INTRODUCTION [- How to Use This Manual This supplement contains information for the 94 CIVIC, Refer to following shop manuals for service procedures and data not included in this supplement. Description [ CIVIC MAINTENANCE, REPAIR and | CONSTRUCTION 92 VoL.1 and VOL.2 | Clvic SUPPLEMENT 93 ‘62SR300A 62SR3008 628R320 ‘The first page of each section is marked with a black tab that lines Lup with one of the thumb index tabs on this page. You can quickly find the first pege of each section without looking through a full ta- ble of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. I Information — — Speci ERIN tricates a strong possibilty of severe personal injury (F 105s of life if instructions are not followed. | | CAUTION: indicates possiblity of porsonal injury or equipment | damage if instructions are not followed, NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note | that this manual contains warnings and cautions against some specif: } ie service methods which could cause PERSONAL INJURY, damage ‘Vehicle or make it unsafe. Please understand that these warnings ‘cannot cover ail conceivable ways in which service, whether or not recommended by HONDA might be done, or of the possible hazardous consequences of every conceivable way, nor could HONDA investigate all such ways. Anyone using service procedures. ‘F tools, whether or not recommended by HONDA, must satisfy him- ‘s0/f thoroughly that neither personal safety nor vehicle safety wi be jeopardized. Allinformation contained in this manual is based on the latest product information available at the time of printing. We reserve the right ‘tomake changes at any time without notice, No part of this publiea: tion may be reproduced, stored in rettieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. First Edition 8/93 All Rights Reserved 380 pages HONDA MOTOR CO.,LTD. Service Publication Office marked sections in this manual As sections with * include SRS components; special procautions are roquired when servicing ra not included *General Info Special Tools Specifications Maintenance Engine — | Fuel and Emissions LL Transaxle Brakes |_ (including (ABS) *Body [*Heater and Air Conditioning *Electrical (Including | SRS })Outline of Model Changes 33 | 94] REFEnENGE vem DESCRIPTION oma ee era [énaine | Moaiioa iB = ‘Adopted + 1522, D18B7 and D16Y1 engines for KA model + 01587 and D16Z9 engines for KB model Changed ° 58,9 + Torque value of mount and bracket bolts and nuts + Recommended engine oil PGM-CARB. | Changed + Wire harness color + Fuel feed pipe, fuel return pipe and fuel vapor pipe materials for 4WD (Except Europe) model ‘Adopted +_D1822 engine for KA model ° u PGM-FI ‘Changed + Wire hamess color + Fuel feed pipe, fuel return pipe and fuel vapor pipe materials, for 4WD (Except Europe) model Out of use a + Fuet-sub pump for 4WD model Added | s Jet pump for 4WD model r ‘Added + D18B7 and D16Y1 engines for KO mode! + 01887 and D1629 engines for KB model Modified + Electronic Control Unit (ECU) | + Throttle body for B16A2 engine ° " Changed + Main wire harness + Main wire harness for 81682 engine + Fuel pressure for 01582 engine + Throttle body Clutch ‘Changed + Torque value of clutch pipe for LHD model ° aan + Recommended grease 7 Manual Changed Transmis- | + Recommended grease ° — sion | + Method of shift fork spring pin installing Modified + Transmission mount, right front mount/bracket and rear mount/bracket Changed | + Torque value of transmission mounting bolts | + Torque value of transmission mount bolt for $20 and ¥21 ° 13 manual transmissions + Transmission breather cap for $20 manual transmission + Shift fork for ¥21 manual transmission + Super-low shaft, 2-4 select lever and transfer shaft for $22 manual transmissionTem ‘Automatic Transmission DESCRIPTION Modified + Hydraulic circuit + Secondary valve body +. Reverse idler gear Changed + Drain plug + Throttle pressure and governor pressure + Reverse selector hub on the countershaft 93 MODEL 94 opel | REFERENCE ‘SECTION Mositied + Hydraulic circuit Changed + Parking gear + Reverse idler gear shaft and holder + Oil guide cap of the sub-shaft + Secondary valve body + Servo body + Countershatt + Clutch assemblies Abolished + AWD disengagement mechanism ° “4 Rear Differential Changed + Rear differential assembly 15 Drivashatts Changed + Rear driveshaft and propeller shaft for 4WD model 16 Brake Moditied + Wire colors between solenoids and ABS control unit Modified + ABS for 4WD model Body ‘Changed + Fastener and spacer for rear window + Limit switch position of sunroof motor unit Added + Some version emblems + Rear seat access cable Abolished + Shim for sunroof panel/glass height adjustment ° 20 Air Conditioning ‘Adopted +_New refrigerant HFC-134a (R-134a) 22 Electrical ‘Changed + Wire color of ignition switch + Data link connector + Alternator brushes (Mitsuba type) + Terminal number of shift lock solenoid Modified + Power supply circuit Changes + Ignition system for KO model + Integrated Control Unit for KQ and KB models, + Seat heater for some KS model Added + Supplemental Restraint System (SRS) type Il 23General Information Chassis and Engine Numbers .. Identification Number Locations . Warning/Caution Label Locations . Lift and Support Points Lift Floor Jack Safety Stands Towing .. Service Precautions (4WD) ...Chassis and Engine Numbers European Model (2-door Hatchback) Vehicle Identification Number JHMEG332005200001 TAT Manufacturer, Make and | | Tove of Van | “HM: HONDA MOTOR CO., LTD JAPAN HONDA Passongor car | Line, Body ond Engine Type | EG: CIVIC 3-door/D1 82 £G4: CIVIC 3-door/D1582, 01521 EGS: CMG 3.door/D1626 EG6: CIVIC 3edoor/B16A2 Body Type and Tranemiesion Type —! 3 2edoor Hatchback 5-speed Manual 4: 2door Hatchback 4-speed Automatic Vehicle Grade (Series) DX (E63: KGIKFIKSIKE EX (EG: KGIKF) : DXi (EG4: KGIKS) LSI (E64: KGIRFIKSIKEIKW) VEi EG4: KG/KFIKSIKE) ESI (EGS: KGIKFIKSIKE) VTi (EGS: KGIKFIKSIKEKW) | Fixed Code Auxillary Number — Factory Code —— _ S: Suzuka Factory in Japan Model Year — 2: 1994 Serial Number -— Engine Number 816A2-1200001 Engine Type B16A2: 1600 DOHC 16-valves Sequential Multiport Fuelinjected VTEC Engine with CATA D13B2: 1300 SOHC 16-valves 1-carbureded Engine with CATA 1D15B2: 1500 SOHC 16-valves Dual-point Fuel-injected Engine with CATA 1821: 1500 SOHC 16-valves Sequential Multiport Fuel-injected VTEC-E Engine with CATA D16Z6: 1600 SOHC 16-valves Sequential Multiport Fuelinjected VTEC Engine with CATA Numb B16A2: 1200001 ~ 01382: 2200001 ~ D15B2: 6900001 ~ 01821, D16Z6: 3700001 ~ ;- Manual Transmission Number '$20-1000001 ‘Transmission Type ‘S20: Except B16A2 engine Y21: For B16A2 engine Serial Number [— Automatic Transmission Number M24A-3000001 se NumberEuropean Model (4-door Sedan) Vehicle Identification Number siitegas400s200001 stayc85400s200001 Manufacturer, Make and Toot varie ne | Shi HONDA MOTOR G0, ero, sepa | HONDN Poseengo eat Lie, Body and engine Tope os EG9: CIVIC 4-dooriB16A2 BHT: CIVIC 4-door 4W0/01627 EH9: CIVIC 4-dooriD 1647, 01626, | 1627 “WHI Body Type and Transmission Type 5: 4-door Sedan 5-speed Manual 6: 4-door Sedan 4-speed Automatic Vehicle Grade (Series) 4: DXi (EGB: KG/KS) EX (EHS: KR) 5: LSI (EG8: KG/KF/KS/KE/KW) 6: VEi (EGB: KG/KF/KS/KE) 8: ESi (EHO: KG/KF/KS/KE/KU} RTSi (EH1: KG) 9: VTi (EGS: KG/KF/KS/KE/KW) Fixed Code ‘Auxiliary Number ~ Factory Code : Suzuka Factory in Japan Model Year 2: 1994 Seve! Nu ae (- Engine Number B16A2-1200001 ecat G00 Done era ame area ice sone eee eee econe Scien a cdl ay anes p168B2: pisz1 p16a7: D1626: 1627: r Manual Transmission Number '$20-1000001 Transmission Type ——— —I ‘S20: Except B16A2 engine and 4WD model Y21: For B16A2 engine ‘$22: For 4WD model Serial Number [— Automatic Transmission Number M24A-3000001 ‘Transmission Type al M24A: For 2WD model M25A: For 4WD model Serial NumberChassis and Engine Numbers Except European Model (2-door Hatchback) Vehicle Identification Number Manufacturer, Make and Til Type of Vehicle HI ( * qT HM: HONDA MOTOR Co., LTD. | JAPAN HONDA Passenger car | [|i |_| Lino, Body and Engine Type —! || EG3: CIVIC 3-door/D1383 | EGA: CIVIC 3-doorD 1888, Disa, orsz2 EGS: CIC SdooriD16A9, biev1 Body Type and Transmission Type — 3! 2adoor Hatchback Speed Manual 4: 2edoor Hatchback 4-speed Automatic Vehicle Grade (Series) PEL (EGS: KT CX (EG4: KO), 1.5EL (E64: KY) EX (G4: KPIKT/KY) Gui tea: Ka) vi teGs: Ka) SHEGS: KPT) Fixed Code —— Auxiiry Numb Factory Code 'S Suzuka Factory in Japan Model Year 2 1994 Seriat Numbor — [— Engine Number D1383-2200001 Engine Type ———_________ D13B3: 1300 SOHC 16-valves 1-carbureded Engine without CATA, 1500 SOHC 16-valves t-carbureded | Engine without CATA, 1800 SOHC 16-valves Oual-point Fuet.injected Engine with CATA 1500 SOHC 16-valves 1-carbureded Engine with CATA 1600 DOHC 16-valves Sequential ‘Multiport Fuelinjected Engine without CATA | 1600 SOHC 16-valves Sequential Multiport Fuelinjected VTEC Engine with CATA Serial Number 01383, D1583, D16A9: 1587: 3700001 ~ 1822, D16Y1: 1000001 ~ 15B3: p1se7: 1822: Di6as: pieyt: 2200001 ~ Manual Transmission Number '820-1000001 ‘Transmission Type Serial Number — ;- Automatic Transmission Number M24A-3000001 J ‘Transmission Type M24A: For D16Y1 engine | MABA: Except D16Y1 engine Serial Number ————— |European Model (4-door Sedan) Vehicle Ident yn Number —— [- Engine Number JHMEH85100S200001 weirs tens | | If Type of Vehicle iN: HONDA MOTOR CO.,LTD. SIAPAN HONDA Passongor car | ||| Line, Body and Engine Type a7: Cie 4doorD 1363 £68: CIVIG 4-doorf016B3, 01887, Diszi EH: CIVIC 4-door/D1281 EHO; CIVIG 4-do0r1D16A9, D161 Body Type and Trensmiesion Type! ': 4-door Sedan S-speed, Engine Type ————_____ D12B1: 1200 SOHC 16-valves 1-carbureded Engine without CATA 01383: 1300 SOHC 16-valves 1-carbureded. Engine without CATA D15B3: 1500 SOHC 16-valves 1-carbureded Engine without CATA D15B7: 1500 SOHC 16-valves Dual-point Fuelinjected Engine with CATA D18Z1: 1500 SOHC 16-valves Sequential Multiport Fuelinjected VTEC-E Engine with CATA D16A8: 1600 DOHC 16-valves Sequential Manual Multiport Fue.injected 6: door Sedan 4-speed Engine without CATA Automatic D16Y1: 1600 SOHC T6-velves Sequential Vehicle Grado (Series) | Multiport Fuo-njocted VTEC Engine with CATA\ Serial Number - - —— 1281, 01383, 01683, D16A9: 2200001 ~ 1887, 01521: 3700001 ~ 1.5EL: (EGB: KP/KTIKY) 2: 1.2EX (EHB: KU) EX (EGB: KP/KT/KY} 1: 1.26 (EH: KT), EL (EG7: KP) | | 4: GLi (EGB: Ka) D16v1! 