/16 in.)
Free play1-5 mm (1/16-3/16 in.)
Master cylinderPiston-to-pushrod clearance0-0.4 mm (0-0.02 in.)
Brake discThicknessFront24.9-25.1 mm (0.98-0.99 in.)23.0 mm (0.91 in.)
Rear11.9-12.1 mm (0.469-0.476 in.)10.0 mm (0.39 in.)
RunoutFront0.10 mm (0.004 in.)
Rear0.10 mm (0.004 in.)
ParallelismFront and rear0.015 mm (0.0006 in.) max.
Brake padThicknessFront9.5-10.5 mm (0.37-0.41 in.)1.6 mm (0.06 in.)
Rear8.9-9.1 mm (0.35-0.36 in.)1.6 mm (0.06 in.)

BRAKES STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE

Air Conditioning System

ItemMeasurementQualificationStandard or New
RefrigerantTypeHFC-134a (R-134a)
Capacity of system600-650 g (21.2-22.9 oz)
Refrigerant oilTypeKEIHIN SP-10 (P/N 38897-P13-A01AH or 38899-P13-A01)
Capacity of componentsCondenser25 mL (5/6 fl oz)
Evaporator40 mL (1 1/3 fl oz)
Each line and hose10 mL (1/3 fl oz)
Receiver10 mL (1/3 fl oz)
Compressor130-150 mL (4.4-5.0 fl oz)
CompressorField coil resistanceAt 68°F (20°C)3.05-3.35 ohms
Pulley-to-pressure plate clearance0.5+/-0.15 mm (0.020+/-0.006 in.)

AIR CONDITIONING STANDARDS AND SERVICE LIMITS SPECIFICATIONS TABLE