1000001 ~ 7: VEi (EGB: KO) } Si (EHO: KPIKT/KY) | | Se [— Manual Transmission Number “a | Fixed Code —______] | Transmission Ty Sorial Number Serial Number [— Automatic Transmission Number M24A-3000001 some ‘Transmission Type = M24A: Except 01281, 01883, D16A9 engine M4BA; D12B1, 01583, D16A9 engine Serial NumberChassis and Engine Numbers Except European Model (4-door Sedan, KB) (- Vehicle Identification Number IHGEH454“RL700001 ean || I |iII | Type of Vehicle || HG: HONDA OF AMERICA HH) MFG., INC. U.S.A, HONDA Passenger cor | || ||| Line, Body and Engine Type! | | EH4: CIVIC 4-door/D1587 EHS: CIVIC 4-door/D16Z9 il | Body Type and Transmission Type — 5: 4-door Sedan 5-spoed Marval [||| | 6: 4-door Sedan 4-speed "Automatic |i R: 1994 [— Engine Number 01587-3850001 T T Engine Type ————________| 'D15B7: 1500 SOHC 16-valves Dual-point Fuel-injected Engine with CATA 1629: 1600 SOHC 16-valves Sequential Multiport Fust-injected VTEC Engine with CATA Serial Number ———_—— 01887: 3850001 ~ 116Z9: 1000001 ~ [— Manual Transmission Number '$20-1000001 eee 1000 sion Type Serial Number ——— Factory Code —— 'S: Ohio Factory in U.S.A. (East Liberty) | Serial Number J ;- Automatic Transmission Number 24A-3000001Identification Number Locations | a | VIN and Engine Numbor (LHD) VIN and Engine Number (RHO} vin Kr) and BUILT DATE, VEHICLE TYPE (Ka) 1-7Warning/Caution Label Locations SRS AIRBAG SYSTEM TYPE.II (Except KB) ae ‘A: DRIVER INFORMATION {SUNVISOR) European models [SRS] _ ALWAYS WEAR YOUR SEAT BELT ‘© THis CARIS EQUIPPED WITH A DRIVER AIRGAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (5.F.S.) © ITs DESIGNED TO SUPPLEMENT THE SEAT GELT. © IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING, SEE YOUR AUTHORIZED HONDA DEALER. [SRS] ATTACHEZ TOUJOURS VOTRE CEINTURE ‘© CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR POUR, LE CONDUGTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE (S.R.S.) (© CE COUSSIN D'AIR COMPLETE LA FONCTION DE LA CGEINTURE DE SECURITE. © SILE TEMOIN SRS S'ALLUME PENDANT LA CONDUITE, ADRESSEZ-VOUS A VOTRE CONCESSIONNAIRE HONDA oFFicieL. [SRS] SICHERHEITScUATE BEI JEDER FAHRT ANLEGEN (© DIESES FAHRZEUG BESITZT EINEN FAHRER AIRBAG. ALS ZUSATZLICHES RUCKHALTESYSTEM (S.R.S.). @ ES IST EINE ERGANZUNG ZUM SICHERHEITSGURT, (© WENN DIE SRS-KONTROLLEUCHTE WAHREND DER FAHRT AUFLEUCHTET, UMGEHEND FINEN HONDA HANDLER AUFSUCHEN (SRS) ORAAG ALTIJD UW VEILIGHEIDSGORDEL ‘© DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN [AN DE BESTUURDERSKANT ALTS EXTRA BESCHERM- ING 18.8.8. ‘© DITIS ONTWORPEN ALS EXTRA BESCHERMING BLJ DE VEILIGHEIDSGORDEL, (© ALS HEL SRS. WAARSCHUWINGSLAMPJE GAAT BRAN. DEN ONDER HET RLIDEN. NEEM DAN KONTAKT OP MET EEN HONDA DEALER, A: DRIVER INFORMATION (SUNVISOR) Except European models [SRS] ALWAYS WEAR YOUR SEAT BELT THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). TIS DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF YOUR SRS INDICATOR LIGHTS WHILE ORIVING SEE YOUR AUTHORIZED HONDA DEALER, ae (SRS) SRSAAYFRYAM, t¥av vary aty FEDS THERITEL caution BEFORE MAINTENANCE, SWITCH OFF THE IGNITION. ATTENTION AVANT TOUT ENTRETIEN, COUPER LE CONTACT. ACHTUNG VOR WARTUNG ZONDUNG AUSSCHALTEN. Ler oP. ZET HET KONTAKTSLOT AF ALVORENS MET HET ON- DERHOUD TE BEGINNEN. 1-8: MONITOR NOTICE E: SRS WARNING (HOOD) LHO mode! NOTICE [SRS] ‘REFER TO SERVICE MANUAL FOR DETAILED IN. STRUCTIONS. REMARQUE ‘© POUR LES INSTRUCTIONS DETAILL'EES, SE REPORT- ER AU MANUEL DE REPARATIONS. Ler UP! ‘© RAADPLEEG HET WERKPLAATSHANDBOEK VOOR NA. DERE AANWLUZINGEN. ACHTUNG ‘© AUSFUHRLICHE ANWEISUNGEN SIND DEM. WERK: STATTHANDBUCH ZU ENTNEHMEN. D: BODY COVER CAUTION TER CAUTION ACHTUNG [SRS] OSRSLY THY ABUI HER BMTSCL. 27 we (© REFER TO THE SHOP MANUAL. (© SE REPORTER AU MANUEL D’ATELIER. (© WERKSTATTHANDBUCH LESEN, (© LEES HET WEKPIAATSHANDBOEK. WARNING (SAS; ‘THIS VEHICLE IS EQUIPPED WITH A DRIVER AS A SUP. PLEMENTAL RESTRAINT SYSTEM. (SRS) ‘ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. 00 NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS. TAMPERING WITH OF. DISCONNECTING THE SRS WIRING COULD RESULT IN AC- CIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYS: TEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS nguRY. ATTENTION _ [SAS CE VEHICULE EST EGUIPE D'UN COUSSIN D’AIR DU COTE ‘CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE ‘COMPLEMENTAIRE (SRS), ‘TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYS- ‘TEME DE RETENUE COMPLEMENTAIRE (SRS) SONT DE (COULEUR JAUNE, N'UTILISEZ PAS UN EQUIPEMENT D’ES- SAIS ELECTRIQUES SUR CES CIRCUITS. NE TOUCHEZ PAS. ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME SRS CAR, CECI POURRAIT DE TRADUIRE PAR LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU RENORE LE SYSTEME IN OPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES, WARNUNG — (SRS) DIESES FAHRZEUG IST MIT EINEM FAHRER-AIRBAG (SRS) ALS ZUSATZLICHEM RUCKHALTESYSTEM AUS: GEROSTET. ALLE ELEKTRISCHEN KABEL, SOWIE DIE ZUGEHORIGEN ‘STECKVERBINDER DES SRS'SYSTEMS SIND IN GELBER FARGE AUSGEFONRT. KEINE ELEKTRISCHEN PROFGERATE AN DIE SRS. VERKARELUNG ANSCHLUIBN. VERANDERN ODER UN. ‘TEBRECHEN DER SRS-VERKAGELUNG KANN NUKONTROL- LIERTES ZUNDEN DES GASGENERATORS AUSLOSEN. ‘ODER DAS SYSTEM AUBER FUNKTION SETZEN. WAS ZU, ERNSTHAFTEN VERLETZUNGEN FUMREN KANN. WAARSCHUWING [SRS] DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN ‘AN DE BESTUURDERSKANT ALS EXTRA GESCHERMING (sRs) ‘ALLE ELEKTRISCHE LEIDINGEN EN AANSLUTINGEN VAN DE SRS ZIJN GEEL GEKLEURD. GEBRUIK GEN ELEK. TRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS. KNOEIEN MET OF LOSKOPPELEN VAN DE SRS LEIDINGEN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKELEN VAN HET SYSTEEM: DIT KAN TOT ERN: STIGE ONGELUKKEN LEIDEN, (cont'd) 1-9Warning/Caution Label Locations r (cont'd) E: SRS WARNING (HOOD) RHD model ‘SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘THIS VEHICLE IS EQUIPPED WITH A DRIVER SIDE AIRBAG. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE ‘COLORED YELLOW. ‘TAMPERING WITH, DISCONNECTING OR USING ELECTRI- CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE ‘THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR ING OF THE INFLATOR, ‘& WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN. ‘TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. : SRS WARNING (HOOD) KS. WARNING [SRS] ‘THIS VEHICLE |S EQUIPPED WITH A AIRBAG SYSTEM AS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). ‘ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE circurrs.. ‘TAMPERING WITH OR DISCONNECTING THE SRS WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY. VARING [SRS] DETTA FORDON HAR EN LUFTKUDDE FOR FORARSATET SOM ETT KOMPLETTERANDE SKYDDSSYSTEM (SRS) SAMTLIGA' ELLEDNINGAR OCH KONTAKTER | SRS: 'SYSTEMET AR GULFARGADE. ANVAND INTE ELEKTRISK PROVUTRUSTNING FOR DESSA KRETSAR, OM DU AN. DRAR ELLER LOSSAR EN SAS-LEDNING KAN DET RESULTERA I EN OAVSIKTLIG UTLOSNING AV TRYCKPUM. PEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA. DA KAN EN ALLVARLIG OLYCKA UPPSTA. varomus. (SR) TASSA AUTOSSA ON YLIMAARAISENA TUKIJARJESTEL- MANA AJAJAN ILMATYYNY. (SRS) KAIKKI SRS. SAHKOJOHDOT JAAITTIMET OVAT KELTAISET. ALA KAYTA SAHKOKOELAITTEITA NAISSA. VIRTAPI IREISAA. SRS JOHTOJEN TUKKEAMINEN TAI RROTAAMM NEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TAI TEHDA JARJESTELMAN KAYTTOKELVOTTOMAKS!. TASTA TAAS SAATTAA AIHEUTUA VAKAVIA VAURIOITA. Gas) ae eS AMS aka Aig gm i Sjlell oba jagos 8 (ens) gia (585) JLB aS py LOIS GL SH DLN gee st ipl gde agAly SHAS SN pga a Je oly SII UGS Shane Jaa Jeu obec ose (Sis) Sua ga LEG Dal ad Sop Lead ge a as agi Hp SS Steg 1-10SRS AIRBAG SYSTEM TYPE-I (KB) A: CABLE REAL CAUTION A : DRIVER MODULE WARNING [sas] REFER TO SERVICE MANUAL FOR DETAILED IN: STRUCTION. POUR LES INSTRUCTIONS DETAILL'EES, SE REPORTER AU. [MANUEL DE REPARATIONS. BURY, RHEY— CATA TLESMLTS KEW, [AUSFOHRLICHE ANMEISUNGEN SIND DEM ZU ENTINEMEN. RAAD PLEEG HET WERKPLAATSHANDBOEK VOOR NA- DERE AANWIZINGEN. ‘8: STEERING WHEEL NOTICE woTice IMPROPER STEERING WHEEL REMOVAL OR INSTALLATION CAN DAMAGE SRS COMPONENTS. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. REMARQUE UN RETRAIT OU UNE REPOSE INCORRECTS DU VOLANT RISQUENT D'ENDOMMAGER LES PIECES CNSTITUTIVES DU_SRS, SUIVRE ATTENTIVMENT LE MANUEL D'EN- TRETIEN. B WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN. ‘TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU ‘© 0 NOT USE ELECTRICAL TEST EQUIPMENT OR PROB: ING DEVICES. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. (© NO SERVICEABLE PARTS INSIDE. DO NOT DisAS. ‘SEMBLE. ‘© PLACE AIRBAG UPRIGHT WHEN REMOVED. © FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. “A ATTENTION LE GONFLEUR DE COUSSIN D’AIR EST EXPLOSIBLE ET S'LL ‘SE DEPLOIE ACCIDENTELLEMENT, IL RISQUE DE PROVO ‘QUER DES BLESSURES GRAVES OU DE TUER, (© NE PAS UTILISER DE MATERIEL D’ASSAl ELECTRIQUE NL DE SONDE. ILS POURRAIENT PROVOQUER UN DEPLOIMENT ACCIDENTEL DU COUSIN D’AIR. © ILN'Y A PAS De PIECES REPARABLES A L'INTERIEUR, NE PAS DEMONTER. © QUAND ON RETIRE LE COUSSIN D’AIR, LE TENIR ALA VERTICALE. © SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU MANUEL D'ENTRETIEN. 1-11Warning/Caution Label Locations D: DRIVER MODULE DANGER* E:DRIVER INFLATOR WARNING TAG* & DANGER, EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY METALS SUCH ‘AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- FUL AND IRRITATING GASES OR EXPLOSIVE COM- POUNDS. STORAGE TEMPERATURES MUST NOT EXCEED. 20°F (100°C). FOR PROPER HANDLING, STORAGE AND. DISPOSAL PROCEDURES REFER TO THE SERVICE MANU- AL, SRS SUPPLEMENT. Poison CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM. NITRATE, FIRST AID If CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) ARE INHALED, SEEK FRESH AIR, IN EVERY CASE, GET PROMPT MEDICAL ATTENTION. KEEP OUT OF REACH OF CHILDREN ‘A DANGER EXPLOSIBLEMNFLAMMABLE TOUT CONTACT AVEC L’ACIDE, L'EAU OU DES METAUX LOURDS COMME LE CUIVRE. LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS OU. DES COMPOSES EXPLOSIFS. LES TEMPERATURES DE RANGEMENT NE DEVRONT PAS DEPASSER 20°F (100°C), POUR LES PROCEDURES DE MANIPULATION, DE RANGEMENT ET DE MISE AU REBUT. VOIR LE SUPPLE. MENT SRS DU MANUEL D'ENTRETIEN. POISON RENFERME DE L'ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES, PREMIERS SECOURS ‘SI LE CONTENU EST ABSORBE. INDUIRE UN VOMISSE- MENT. EN CAS DE CONTACT AVEC LES YEUX, LAVER A GRANDE EAU PENDANT UN QUART D'HEURE. EN CAS D'INHALATION DES GAZ (PAR CONTACT AVEC L’ACIDE ‘OU VEAU), ALLER A L'AIR FRAIS, DANS TOUS LES CAS, ‘OBETENIR PROMPTEMENT DES SOINS MEDICAUX. TENIF HORS DE PORTE DES ENFANTS. “Label D and E locations: Refer to page 1-11 & WARNING ACCIDENTAL AIRBAG DEPLOYMENT CAN SERIOUSLY HURT OR KILL YOU. INSTALL THE RED SERVICE CONNECTOR WHEN THE IN FLATOR HARNESS IS DISCONNECTED. ‘ATTENTION TOUT DEPLOIEMENT ACCIDENTEL DU COUSSIN D“AIR RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE ‘TUER QUAND LE FAISCEAU DE FILS DU GONFLEUR EST DECON. NECTE, INSTALLER LE CONNECTURE D'ENTRETIEN ROUGE. F: SRS WARNING (HOOD) ‘SUPPLEMENTAL RESTRAINT SYSTEM (SAS) THIS VEHICLE 1S EQUIPPED WITH A DRIVER AND FRONT SEAT PASSENGER AIRBAG. [ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. ‘TAMPERING WITH, DISCONNECTING OR USING ELECTR. ‘CAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE ‘THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR: ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN: TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. Gc: LABEL [aireaG] 1-12H: FRONT SEAT PASSENGER INFLATOR WARNING TAG |: GLOVE BOX INFORMATION ‘WARNING ACCIDENTAL AIRAG DEPLOYMENT CAN SERIOUSLY HURT OR KILL YOU. INSTALL THE RED SERVICE CONNECTOR WHEN THE IN. FLATOR HARNESS IS DISCONNECTED. ‘ATTENTION TOUT DEPLOIEMENT ACCIDENTEL DU COUSSIN D’AIR RISQUE DE PROVOQUER DES BLESSURES GRAVES OU DE ‘TUER. QUAND LE FAISCEAU DE FILS DU GONFLEUR EST DECON- NECTE, INSTALLER LE CONNECTURE D’ENTRETIEN ROUGE, ‘AIRBAG INFORMATION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘© THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS INSTALLED. THE DATE OF INSTALLATION IS SHOWN, ON THE CERTIFICATION PLATE, LOCATED ON THE DRIVER'S DOOR JAMB, © DIAGNOSTIC CHECKS AND REPLACEMENT OF SRS COMPONENTS MUST BE DONE BY AN AUTHORIZED DEALER. (© SEE YOUR OWNER’S MANUAL FOR ADDITIONAL SAS. INFORMATION, (cont'd) 1-13Warning/Caution Label Locations (cont'd) J: FRONT SEAT PASSENGER AIRBAG MODULE DANGER K: MONITOR NOTICE & DANGER EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY METALS SUCH [AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM FUL AND IRRITATING GASES OR EXPLOSIVE COM. POUNDS. STORAGE TEMPERATURE MUST NOT EXCEED '200°F (100°C). FOR PROPER HANDLING, STORAGE AND. DISPOSAL PROCEDURES REFER TO SERVICE MANUAL, ‘SRS SUPPLEMENT. POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE, FIRST AID IF CONTENTS ARE SWALLOWED, INDUCE VOMITING, FOR EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MINUTES. IF GASES (FROM ACID OR WATER CONTACT) [ARE INHALED, SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL ATTENTION, KEEP OUT OF REACH OF CHILDREN. “&. WARNING ‘THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN- TALLY DEPLOYED, CAN SERIOUSLY HURT OF KILL YOU. ‘© DO NOT USE ELECTRICAL TEST EQUIPMENT OR PROB. ING DEVICES. THEY GAN CAUSE ACCIDENTAL DEPLOYMENT. (© NO SERVICEABLE PARTS INSIDE. DO NOT DISAS ‘SEMBLE. PLACE AIRBAG UPRIGHT WHEN REMOVED. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY. ‘DANGER EXPLOSIBLE/INFLAMMABLE TOUT CONTACT AVEC L’AGIDE, L’EAU OU DES METAUX LOURDS COMME LE CUIVRE, LE PLOMB OU LE MERCURE RISQUE DE PRODUIRE DES GAZ NOCIFS ET IRRITANTS OU. DES COMPOSES EXPLOSIFS. LES TEMPERATURES DE RANGEMENT NE DEVAONT PAS DEPASSER 200°F (100°C). POUR LES PROCEDURES DE MANIPULATION, DE RANGEMENT ET DE MISE AU REBUT, VOIR LE SUPPLE- MENT SRE DU MANUEL D'ENTRETIEN. POISON, RENFERME DE L’ACIDE DE SOUDE ET DU NITRATE DE POTASSIUM TOXIQUES. PREMIERS SECOURS SILE CONTENU EST ABSORBE, INDUIRE UN VOMISSE- MENT. EN CAS DE CONTACT AVEC LES YEUX, LAVER A GRANDE EAU PENDANT UN QUART D’HEURE. EN CAS D'INHALATION DES GAZ (PAR CONTACT AVEC L’ACIDE ‘OULEAU), ALLER AL’AIR FRAIS, DANS TOUS LES CAS, ‘OBETENIR PROMPTEMENT DES SOINS MEDICAUX. TENIN HORS DE PORTE DES ENFANTS. ‘A ATTENTION LE GONFLEUR DE COUSSIN D’AIR EST EXPLOSIBLE ET S'LL ‘SE DEPLOIE ACCIDENTELLEMENT, IL RISQUE DE PROVO- ‘QUER DES GLESSURES GRAVES OU DE TUER. "© NE PAS UTILISER DE MATERIEL D’ASSAI ELECTRIQUE IDE SONDE. ILS POURRAIENT PROVOQUER UN DEPLOIEMENT ACCIDENTEL DU COUSIN D’AIR © ILW'V A PAS DE PIECES REPARABLES A LINTERIEUR. NE PAS DEMONTER, (© QUAND ON RETIRE LE COUSSIN D'AIR, LE TENIR A LA, VERTICALE. © SUIVRE ATTENTIVEMENT LES INSTRUCTIONS DU, [MANUEL D’ENTRETIEN. NOTICE SRS] NO SERVICEAGLE PARTS INSIDE © REFER TO SERVICE MANUAL FOR DETAILED IN. ‘STRUCTIONS, 5B DLT EE. BURY. BHAT CAT REM. AP UEBRL TS REMARQUE (© AUCUNE PIECE REPARABLE A L'INTERIEUR. ‘© POUR LES INSTRUCTIONS DETAILL'EES, SE REPOR. TER AU MANUEL DE REPARATIONS. Ler upt ‘© GEEN ONDERDELEN BINNEN DEZE UNIT WAARAAN WERKZAAMHEDEN KUNNEN WORDEN VERRICHT. (© RAADPLEEG HET WERKPLAATSHANDBOEX VOOR NA- DERE AANWIJZINGEN. ACHTUNG ‘© DIE INNENTILE BEDORFEN KEINER WARTUNG. (© AUSFUHRLICHE ANWEISUNGEN SIND DEM WERK. STATTHANBUCH ZU ENTNEHMEN. Label J and K locations: Refer to page 1-13. 1-14== ‘SERVICE INFORMATION Gates Ks) BATTERY CAUTION ‘AIR CLEANER, RECOMMENDED OIL and FILTER SERVICE Ce JRMATION SP INFO} ‘TIRE INFORMATION HD: Lao: Except KY 3-doorLift and Support Points r Lift FERIA When heavy rear components such as suspension, fuel tank, spare te and hatch are to be removed, pla jonal weight in the luggage area before hoisting. When substantial weight is removed from the rear of the car, the center of gravity may change and can cause the car to tip forward on the hoist. NOTE; Since each tire/wheel assembly weighs approximately 14 kg (30 Ibs}, placing the front wheels in the trunk can assist with the weight distribution, 1. Place the lift blocks as shown, 2. Raise the hoist until the tyres are slightly off the ground and rock the car to be sure it is firmly supported, 3. Raise the hoist to full height and inspect lift points for solid support. FRONT SUPPORT POINT ur cocks REAR SUPPORT POINT 1-16r- Floor Jack 1, Set the parking brake and block the wheels that are not being lifted. 2. When lifting the rear of the car, put the gearshift lever in reverse (Automatic in [B] position. 3, Raise the car high enough to insert the safety stands. 4, Adjust and place the safety stands as shown on page 4-18 50 the car willbe approximately level, then low- er the car onto them. Front ‘Always use safety stands when working on or un- der any vehicle that is supported by only a jack. © Never attempt to use a bumper jack for lifting or supporting the car. CCentor the jack bracket in the middle of the jack it platiorm, JACK LIFT PLATFORM, Center the jack bracket in the middle JACK LIFT PLATFORM, ff the jack it platform. 1-17Lift and Support Points r- Safety Stands RUBBER ATTACHMENTS FRONT SUPPORT POINT SAFETY STANDS REAR SUPPORT POINTTowing If the car needs to be towed, call a professional towing service. Never tow the car behind another car with just ‘rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a car: Flat-bed Equipment — The operator loads the car on the back of a truck. This is the best way of towing the car. Whee! Lift Equipment — The tow truck uses two pivot ing arms which go under the tires {front or rear) and lifts them off the ground. The other two wheels remain on the ground. NOTICE: On 4WO mode! Never tow your car with the front or rear wheels off the ground and locked on the towing dolly as shown in the iMusteation, ‘This method of towing may damage your car's transmis- sion and the vehicle may jump off the dolly. ‘Sling-type Equipment — The tow truck uses metal ca- bles with hooks on the ends. These hooks go around parts of the frame or suspension, and the cables lift that fend of the car off the ground. The car's suspension and body can be seriously damaged if this method of towing is attempted. If the car cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the car must be towed with the front wheels ‘on the ground, do the following Manual Transmission © Release the parking brake. © Shift to transmission in neutral ‘Automatic Transmission © Release the parking brake. © Start the engine. © Shift to transmission in [Ba] position, then in [N] po- sition © Turn off the engine. NOTICE: Improper towing preparation will damage the ‘transmission. Follow the above procedure exactly. If you cannot shift the transmission or start the engine (auto- ‘matic transmission), the car must be transported on a flat-bed © It is best to tow the car no farther than 80 km (50 miles), and keep the speed below 85 km/h (35 mph). NOTICE: Trying to lift or tow the car by the bumpers will ‘cause serious damage. The bumpers are not designed to support the car's weight. Front: CAUTION: If the car is equipped with a front spoil remove it before towing so it is damaged. Rear: ‘TowING HOOK 1-19Service Precautions (4WD) ‘This 4-wheel drive model is not equipped with the sys- tom that mechanically shifts the drive system to the 2-wheel drive. ‘Therefore, perform the speedometer test by using the free rollers. Tip on use of free roller: @ Test cannot be made by using the chas namometer. © Do not operate the accelerator pedal, clutch, brake system and steering wheel quickly. The car can roll hard or dash out during the test which is very dan- gerous. © Do not raise the speed more than 50 km/h. © Do not use the free rollers continuously for more than 3 minutes at one try. ‘© Secure the car for safety. Attach the ropes to the car not to allow it to roll of dash out during the test. (Use the free rollers for the rear wheels) dy: 1. Set each of the free rollers at the wheelbase and track of the car. NOTE: Be sure that the free rollers and speedome: ter tester rollers are set parallel with each other. PREE ROLLER SPEEDOMETER TESTER REAR WHEEL SIDE FRONT WHEEL SPEEDOMETER TESTERS SIDE FREE ROLLERS WHEELBASE 7 Set the positioning posmonie uni "etches on the line. 2. Move the car to set the front wheels on the speedometer testers and the rear wheels on the free rollers, Be sure that the wheels are set at the center of the speedometer testers and free rollers respec tively, CAUTION: Be sure that the front and rear wheels are set at the center of the speedometer tester and {rae rollers securely, of the car can roll hard or dash ‘out during the test, which Is very dangerous, 3. Attach the ropes to the trailing hook and tie-down hhooks to secure the car (For prevention of the car from rolling hard or dashing out during the test). CAUTION: (© Be sure that the ropes attached to the car for prevention of rolling are not slack. Slack ropes do not effectively secure the car and the car can roll during the test. ‘© Attach the ropes to the car not to interfere with the bumper. © Donot attach the ropes to any section other than the specified section. ROPE (for provention of the car from dashing out) ‘attach to the trailing hook. ROPE (for prevention ff the car from rolling) the car from rolling) attach to the “Attach to the tailing hook. hook: ROPE (for prevention of 4. Start the engine. With the gearshift lever in the Srd range on the manual tranemission car o the gear: shift lever in the D1 or D2 position on the automatic, transmission car, start the car and raise the speed gradually, CAUTION: Take care not to exceed 50 km/h of speed and do not test for more than 3 minutes con- tinuously. 5. After the test, slow down the car until it stops by ‘applying the brake gradually. 1-20Special Tools Individual too! lists are located at the front of each section,Specifications Standards and Service Limits Body Specifications ...Standards and Se rvice Limits ,- Cylinder Head/Valve Train — Section 6 D12B1, D13B2, D13B3, D15B2, D15B3, D15B7, D15Z2, D16A7 Engines | MEASUREMENT STARDARD (NEW senvice nwt Tamereaion | aba ipa Noma “0 130,160 | so opon tonto Nena soos 1s) | ioe tizens at eae wanton | 2028 28 Cylinder head ‘Warpage = | 0.08 (0.002 [Roa 2496-0505 9738-3740 Canna End oy 0055 0.002 0.008) oem Eameheh soho clearance oso. oees wana | oxsioo08) Tera rane dostosnt mee toe tomme Ecmiobeheigh 01261, D1382,01983 ww | Seva rane a x | Seooo anes = orses ie | Seeos teeny Be | noe (hacen : owssr wh | deo ern = & | dedeo (eas — rear ik | devee teen = & | dea ase = ose, 01522 we | Seosr tate) = Bx | detos zen = Tae Valve desance in| 018-022 0007-0308 = & | G35-027 00-00) = Valve stom 00 | Gie-saoearcoaien — | Sas oz & | fee-stsoweoaes | Sa tozise stan to-guideclorance in | b02=e0s 001 o00n Soe loons bx | $0s=208 one 0008 48 foa08 Take wat wah TN] 0851150089 0048 Ts oer x | $25- 188 009 -o0en 2oIoor Stem insta eight ik | tases" ese nates” seco. | Sree & | eee casesiaee- tana | fooss econ Valve wong | Foo Tongs D189, D198 OT3BT Inara a0) — & | Stones = rsez ors02 06a iN | ease ln i = & | Sisnasn = ise, 01522 in| Sra0 tou = ras our = ex | asian = Baia vers = Take goles east sme sa orm WR | t205- tocsiosoe™ occ) Ox | te58- teas nees te) ask aom | rains IN| #17 ~wos0 0.0007 -oonza | 008 mem Bc | Sote=teet Gomme | Sosa "ION WATSUIO mantactued va ping, "8 GAUO WATSUTO mantatured wav spring(— Cylinder Head/Valve Train — Section 6 Unit of length mm find 1521, D16Z7, D161 Engines MEASUREMENT STANDARD (NEW) SERVICE LMT Compression | 260 min irpmi one Nominal 73001186, 184) wide open thrattle Minimum 43501915, 186) KPa gion? pe Maximum variation | 200 (20, 28) a Cylinder Bead] Warpose = ‘0.05 (0.00%) Hoon. 92398 - 92.05 3.659 - 3.663) — | Comsho End play (005 - 0.15 (0.002 - 0.006) aes Camshafeto-holder oil clearance {050 ~ 0.099 0.002 0.004 Sea | Toret runout 0.036.001) max. eae Comlobe 01821 IN Primary | 38.427 1.5129) height Secondory | 32282 (12713) x 31907 (0.4950) = Except 01621 IN Primary | 35.900 (1.4138) Mia 38.107 (15009) Secondary | 38-196 (14250) {= x 36008 (14988) _ Valve Valve desrance iN | 018-022 (0007-000) = ex | 023-027 0009-0011) = Valve stem 0.. IN | 49-849 02157-02100 545 02109) Ex | 845 ss (02146-02150) 842 10.2198) Sterto,qude clearance IN. | 602.05 0.00% - 0.0021 808 10.003 & | 606-600 0002-909 0.120.051 _| Valve oat | 05-115 (0073 0.085) 1.6 (0.0831 Ex | 5125-1136 0.048 0.060) 2910973) | IN. | 53.165 ~ 53.635 (2.0931 2.1116) | 53.885 (2.1218) €x | $3.168 S398 0st 21116) _| S386 2.42461 Vale srg IN| Se78 G5 — Bx | $8.23 2.20307 — | Seas ase = Except 01621 wn | 5797 2260) — Ex | saa! fro Valve aude 0. WW | 851-959 0217-021 Tao Oz Ex | S51-653(0217 021) 5460 0220) | states hohe Im | 47.85-18:350.709~0:720 = Ex | 1995-193510734~0750) | —— Racker ar “Remo shat clearence iN] 0017 -0.050 «00007 - 0.0020) | B08 000) Ex | 0018-0054 (00007-00021) | .08 0.003) *T NIHON HATSUIO ‘manufactured valve spring, °2: CHUO HATSUJO manufactured valve spring 3-3Standards and Service Limits ,- Cylinder Head/Valve Train — Section 6 D16A9 Engine 1 MEASUREMENT stanpanpivew) | _ SERVICE LIMIT ‘Camoression | 20 min pm) and Nominal 73501935, 192) ride open tree intro seo 08, 138) VPs gion ps Maximum varition | 200(20,26) Ginger heed} warpage = ] cas o00m Heian 13196-12208 6195-100 | _ Camahat Tenses, 9.05 -0.15 (0000-0008) a5 (00m, Camahettosholde oil clearance {8.060 - 0.008 (0.002 0008) 19,0008) | Tora amour 8.3 (0000) max | 008 002) Cam lobe height ww | 33021113000 — _ &x | sesezqzm | Valve Valve ceerance ww} 0.13 -0.17 (0005-007 — Bx | 0138-019 o008 0.000" ‘Valve stem 0.0. IN | 6.68 -6.59 (0.2591 - 0.2594) | 6.55 (0.2579) &x | 855~8:6 02579-02560) 852 0.2507) | stemto-ouide clearance in | d02-808 2001 oom 8080.03, | _ x | dias 0.09 002 dos (0008) Valve west [wie nN | 128-135 099-08) 2010078) Ex | 4125-135 0.049 - 0.06%) | 2oro0rs) Stem stated height In | agus “aoorerr7e9- ter — | ease nan) ek | aFe8 S205 701-1700 | ASABE Valve spring Free ath Np a7agia7oy a 5x | seas 808 | tease Vane guide 1B. and Ex | 61-669 (0280-0200 665 0262) Instated height iWandex | iars=r9estere-o7r | “Measuring point between cornshaf and Yooker armUnit of length: mm fi -— Cylinder Head/Valve Train — Section 6 B16A2 Engine MEASUREMENT STANDARD (NEW) SERVICE LMT Compression | 250.min* (rpm) and Nominal 1.550118, 220) ‘wide open thrate Minimum 95095, 135), KPa tagier psi) Maximum variation | 200/20, 281 Cvlinder head | Warpeoe = | 0.06 002 Height 14195-14205 (5509-5593) | — Camano End play 10.5 ~ 0.15 (0.002 - 0.006) 05 (0021 Camsheteso-hotder ol clesrance 6.050 0.089 0.002 0.008) 0.15 (0.008) ‘otat runout 0.03 (0.001) max 0.04 (0.002) Cam lobe height IN Primary | 38.088 (130271 — Mia 38.267 (1.4278) — Secondery | 34978113770 — ex Primary | 32.785 (1.2907 = Mid 35.720 1.4089) — Secondary _| 34.691 (1.3658) — Valve Valve clearance IN| 025 -0.19 0.006 0.007 — Ex | 0.17021 007 0.008)” Valve stem 0.. in | 5475-5485 (02186-0.2159) | 5445 (02140 ex | 5450-5.460(02166-0.2180) | 5.420 0.2130 ‘Stemo-guide clearance IN | 0.025~0.055 10.0010- 0.0022) | 0.08,0.0031, | &x | 0.050 0.080 (00020-00031) __| 0.11 10.008) Valve seat Wir IN| 125-155 0089-00061) 2010.079) x | 125158 10.049 0.06%) 2.010.073) Stem installed height IN | 37.495"3799517.4750~ 1.4938) | 58.185 7.5033 Ex | 37-165 37.596 (1.4032 —14817)_| 57.886 18918) Valve spring Fro length TW OUTER | aoe2 ern" aot nisin = wwver | 36,71 (9.488) = ex 44196 1.652)" = _ ‘494 (1651 Valve guide 19 WN | S51-553 0277-021 5550710) ex | 551—55310217-0.216) 555 (0218) Installed height IN | 1286-1305 10498-0510) —— Ex | 1255. 1308 0.494 0510 = Rocker aim “Ramo-ahaf clearence iN | 0.920082 (0.0008 0.0020) | 0.08 10000) Ex | 0.025 ~0.082 (00008-00020) | 0.08 1.003), ‘Measuring point between camahalt and rocker arm, “SINIHON HATSUJO manufactured valve spring. "2: CHUO HATSUJO manufactured valve spring 3-5Standards and Service Limits -— Engine Block — Section 7 Except B16A2 Engine MEASUREMENT STANDARD (NEW) SERVICE LMT Cylinder block | Wapage of deck surface 57 6.0) max @:10;0.008) Bore diameter 7500-7502 (2953 - 2.954) 9507 2986) Bore tor 0.05 0.002) Reboring iit 051002 ston SktO0.— AviémmOSin 74.960 74990 25520-29528) | 78.970 25516) from bottom of sit Ctosrance in cylinder 0.010-0040(0.0004-0.0016 | 0.050.002) } Groove width or rng) | "Top" D1Sz21 1.020. 1.030 00802-00406 | 1.05,0.08) Excopt 01821 1220-1720 (00480 00486) | 1.25,0049) | Secona o1e21 41220-1230 (00480-00480) | 1.28 0.040) ‘Except 01821 11520 1590 (20598-00502) | 136 081) } on Drezh, Dr6z6, prez7, orev 2a05 -2820 01104-0110) | 285 (0.112) 1822, 01882, 1567, D16A7, OT6AS 2eog2ea5 o.nt0e-o.iay | 28/0112) 20, 01382, 01963, 01583 00s - 02s 0177-01585) _|_ 498 10.159 Piston ring ing to eroove Top Oi8zi 0.096 0.060 1.0014 0.0028). | 0.130.061 | ctesrence Except 01621 | 0.090~ 0.086 (00012 9.0022)" | 0.13 10.008) 61690 - 0.080 1.0012 0.0024)" | 0.330.081 Second 01821 | 1085 0.080.014 ocazai+! | 0.130.005 0090-0055 10.0012 -0.0022)+* | 0.13 (0.005) Exoept 01621 _| 0.030 0.085 (0.0032 0.0022) _| 0.13 (2005) ing end gap Top | 9.15 0.20 (0008-0012) 960 0.028) Second 030-045 (0012 0010) 07010028) onotsz1 020 0.50 (0.008 - 0.020)" 0700028), } 0:20 0:70 (0.008 0.026)" 82010030) 01626, 01671 8.20 - 0.50 (0.008 ~ 0.020)" 07010028) 020-080 0.008 -003%)-* 09010095) ovez 020-050 (0.008 0.020 07010028), Except 01621, 01626, 01627, 016¥1_ | 020-080 10008-0091) 890 (0.05 Piston Pin oD 18994 - 19.000 (0.7478 0.7480) Pinrt-piston clearence a.910~002210.0006-o.0000) | Connacing rod | Pin toxod interference {0.014 0.040 (0.0006-0.0018) | —— Small ond bore clametar 1896 - 1898 0.740~-0.747) = Large ena bore diameter Nominal 01281, 01982, 01989 430180 1862, 01893, Dis67, Ovsz1, orszz | 450(2.71 — DIGAT, DIBAG, D16Z8, DI6ZT, DIS? | 48.0 (1.89) —_— End play installed on ernst 05-020 19006-0012) 400.010) Cranks Main journal damater ‘bizar, 01902, 01983, 01582, 01589, D1887, Dr8z1, | 44.976 45.000(1.7707 1.7717) | — ise DiGar, D16A9, 01626, 01627, D16¥1 58.976 55.000 2.1644~2.1656) | — Rad journal diameter i281, 01382, 01989 39.976 40.000(1.8729- 18740) | —— sea, 01883, b1587, D162, brsz2 | 41.976 ~ 42.000 (1.6258 1.6535) | —— | Dea, DrBAd, Diez6, Diez7, Drew’ | 44976 — 45.000 (1.9709 - 1.7739) Teper {0.0028 (.000%0) max 1.008 (0.0002) | Out'ot round 0.0025 (0.00010) mas, 8.008 (0.0002) | Ena piay 80-098 (00040012) bas ioow “otal renout 0.030.001) max 0.040.002) Searings | Main beorng-t-journal ol clearance No. and 8 journals | 0.018 -0.036 0.0007 -0.0014) _} 0.05 0.002) No.2. Sand 4jourals | Odze 0042 0.0008-0.0077 | G05 10.021 | Rod besring-t-iournal ol clearance 8020-0036 0.0008 d.00%e) | 0.05 0.002) ST TEIKOKU PISTON FING manufactored piston ring 12: RIKEN manufacture piston ring, *3: ALLIED RING CORP manufactured piston ring-— Engine Block — Section 7 Unit of length: mon in B16A2 Engine (MEASUREMENT [STANDARD (NEW) SERVICE UnarT Cylinder block | Warpage of deck surface ‘0.05 (0.002) 0.08 0.03), Bore diameter 81.000 -81.0203.1890~ 3.1698 | 87.070 (2.1917) Bore taper — 0.05 0.002) Feboring limit _ 0.25 10.01) Pieton | Skit 0.0, at 15 mm 0.59 6) 30.880 — 80.980 (31882 3.1886) | 80.970 3.1878) from bottom of skit Clearance in cylinder 0.010-0.035 0.0008 0.0014) | 0.08 (0.002) Ring groove width Top 11030 = 1.040 (0.0406 0.0408) | ¥.080 (0.0617) 2nd 1.230- 1.240(0.0484 0.0888) | 1.260 (0.0436) LL ch 2805-21820 (0.1108-0.1710) __| 2840 (0.1178) Piston ring Pisionsto-ring dlearance Top 0.045 0.070 (0.00%8 0.0028) | 0.13 (0.005) 2nd 0.080- 0.065 (0.0016 0.0026) | 0.13 (0.005), ing and gap Top 0.20- 0.35 (0.008 - 0.014) 0.800.028) 2nd 9.40 0.35 (0.016-0.022) 0.7010.028) ou 0.20 0.50 (0.008 - 0.020) 0.800.031) Piston pin Diameter | 20.996 ~ 23.000 10.8268 - 08268) Pin-to-piston clearance 2.010 0.022 (0.0008-0.0008) | Connecting od — | Pinto-rod interference 0.013 0.082 (0.0005 0.0013) | —— ‘Small end bore diameter 20.968 - 20.981 (0.8255 0.8260) | —— Large end bore diameter Nominal | 48.0(1.69) = | End play installod on crankshaft 0.18 - 0.90 (0.006 - 0.012) 0.400.016) Crankshak Main journal ameter ‘No. 1.2,4and 8 journals 54976-55000 (2.1644-2.1658) | —— | No. 2journal 54970 -s4.996.2.1642- 2.1651) | Rd journal diarneter 144976 45.000(1.7707-1.7717) | —— Journal taper 0.005 0.0002) max. (0.010 (0.0008) ‘Journal out of round 0.00¢ (0.0002) max. 0.008 0.0002), End olay 0.10 0.35 (0.004 0.014) 0.45 (0.018) Tota inout 2.020 (0.0008) max. 0.030 0.0012) Bearing ‘Main bearing to journal oll clearance No.1, 2,4 and 8 journal 0.024 - 0.042 (0.0008-0.0017 | 0.050.002), No. 3 journal 0.030 -0.088 0.0012- 0.0018) | 0.060.002, Rod bearing tourna! ol clearance 0.032 ~ 0.050 10.0013 0.0020) __| 0.080.002)Standards and Service Limits [— Engine Lubrication — Section 8 Except B16A2 Engine Pa kgm atiale 323,000 min" (rom) MEASUREMENT STANDARD (NEW) SERVICE LMT Enoine Capacity FWUSat imp at) Excopr DIBAS $0142, 38) for engine overhaul 3385, 29) for oll change, Including fiter | 30,2. 28) fr ollango, without fiter Disa9 43145, 38) for engine overhaul 25127, 3.1 for oll change nelding itor 32 (3.4 2.) for oil change, without iter Ol pame inner to-outer rotor radial dlearance 0.02 0.14 (0.001 -0.006) 020 008 | Pump body to-outer rotor raga learsnco 0.10 ~0.18 0.008 0.007) 920 0.008) Pump body-to-otor axial clearance. 8.03 0.08 10001 0.003) | 0.18 10.006) Rolie valve Pressure setting °C (17677) Pa tgler’ os) st ite 70,023, 10) min | 233,000 in gpm) | 350 (3.5, $0) min, (— Engine Lubrication — Section 8 B16A2 Engine MEASUREMENT STANDARD jew) | _SERVICE LIMA Engine oi Cepacity FS. Imp atl BUG, 42) for engine disassembly {406.2 35) for ol change, including oil fiter 27188, 2) for ol'cnange, without itr OT pump Inner to-outer rotor radial clearance 0.08 0.16 (0.002 - 0.006) 0.20 (0.058) Pump bodyto-oter racial clearance (0.10 ~0.19 (0.008 -0.007) 020 (0.008) Pump body 10 rater axa clearance 002-007 (0001 0.003), 0.15 (0.006) aliek valve Prossuro siting 60°C (1767) 70 (07,10) min 350 (35, 50) min 3-8Cooling — Section 10 L oe Unit of langth: men fin STANDARD (NEW) Radiator Coolant capacity _¢ (US at imp ab line and reservoir (4 ¢ 10.2 US at, 0.35 Imp ad ‘ncluding engine, heater, cooling wit BTeAD 448 (51, 42) for overhaul 3.9 (4.1, 3) for coolant change: 45 (48, 40) for overhaut 36 138,321 or coolant change Diez 4.4 46,291 for overhaul 35 (37, 3.1) for coolant change: 1281, 01582, 01583, 01587, 4.446, 39) for overhaul 35 (37,311 for coolant change 16a, 01626, D16z7, Diev 47 (50, 4.1) for overhaul 3.8 (40, 3.31 for coolant change Radiator cap Thermostat ‘Opening pressure Wa kale pa) Start to opening “CFF Fully open °C CF} Valve lif at fully open Disz Excopt 01821 orsz1 Excopt 01621 Tao-sa7e—vas) ‘95 125 (0.95 1.25, 14-16) 76-80 (169-176), 95 (203) 90 (134) 8.0 (0.31) min Cooling fan Thermoswitch "ON" temperature ‘Thermoswitch “OFF” tempareture “ere Scr) ‘9.0 95.0 (198-703) — Subtract 3-8 (5-15) trom actual “ON” temperature 3-9Standards and Service Limits [— Fuel and Emissions (Carbureted Engine) — Section 11 MEASUREMENT STANDARD (NEW) Fuel pump | Displacement seconds em (ox np oz) $58.3 1282, 20.8) min Relief valve opening pressure KPa tkglem®, psi 68-22. (007-023, 10-32) min Foot tank {Capacity ¢ (US o@l, Imp gall a5 (11.93.99) _ Engine Tale speed with headlight and cooling fan off MIT: Newt ‘AIT: (a or P] position saree 1261, 01583 300-50 7,000: 50 (1382, 01963, D18z2 800+ 50 isle co With CATA 05 max, Without CATA 1.0 max [— Fuel and Emissions (PGM-FI Engine) — Sectior MEASUREMENT ni 'STANDARO INEW) hose disconnected kPa (kglem’, pl Except 01582 Foal pump Displacement0 seconds em War, imp on) 720140, 42) rin Relief valve opening praseure kPa iglcm®, psi). 450 ~ 600 (4.5 6.0, 84~ 85) min Prossure regulator | Pressure with regulator vacuum 1862 245-285 12.45 - 2.85, 35-41) 290 330 (28-33, 40~ 47) Fost tank Copacity_¢ (US gal. Imo gal 51713, 98) - — Engine Tle speed with headlight and cooling fan off MIT: Neutral AMT in or] position CiaeD Disee a0 50 10-50 i587 750 450 75050, Di6Ad, 01626, 01627, DI6y1 75050, 750550 biszt 70060 mre 1687 T1050 — B16A2 __ 780850 = tale CO % With CATA 0.1 max Without CATA 10.0 [- Clutch — Section 12 MEASUREMENT STANDARD (NEW) [SERVICE LIMIT Clutch pedal Pedal height To Tioor | 7641646) = Stroke 130-140 (5.12~ 5.51) — “Total foe play 42-71(05-08) — Disengagement height tottoor | 8313.27) min = tocarpet | 55.22) min, Reference Fiywhee! “Gatch surface ronout 0.06 (0.0021 max 0.18 (0.606) Clutch ise vat depth 73 (0.051) min 020.008) Thickness _ | 64 9.11033 036 6010.28 Pressure plate | Warpage 0.08 (0.0011 max. 0.15 (0.008) Diaphragm spring finger alignment 0510.03) max 391008) 3-10[— 2WD Manual Transmission $20 — Section 13 Uae engts mm tot MEASUREMENT STANDARD (NEW) SERVICE UNIT aaa = = AS eens | eee eee poms | Transmission ol! | Capacity ¢ (US at. Imp qu 19120, 17) for overhaul 1.8 (18, 1.6 for oil change Mancha End play 0.11 018 10.008 -0.007) ‘Adjust Diameter of ball bearing contact ares A 21.987 - 22.000 (0.8656 -0.8861) | 71.930 0.8634) (Transmission housing side) Diamotor of ah, th gear contact aroa B 26.980 - 26.999 (1.0622 1.0827) | 26.930 1.0602) Diameter of 3rd gear contact area C 33.984 - 34.000 (1.3380 13385) | 33.930 (1.3358) Diameter of ball bearing contact area D 25977 - 25.990 (1.0227 - 10232) | 25.920 1.0205) (Clutch nousing side! Funout 0.02 0.001) max. 0.05 10.002) : Miainehat Sed and | 10. 139,008 39.025 (15368-15368) | 39.07 (1538) ‘th gears End play 3rd | 0108-021 0.002 = 0.008) 0.33 0.013) ‘ath | 0.08 0.18 (0.002 - 0.007 0.31 (0012) “TWicknese 34a | 30.22 - 30.27 (1.190 1.1921 30.18 (1.187), fan | 50.12 30.17 (1186 1.188) 30.05 (1183), Tiainshortan | 1D. 37.000 37.025 (1.4870 1.0577) | 37.07 (1.450) ‘ear | Ena ptey 0.08 0.19 (0.002 -0.007), 0.31 (0.012) [Thickness 28.82 - 28.47 (1.119 - 1-121) 28.38:(1.116) Countersha Diameter of neodie besring contacts 30.000 30.015 (1.1671 - 1.1877) | 29.950 (1.1797) Diameter of 1s gear contact area B 36.984 36.000 (1.4167 - 1.4173). | 35.950 (1.4146) Diameter of ball boaring comtact area C 24.980 24.993 (0.9835 -0.9840) | 24.950 (09815) Runowt 7 {0.62 10,0008) max 04.08 (0.02) reba Tat | 1. 17,009 ~ 47.025 (16145-18182) | 41.07 (1.617) End play (When tightened by the specified torque) | 0.03--0,10 10.001 - 0.008) 0.22 0.008) Thickness 30.41 30.48 (1-197 1.198) 30.36 (1.195) Counterehak 2nd | 1D, “4,000 - 44,025 (1.7326 - 1.7333) | 44.07 1.735) gear End play (When tightened by th 0.03 - 0.11 (2.001 ~0.008 | 223,0.600 Thickness 3192-3197 (1.257 -1.259) 39.85 (1.254) Spacer colar 10. 39.000 - 33.010 (12992 - 1.2986) | 33.05 7.507) (Countershatt 2nd | 0.0. 38.989 -38,000(1.5350 ~ 1.5354) | 38.95 (1.533) | cart Length 32.03 ~ 32.06 (1.261 - 1.282) 32.01 (1260), ‘Spacer collar 10. 27-002 ~ 27.012 (7.0681 - 1.0835) | 27.06 1.068) (Wainshat an — | OD, sem | 33989-34000 (13381 - 1.3386) | 33.93 (1336) and 5th g sth | 31.989 ~ 32.000 (1.2594 1.2598) | 31.99(1257), Length atm | 2285 ~22.85 (0.899 - 0.900) 22.81 (0898) th | 2383 2356 0.926 0.928) 235105926) Reverse idler gear | 10. 15.016 - 15.043 (08912-05022) | 1508 (0590) Goartoreverse gear shaft clearance 032-0077 40.0013 0.0030) _| 0.14 (0.006) ‘Synchro rng Ring to-gear clearance (Ring pushed againet gear) | 0.73 1.18 (0.029 0.086) 0.4 (0076) ‘Shift fork Fork finger thickness 6.465 (0.252 -0255) - Forkto synchro sleeve clearance 025 -0.45 (0010-0018) 08 (0.022) Reverse shiffork | Fork pawl groove wicth 127 -130(080-050) — Forkto-everee idler gear clearance 05-11 (0020-008) 18.071 groove wicth | 705 -7.28 (0278-0288) “ Fork-to-Bthireverse shift piece pin clearance 0.06 - 0.35 (0.002 - 0.014) | 0s (002) Shit arm A Tner dlamoter of shift arm C contact point 13.08 13.13 (0834-0817) = Shift arm Ato-shift arm C clearence 0.05 ~ 0.23 (0.002 ~ 0.008) 035 10.074 Shittarm 6 Inner diameter of shift arm B sheft contact point 13973 16.000 (05501 05512) Shift arm Bto-shalt clearance 2.013~0.070 (0.0005 - 0.0028) | 0.18 (0.c06) Shit orm Bo-shit piece clearance 0.208 (0.008 -0.020) ‘0.62 0.0244) Diameter of shit piece contact point 129 ~13.0(0.508-0.512) {1278 (05030 3-11Standards and Service Limits ;— 2WD Manual Transmission Y21 — Section 13 MEASUREMENT { STANDARD (NEW) SERVICE LIMIT Transmission oil | Capacity ¢ (US qt, imp at) | 2312.4, 20) for overhaul ___| 22123, 19) or oitenange ‘Mainahat End play [0.11018 (0.008 - 0.0071 Aajust } Diameter of ball bearing contact area A 27.977 ~ 27,990 (1.1015 ~ 1.1020) | 27.990 (1.0996) | (lutch housing side | Diometer of 38 gaar contact area B 27.984 - 38.000 (1.4958 - 1.4960). | 37.990 (1.4999) Diameter of ball bering contact erea C 27/987 - 28.000 (1.1018 —1.1028) | 27.940 (11000) (Transmission housing tie), Runout _ | 0.02 (0.001) max 0.05 (0.002) Moinsho 3rd and | 1. 123,009 - «3.025 (16933-16939) | 43.08 1.696) 4th gears, End play 0.08 - 0.21 (0.002 -0.008) 03.000) ‘Thickness arg | 3492-2497 (1.78- 1.37) 34811370) | ath | 542-3197 (1257-1239 | 31302221 Mainsha oth | 10. 15,009 - 49.025 (7.6933 - 1.6939) | 43.08 1.686) ear End play 0.08 - 0.21 (0.002 0.008) 0.31001) “Thickness. | saz — 31.47 1.257 ~ 1.238) 31.3(1.232) Countershatt Diameter of bal bearing contact area A | 24.980 - 24.983 (0.8835 -0.9880) | 26.940 10.9818) | Diameter of tst gear contact area B 36.984 37.000 (1.4561 ~ 1.4587) | 36.830 (1.4539) Diameter of needle bearing contact area © 535.000 33.015 (1.2992 1.2998) | 32.950 (12970) Runost 0.02 (0.0008) max. (0.05 0.002) Countorshat tet | 10. 12,009 - 42.025 (1.6539 1.6545) | 42.08 (1.657) | gear End play (When tightened by the specified torquel | 0,08 - 0.12 (0.0016 ~ 0.0047) 0.18 10.0071), Countershalt 2nd | 10. 147.008 - 47.035 (1.8507 —1.8514) | 47.08 (1.854) sear End play (When tightened by the specified torque! | 0,05 ~0.12 (0.0020 0.0047) 0.18 (0.0071) “Thickness. 2892-2897 (1.1306 1.1405) | 28800130) ‘Spacer collar 1D. 36.48 36.49 11.436 — 1.437) 13650 (1.439) (Countershaft 2nd. | 0.0 141.989 42.000 1.6531- 1.6535) | 41.94 (1.651) gear) Length & | 29.02 29.08 7.1828~ 1.1499) _ 8 | 20.07 — 29.09 11.1448 — 1.1453) = ‘Spacer colar 1B. ‘3.002 - 31.012 (1.2208 - 1.2208) | 3-06 0-223) Mainshat ath — | 0.0. 37989 — 38.000 1.4956 14961) | 37.94 (7494) ‘and 5th gear) Leneth 156.45 ~ 56.55 (2.2228 2.2288) uysth gear side _| 26.03 26.08 (7,025 ~ 1.027) = 3-12[— 2WD Manual Transmission ¥21 — Section 13 Unit of length: mm tind Groove wicth of select arm contact area 1208 -12.15 (0.474 0.472) | (MEASUREMENT [STANDARD (NEW) SERVICE LIMIT Reverse idler gear | 1D. 20.016 - 20.043 (0.7880 -0.7687) | 20.09 0.7900 Geor-to-reverse gear shatt ck (0.035~ 0.086 0.0014~0.0033) | 0.18 (0.006) ‘Synchro rina Ringto-gear clearance (Ring pushed against gear) | 085-110(0033-o083) ‘| 0.4 (0.016) Double cone Clearance (fing pushed against gear) ‘synchro ring ‘Outer synchro ring to-gear | 995-168 0.037 - 0.080) 06 (0.028) Inner synchro ing to-Jear 05~1.01002-0.08) 03 (001) Cuter syneneo ring to-Synchvo cone 05-10 (002-008) 031000, ie Shit Tork Fork finger thickness 7.4-7.6 (0291-0290) Forkto synchro sleeve clearance 0.35 - 069 (0015 0.026) 10 (0.08) Feverze sift fork | Fork pawl groove wiath 130-133 (0512 ~0526) y Forketo reverse idler gear clearance 05-11(0.02-0.08) 181007) groove wath AAtbih goarside | 7.47.7 (0.29 -0.30) —— traverse side | 7.09-7,25(0.278 - 0.205) = Fork to Sthroverse shift piece pin clearance 'ALBth gear side | 0.4-0.9 (0.02 -0.08) = | _ ‘Acrevorse side | 0.05 ~ 0.45 0.002 ~ 0.018) = Shift piece ‘Shif piece to-ehif arm clearance (01-03 (0008-0012) 6002 Groove width of shift arm contact area 81-82 (0.319 -0.325) Shife-piece-to-shift fork shat clearance 02-05 (0.008 0.020) 06002) ‘Width of shift fork contact area M9120 (0.469 0.472) = Select arm Select r-to-interiock clearance 0.05 = 025 10.002 - 0.078) ] asia Select arm to-shim eleerance 0.01 0.2 (0.0006 ~0.008) —— inter ‘Width of select arm contact area 9.9 10.0(0.300-0.398) — Change piece | Change piece-to-ehift arm holder clearance (0.05 0.35 (0.002 0.014 03 (003) Groove width of shift arm holder contact ares 1205 12.15 (0.474 0.478) Change pieco-to-seloct arm clearance 0.05 0.35 (0.002 - 0.014) 08 (0.03) 3-13Standards and Service Limits r AWD Manual Transmission S22 — Section 13 (MEASUREMENT STANDARD (NEW) | SERVICE LIMIT Tansnioion at} Capaciy 1 US imp ad TEER forsee Feee Ta eratchonse Mainshaft End play. 0.11 - 0.18 (0.004 - 0,007) Adjust | | Bran of 8120 bat bering conaetarona | Svar satrnapie soa | 278% aso | Barat ot 1 gear cnt eo Sesue Spann are—130a0) | Season) Diamar cteledeswartacvocenacanec | Zeostaseeeotnsesr agers | aus loans | Diameter of 4th/sth spacer collar contact ares 27.987 ~ 27.000 (1.1018 - 1.1024) | 27.930 (7.0996) Pwo Soetoact mee Sos vou Taina 10: 0008-002 (STE2— VETER | 407 ST Seger tha pay Soetaa 00: 0.08 owen nate Seta eaiize-tne | Sastre Tina iB ‘Oa0b «0026 1s7a2- 15768) —| «007 ts) eer td pay soca te. om Sune rarer | Siete SesaSsoorteme tie | Sasa Wana ro ‘Onnd—anaze sree 157E6)—] «007 (sr Big tea pay Stas o oe oon Sone iekte Sosa sou trace ato | Sastiiaay Courtrahatt | Dirt of pedi basing ones eo peat oars hav] 28900 SH Diora ofr gor amas seaB Jeaetasecao asso tase) | seein aa Biomater af al Bering comact are © Stosrogsow loser ogee) | aravo losers unoet der 102001 mn Sosvoone Taunka [3 Sats naz (98 —T9M—B S007 HTH ‘aoe tha pay When tghened bye apectiedtraue) | Sas ous ean) neua) Sean _| Rakes S2a5-Ssan{tzor 200) | Sassi Toomer So.tH = snz5 (9680-19687 | S007 arn raven Ena ple When ohtnedby he specfodtoray) | @es-oasiouo!-o00a)" | aveiouom | Srstets | s2e2 ose tte ae) | Setar Taina aan | 1 Sea DE one oR] Ses Mrccertcence | Ob 3eaie seam ave—tare | sess tur eoise a Bos asostios aan” | Feeney Counceatat ind] 36.5548 06-taT| aes 8 Sordnones™ | Op Soe teow ren | satan sue nat seaceasaotio nae | duet Teveno Wargo | 1 00rd 20045 07680-0780] 20.08 O7RH) Ceartoshat earnce Sess! ogee ouureeaansee| aietsooe) Sapariow Diane of needle bang cone g08i- 73985 6H) 0916] Za 09Kz) See eae Super iow ara fod baw onan oes ‘aaee sama area | Saoer Ty sans benny coat ek Hestaonea ez | Heras 3-14Unit of length: tin [— 4WD Manual Transmission $22 — Section 13 MEASUREMENT STANDARD (NEW) [SERVICE LMT raha | Diameter of needle bearing contact area ‘4000 64.015 2.125 - 3.17) | Ba94 12.120) Diameter of taper bearing contact area 16.989 - 17000 (0.8589 0.6653) | 16.93 (0.667) Diameter of drive bevel gear contact area 24979 25.000 0.983-0.984) | 2492(0.98) Runout ‘002 10.001 (0.05 0.002) Transterarive | 10. 25.000 25.027 09843-09851) | 25.05 (0.987) bevel gear Diameter of taper bearing contact area | 35.002 35.018 (1.3780-1.3787)_| 34.95 (1.376) Transfer driven | Backlash ‘0:10-0:15 (0.006 - 0.006) [Aaiust bevel gear Diametar of taper bearing contact area “Transter driven gear side | 25,002- 25018 (1.9700- 1.2767) } 38.95(1.376) Locknut side. 27.987 - 28.000 (1.1018 1.1024) _| 27.8311.100) Synchro tng ing to-gear clearance (Ring pushed against gear) | 0.85 1.10 (0.033 - 0.083), (041002), ‘2nd shift fork | Synchro sleeve groove with 735-808 (0313-0317) — and rdiath shift | Shift fork-to-synchro sleeve clearance Theust | 045-065 (0.018 0.026) 1010.08) fork Radial | 0.05~ 0.48 (0.002.018) 0.3 (003) Shift fork finger thickness 74-75 (0.29030) ae ‘ih ahi York ‘Synchro sleeve groove wiath ‘5.95 605 (0.238 0.238) — Shit forkto-syechro sleeve clearance Thrust | 025—0.45 (0.010- 0.018) 08 (003) Radial | 0.05— 0.46 (0.002 0.018), 0.8 (0.03) Reverse shift fork | Fork pawl thickness 13.0 13:31051-052) Forkto reverse idler gear clearance 025-0864 (0.010 -0.033) = | L-groove with 7.05 -7.25 (0278 - 0.285) = 7 Forketo sthvroverse shit piece pin clearance 0.05 - 0.35 (0.002 -0.014) 05 (002) Shittorm A Diameter of sift piece contact area 128-130 (0508-0512) — Shift erm-o-shit piece clearance 02-05 0010.02) 07 (003) 10. 16.000 - 16.068 (0.6200 - 0.6326) | —— Shift arm-to shaft clearance 011-0092 10.0008-0.036) | —— Shittarm ‘Diameter of shift arm A contact area 11.8 12.0 (0.469 -0.472) — Solect arm-to-shit arm A clearance: 0.65 0.25 (0.002 - 0.010), 05002) iu ‘Select arm Diameter of shift arm A contact area 795-800 0313-0318) — ‘Selactarm-to-shift arm Aclearance 0.10025 (0.004 - 0.010), 05 (0.02) Superiow shift | Synchro sleeve groove wicth [575-825 (02728-0230) ic fore | Forkto-synenvo sleeve clearence Thrust | 0280.45 (0.010 0.018) 08003) Radial | 0.05048 (0.002 — 0.018), 038 (0.031) 3-15Standards and Service Limits [— 2WD Automatic Transmission M48A — Section 14 4th clutch pressure at 2,000 min (pm! [i position £850 900 (8.5 - 9.0, 121 128) throtle more than 1/4 opened MEASUREMENT SSTANDARO (NEW) senvice unr Tensnieson | Capaaly CUS imp at EAST. 40) for overaul fe 24 (25,2 or hundchange yao Tine sesnire a 000 nop Rlar@] postion | 000-950,80- 05, 11¢= 12) | 75075 107 pressure : “20142, eo) 370187, =) Bobet oa | zetowen see 20 miro Beton | Set 30187 5 : ; [ee Bra latch pressure 3t 2000 minim postion | gop hso(ea-as, 14-120) | 750¢4.8 107 SMoulemorethen Ve opened | tte more than 374 “4th clutch pressure at 2,000 min: (rpm) [Bs position i EXT fae 2rd uch pressure ot 2000 min postion | GIO 6G0TEO-8S, TA TaN 15007 10H ‘tcc presera a 2.009 min epm) (or | gon -a50190-28, 14-120,” _| 750475, 107) ‘Governor pressure a 0 kh 38 mi TaN OTS aH Thre prevsre Twowe fly dosed | © Tate fly open | 8o0-e50i0~a5. 114-120 _ | 750075. 107 Thal presse A Tht fly closed | 0-8 (0-005 0-H Throne ly open | Bis-s90(66-83,70-76) | $101.70) ara Tino presura a 2000777 pI or postion | €50 0008-80, 121 1267 | e000. 14), pressure rt 420 (4.2, 60) 370 (3.7, 63) Beige par | 2nd clutch pressure st 2.000 min pm BD postion | $204.2; 80) $7087 59) | ores vi fy ova 1300 8.0, 114) throttle more than Wt ‘opened “nd clutch proswure 9€ 2,000 mi lepm™) [a] postion 1850900 (85-80, 121-178) 900 (8.0, 1% ‘st clutch pressure at 2,000 min (rpm) ‘850-900 (859.0, 121128) | 600180, 114) position ‘Governor pressure at 60 kmh (8 mph Wet 16ST 1812) | BSD Throttle pressure 8 Throtte fully cloved | 0 — Treotle fully apon | 200-850(80-85, 114-121) _| 7507.5. 107), Throttle pressure A Throtte fully closed | 0-5 (0-005, 0-1) — Treotlefuly pan | $15~830(5.18-5.3, 73-78) __| 8106.1, 73) 3-16-— 2WD Automatic Transmission M48A (cont'd) — Section 14 Unit ofangth: mi ti 3rd elutch pressure at 2,000 mie (cpm) (5 position {ath clutch pressure at 2,000 min (rpm) (03) position 850-900 1859.0, 121-128) {hole more than 1/4 opened MEASUREMENT STANDARD (NEW) SERVICE LIMIT ydraclie Line pressure at 2000 min“ (rpm) (id or[B) position | 860900185 -9.0, 121-128) | 800180, 114) pressure kPa = 2042, 60) '370(37, 53) trier pit 2nd clutch pressure at 2000 min" (rpm) position | $20.42,50) ease Dias i r 9008.0, 114) throtle more than 1 ‘opened 2nd clutch pressure st 2000 min" rem) ) position | 650-900185—9.0, 121-128) | #00(a0, 114) ‘st clutch pressure at 2,000 min (¢pm) Ds or ‘350-900 (8.5~9.0, 121-128) | 800(80, 114) [Bd position Governor pressure at 60 Kr (38 mph? Wes 7H)_| BTS Throttle pressure 8 Throtie fully closed | 0 Throtle fuly opon | 800-85018.0-85, 114-120) __ | 7507.8, 107 Throws pressure A Throttle fully closed) 0-5 (0 -0.05, 0-1) Throttle fully open | 495-510 14.95 8.3, 70-73) 49049, 70) ‘Stall speed mine pm) (eheok with car on level ground 2.600 2,300 - 2,900 ‘clutch ‘Clutch initial clearance Ta ind (0.65 088 10.026 0.033) 2rd, ath 0.40 060 10.016 0.024), Clutch retun spring free length ist 31,011.22) 000 2nd, ara, ath | 305 (1.20) 205032 Clutch ise thickness 4138 ~ 2.00 (0.074 - 0.079) Until grooves worn out Clutch plate thickness a8 155 — 1.65 0.081 — 0.065) Discoloration 2nd, 3ed,ath_| 1.95 205 (0.077 - 0.081) Discoloration ‘Clutch end plate thickness MARK? | 22-23 (0.087 - 0.091), Discoloration 1281, D1883, Mark 2 | 25-266 (0.098-0.102) marca | 28-29 (0.110-0.114) marca | 31-32 (0122-0126) marks | 34-35 (0.19¢ 0.138) Mark 11 | 205-215 (0.081 - 0.085) MARK 12 | 2.35 245 10.083 - 0.096) MARK 13. | 2.65 275 0.108 -0.108) MARK 14 | 295-305 0.116 -0.120) MARK 18 | 3.25-3.3510.128 0.132) MARK 16_| 3155-365 (0.140 -0-148) Discoloration ‘lutch end plate thickness MARK y | 23-24 (0.091 0.008 Discoloration 16a9 MARK 2 | 2.82.5 (0.098 0.098) Marka | 25-26 (0.098 -0.1021 Mare «| 26-27 (0.020.108) MARKS | 27-28 (0.108-0.110) MARKS | 28-29(0.110-0.118) MARK? | 29-30(0.114-0.18) MaRKe | 30-31 (0.118-0.122) Mark9 | 31-32 (0.122-0.126) | MARK 10 | 32-33(0.126-0.130) MARK 11 | 20-21 (0.079 0.083) MARK 12 | 2.122 (0.083 -0.087), Mark 13 | 2.2-2:3(0.087 -0.090) Discoloration (cont’a) 3-17Standard: Is and Service Limits MEASUREMENT STANDARD (NEW) F- 2WD Automatic Transmission M48A (contd) — Section 1 SERVICE UNIT Transmission Diameter of needle bearing contact area ‘On mainsheft and stator shaft, (On mainshof 2nd gear On mainshott ath goar collar On mainshaf 1st geo colar On countorshatt (ese) On courtershat 3rd gear distance collar On courtershaft ath ‘On countershatt reverse gear collar (On countorshat 18t gear collar On reverse idler goar shaft On mainshat 1s Inside diameter of needle bearing contect area ‘On mainshat 2nd gear ‘On mainshaft ah gear On countershat 1s ge (On countorshat 3rd gear Oncountarsheft ath ge On countershat raverse gear ‘On rovorse idler goor (On stator shaft (side) (On stator shaft (stator sido) (On reverse ier shaft holder End olay Mainshaft 1st gear Mainshat 2nd gear | Mainshaft 4th gear Countershatt ist gear ‘Countershaft 3rd gear Countershaft 4h gear Reverse ier goat Countershat reverse gear Selector hub O.D. Mainshatt ath gear collar length Maingha® 1th gear colar length Mainahaft 1th geor collar flange thickness 19.900 - 19,999 (0.7666 - 0.7871) 35975 — 35.991 1.4163 14169) 31,975 — 31.991 (1.2589 - 17596) 27978 —27:995 (1.4014 - 1.1022) ‘36.004 36.017 (1.4175~ 1.4180) 31.975 ~ 31.991 (1.2589 - 1.2595) 27.980 - 27.993 (1.1016 — 1.1020) 29.980 - 29.993 (1/1803 — 1.1808) 729.980 28.993 (1.1803 - 1.1808) 13.990 ~ 14.000 (0.5508 - 0.5512) 33,000 - 33.016 (1.2992 - 1.2988) 461.000 ~ 41.016 (1.6142 - 1.6148) ‘38.000 38.016 1.4961 - 14967) ‘35,000 - 35.016 (1.3780 - 13786) $38,000 ~ 38.016 (1.4961 - 1.4967) $3,000 33.016 (1.2992 - 12998) ‘36.000 - 36.016 (1.4173 - 1.4179) 18.007 - 18.020 (0.7089 - 0.7004) 26,000 - 26.013 1.0236 - 1.0241) 24,000 28.021 (0.9849 - 0.9487) 14.416 — 14434 (0.5676 - 0.5689) 0.08 -0.24 (0.003 - 0.008) (0.07 ~0.15 (0.003 - 0.006) (0.100 22 (0.008 - 0.000) 0.10 ~0.45 (0.008 - 0.018) 0.07 ~0.15 (0.003 - 0.008) 0.07 ~0.15 (0.003 - 0.006) 0.05 ~0.18 (0.002 0.007) 0.10-0.45 (0.008 0.013) 51.87 - 51.90 (2042-2043) 40.00 - 40.05 (1.5748 — 1.5768) 25,00 - 26.15 (0.9043 - 0.9902) 25-26 (0.098 0.102) Wear or damage 1 Wear oF damage Wear or damage 4 \ Wear or damage | ‘Wear or damage Wear or domage CCountershaft distance collar length "3897 ~ 39.00 (1894 1.595) 38.02 ~ 99.05 (1596-1537) 39.07 ~ 39.10 (1538 - 1539), 39.12~39.18 (1540-1580) 39.17 ~ 39.20 (1542 - 1543) 39.22 - 30.25 (1544-1545), 3927-3930 (1546-1587) 38.87 ~ 3890 (1590-1531) 38,92 — 3895 (1592 - 1533) IIT UILI Counterahat reverse gear collar length CCountershat reverse gear collar flange thickness Countershatt Ist gear collr length Countershatt 1et gear collar flange thickness {45-1495 (0577-0579) 2.45 2.5 (0.096 0.100) 1450-1455 (0571-0573) 2.45 ~ 2.55 (0.006 ~ 0.100) Wear or damage \ ‘Wear or damage 3-18[- 2WD Automatic Transmission M48A (cont'd) — Section 14 (MEASUREMENT STANDARD (NEW) Unit oftength mm tind |___service unre Traneriasion (cont) Mainsha 2nd goar thrust washer thickness 3a 352 350 0.197 -0.198) '3.55.0.139 0.140) 357-360 (0.141 0.182) 3.62365 (0143 0.184), 3.67 -3.70 (0-148 - 0.188), 372) 377- 362- 37510.147 0.148) 3.80 (0.148 0.150) 3.850.151 -0.152) 3.87 3,90 (0.183 0.154) Weor or damage Wear or demage “Thrust washer thickness ‘Mainshat ath gea Mainshaft bell bearing L side Mainchaft tet gear L. side Mainchaft 1st gear Aside a45— 298. has. 243 4.55 (0.175 -0.179) 3.05 (0.116 0.120) 1.50 (0.087 - 0.057), 2150 (0.096 0.098) Wear or damage ‘Weer of damage ‘Countershaft 3rd gear splined washer thickness: ‘Wainahaft &h gear thrust woshor thickness One-way clutch contact area I. ‘Countorshatt Tot gear Parking gear 287 292 2s7- 302- 307- 312 3a7- 322- 327- 332- 337- 293 7eane 57.755 - 67.768 (2.2730 -2.2743), 2.90 (0.113 0.114) 2.95 (0.115 0.116) $3.00 (0.117 0.118) 305 (0.119- 0.120) 3.100.121 -0.122) 3.150.123 0.128) 3:20 (0.125 - 0.126) 3.25 (0.127 0.128) 3.20 0.129 0.190) 3.35 (0.131 -0132) 3.40 (0.133 0.134) 3.00 (0-115- 0.178) 74440 (2990-2930) Wear or damage \ Wear or damage Wear or damage t Wear at damage ‘and parking brake Parking beake ratchet paw! Mainshaft feed pipe A. 0.0, 897-898 (0353-0.354) 3.95 (0.352) Mainshott feed pipe 8, 0.0. 597 ~ 5.98 102380 -0.2354) 5.95 (0234) Countorshatt feed pipe 0.0. 797 ~7.98 (03138-03142) 795 10.313) Mainahafteealing Fig thickness 11920-1996 (00760 ao7as) | 1.801007) Mainsheft bushing 1D. 6.018 6.030 10.2369 -0.2374) | 6.045 (0.2380) Mainehaft bushing LD: $.000-9.015 103543 0.3549) | 8.030 0.358) Countershatt bushing 1. 8.000 2.018 (03160-03155) | 8.030 (0.3161) IMainahaft sealing ring groove width 20025 2.080(0.0787 0.081) _| 2.080 (0.082), Regulator valve | Sealing ring contact |. 32,000 - 22.026 (1.260 1.261) | 32.05 (1.262) body ‘Shifting davies | Reverso shift fork finger thickness 590600 (0732 0736) 3.40 (0218) Wear or other it pump driven gear LD. Oilpump shat OD. Wo 16- 14.034 (05518-05525), 13.900 ~ 13.990 (0.5504 0.5608) control Parking brake gear = defect Throtie cam stopper height 395 — 18. (0.728 -0.732) Servo body ‘Shift fork shaft bore 1D. A] 14.000 - 14.005 (05512 - 05614) | —— @ | 19006- 14.010 (05514-5516) | —— € | s40r1- 14015 (05516—o51=) | —— Shift fork shaft valve bore 1.0. £37000 37.039 (1.4567 — 1.4582) _| 37.085 (1.4885) Oilpume (Oil pump gear side clearance ‘9.03 ~005 (0.001 - 0.002) (0.07 0.003) Oil pump gear-to-body clearance Drive | 0.240 -0.266 (0.008 - 0.010) Driven, | 0.063 0.068 (0.002 0.003) Weer or damage Wear or dara (cont'd) 3-19Standards and Service Limits MEASUREMENT [— 2WD Automatic Transmission M48A (cont'd) — Section 14 STANDARD (NEW! Wire Dia. 00. Free Length No, of Coils ‘Spring Zadorifee control DI2BYDTSBS | __0910.03H 610260) | 4127.62) 20 valve spring Dress: 0.9 (0.035) 6510260) | 45.111:776) zo 3-4 shift valve sping 0.7 0.026) 9610378) | 82917295) a ‘3:4 ehift valve bal spring 045 0.078) 45 (0.17) | 12.00.47) 67 Cooler ‘ele valve spring 1.110.083) 134 (0581) | 96.6 1.453) 120 Relief valve spring Toros | serosa | 33811390 125 2. shift valve spring (07 (0.028) 7.50299) | _43.041.689) 127 2.3 shift valve ball song 0.4 0016) 450177) | 147 (0879) 73 12 shift vaive epeing (05 0020) 45 (0.177) | 445 (1.752) 35.4 12 shift valve bal sing 0.4 (0016) 45 (0.177) | 11.3 (0.448) 80 Regulstor valve Dizswpises | 180.071) 147 (0879) | 86.5 (3.408) 165 spring A reas 13,0071), 14710579) | 68.1 (3.488), 165, Regulstor valve spring & 18 0070, 96 (0.376) | 44.010.732) 75. Stetor roaction spring 55 0217) | *264(1.039) | _90.3(7.103) 24 Lock-up contol Diasyprses | 0.710.028) 65(0260) | 825(1.280) Teo) valve spring Disas 0.5 (0.024) 6.5(0.260) | _528(1.201) 158 Torque converter check valve spring 110.089), 34 (0.331) | 366 1.433) 120) ‘Modulator valve Di2BVDI563 1210087) 77.0 (0276) | 26.31.0369 30 spring 1210087), sroi2 | 720.070 80. Dieas 1210087) 7.0 0276) | 26.31.0386) 80 12 (0.087) +7010276) | _ 26.4 11.038), 30 Throttle valve A Di2BiDises 110.083) 85,0335) | 23,0878) at spring) 110.083), 350335) | 723 (0878) 78 100.039), 35.0335) | 22210878) 50. 10:0.038), 35,0335) | 22110870) 55 ‘Di6AS 1.00039), 35 (0.335) | 222 (0878) 0 10 (0.038), 85 (0.335) | 22110870) 55 190.039), 3510335) | 22510896) 13 1.910.038), 8510335) | 22310.878) 55 Throtie valve A adjusting spring 0810031) 62(0.288) | _27.011.063) 85. Throtte valve B ‘D121 168s 114 10.056) 3510398) | «1.5 (1.838) 705) toring 1410.055), asioas) | 41811636) m2 1.410.058), 3510.35) | 47.6(1.638) a Dieas 1.610.083), 5.0335) | #1311626) 138 11910.083), 35,0335) | 41.441630) 17 116 10.083), 3510335) | 41311626) 130 3-20 Inside Diemetor(— 2WD Automatic Transmission M48A (cont'd) — Section 14 STANDARD (NEW) Unit of lng: mm tin techie Wire Dia oD. Free Length | No.of Coils Spring Throie valve B adjusting soring 0.8 0.031) 320789 | 30.00.181) 30 3ed aceumulater spring 2.8 (0.110) 355 (0610) | 625 (0.248) Wr 2nd aceurnulator Diaeyorses | 380.150) 20210795) | 78.3(2.965) 108 spring Dress 3.8 (0.150), 20210795) | 78.112957) 38 ‘ath accumulator spring 32 (0.126), 18.6 (0.732) | 82.71(3.256) 720 Reverse timing valve spring 070.028), 5.6(0.220) | 43.8 (1-728) 27 ‘Serva control valve spring 1.010.089) 7.6(0.299) | 39.41.55) 182 Lock up hi DizeiDisss | 0.7 0.028) 1 (0319) | 38.0(1.538) 154 valve spring Drea) 1.110.083), 8110319) | _§1.812039) 23 Locksup sing valve spring 1.010.039) 6.50260) | _82.3(2.059) 301 Governor spring A. 1.0 (0.039) 78 (0740) | 20.40.80) 40 Governor spring & oa (0030 vig (oassy | 9097217) 60 0.80030) ria oss) | 28.70.0850) 6 Kickdown valve spring 1.310051) 70.1 (0.398) | _83211.307) 703. Orifice contrat DizevD1sas | 08 0030) 6.1 (0.240) 36.2 (1.425) 146 valve spring D16A9 09 (0035), 610240) | 36011417) 198 ‘Shift timing vaive spring 0.910.035), 86 0.339) 42.9 (7.689) za ‘th exhaust valve spring 0. (0.038), 6.110.240) | #3.7(1.720) 203 ‘Accumulator control DI2BVDISES | 1.210.087), 3610399) | <69 (1846) 152 valve spring Disas 12 (0.047, 8610339) 85.6 (1.795) 147 Look-up cut valve spring (0.7 (0028) 7.6 (0299), 29.0 (1.142) 180) Reverse contol valve sping 07 (0028) 7.6 (0229) 37-2 (1-468) 163 ‘CPC (Clutch Pressure Controb 0.9 (6.038) 36033) | 18210717) | 558 valve spting ‘st accumulator oneaway ball spring ozo ‘ororen | 14000880) io Tat acounulator spring A 290.114) 21510846) | 586 2.318) 73 Tet accumulator spring 8 23 (009%) 7.510295) | 39.0 (1.535) 58 3-21Standards and Service Limi -— 2WD Automatic Transmission M24A — Section 14 its ses, D16v4 Hydrate pressure KPa tkofem, pst 1582, 01587 3rd clutch prossure at 2,000 min" (rpm [i positon {th clutch pressure at 2,000 min rpm) [Bd position tote ft eoses £850 - 900 (8.5 - 9.0, 121-128) throtie more thon 18 opened (MEASUREMENT STANDARD (NEW) SERVICE LIMIT Tranamnssion Capachy TUSa. impai) ~)59162,52) for overhaut fivid| | 27 (28, 2.8) for fluid chenge Hydeoule {ine presoure at 2,000 min" (ram) inl or Bl position | 850-900 (85-80, 121-128) | 800180, 118) kPa ikgiem®, psiy | 2nd clutch pressure at 2,000 min (rpm) [Bi position | 400 (4.0.57) pee ‘theo fully closed 800 80, 14, throtle moro than 17 ‘opened 2nd clutch pressure at 2,000 min (pm) ‘3rd eltch pressure at 2,000 mie ppm) [Od position 4th clutch pressure t 2,000 min pm) [bs] position ‘throtle fully closed 900-850 (8.08.5, 114-121) {hrotie more than 1/8 opened ‘2nd clutch pressure at 2,000 min” irpm)[2)position | 850 - 900 (8.59.0, 121-128) 800 (8.0, 194) ‘st elutch pressure at 2,000 min-* (rpm) [Os oF ‘850 - 900 (8.59.0, 121-128) 800 (8.0, 174) position ‘Governor pressure at 60 kmih (38 mph) "182 — 192 (7.82 - 1.92, 26-27) 477 G77. 25) Throttle 8 pressure Trowe fully dosed] 0- 18 (0-0.16, 0-2), ;— Trotle fully open | €50~900;85-80, 121-126) _| 300160. 14) | Tivoito A pressure Trot fully closed | 0-8 (0-005,0- 0) 7— ‘rotte fuly open | 485-500 (4.85.00, 69-71) _| 4804.8, 68) Line pressure at 2000 min (roml(n)or[Pl position | 800~850(8.0-85, 114— 121) | 750(76, 107) 20049, 57) 350 (35,50) thot fully closed i 780 7.5, 107) throttle more than 18 opened ‘2rd clutch pressure at 2000 min” (7pm [2] postion 300 660 (80-5, 114121) 750 7.5, 107) Tet clutch pressure a 2,000 min” (pe) (Bs ori ‘800 650 (80-85, 114-127) 750 (78, 107) Governor pressure at 60 nih 138 mph Vea 192 (1821.92, 26-77) T7728) Throttle B pressure Trotteflly losed | 0-18 (0-0.18,0-2) ‘Trotte fully open | 8005018085, 116-12 __| 7500.5, 107) Throtte A pressure Trotte fully closed | 0-510 0.05,0-1) ise. Trottle fully open | $15.~530(5.15-5.30, 73-75) | §10(6.1, 73) Throttle A pressure Trotte fully closed | 0-5 10-008, 0-1) Disa”, Tote fuly open | 485~50016.85~5.90,69-71) __| 4608.8, 68) ‘Stall speed min" (cpm) (check with eae on eval ground 72.800 72400-2800 3-22c 2WD Automatic Transmission M24A (cont‘d) — Section 14 Gute MEASUREMENT Gluteh inital clearance Ccutch return spring free length Clutch cise thickness {Glteh plate thickness Tat 2nd Tethold 2nd, 3rd, ath iethoid Except 1s [STANDARD (NEW) ‘065 ~ 085 (0.028 - 0.033), (040-060 10.016 0.024) 05-08 (002-003) 3191122) } 305.020) 346138), 41.88 - 2.00 10.074 - 0.079) 1155 ~ 1.65 0.061 — 0.065) 1195-205 (0.077 - 0.081) ‘Clutch end plate thickness (except Tat hole) | Chatch end piato thickness Aistholal MARKT MARK 2 MARK 3 MARK & MARK § MARK 6 MARK 7 MARK @ MARK 9 MARK 10 MARK 11 MARK 12 MARK 13 MARKT MARK 2 MARK 3 MARK & NO MARK MARK MARK 7 23-24 (0.091 0.098 24-25 (0.096 0.098) 25-26 (0.096-0.102) 26-27 (0.102 0.106) 2.7-28(0.106-0.110) 28-2910.310-0.114) 29-30(0.114-0.118) 30-31 (0118-0122) 31-32(0.122-0.126) 32-33 (0.126-0.130) 20-21 (0079-0083), 2122/0083 0.087), 22-23 (0.087 -0.091) 2.05~ 2.10 (0.08% ~ 0.083) 2.15 - 220 (0.085 - 0.087) 225-230 (0.089 - 0.091) 2.35 2.40 (0.089 - 0.098) 2.45 2.50 (0.096 - 0.098), 2158 2.60 (0.100 0.102), 2.65 2.700.104 ~ 0.108), Unit of length: ram ind SERVICE LIMIT 2901118) 288(1.12) 326 (1.28) Until grooves worn out Discoloration Discoloration Discoloration 4 1 Discatoration Discoloration 1 Discoloration (cont’a) 3-23Standards and Service Limits (MEASUREMENT STANDARD (NEW) _— 2WD Automatic Transmission M24A (cont'd) — Section 4 $$ SERVICE LTT “Transmission Diameter af needle bearing contact arco ‘On mainshaft and stator shaft On mainshatt 2nd gear ‘On mainshaf Ath gear collar On mainshott 1st gear colar On countorshatt(Lside) On countershaft 3rd gear On countorehatt sth gear On countershatt reverse gear collar On countorshatt tet goar collar On subshat iL. side) (On subshat th goar collar (On rovorse idler gear shaft (On mainshaft st gear ‘On mainshaft 2nd gear On mainshaft ath gear On eountershaft 1% gear Inside diameter of needle bearing contact area ‘On countarshat 3d goar On countershslt ath gear ‘On countershatt reverse gear ‘On subshaft 4th gear On reverse ilor gear (On stator shaft (R side) (On stator sof (stator sce) On reverse iler gear shaft holder End play Mainehaft 1st gear Mainshaft 2nd geor Mainchaft &th gear Countershaft tt gear Countershaft 3d pear Gountershaft &th gear Subshatt sth geor Reverse idler gear Counteranaft reverse gear Selector hub O.D. Mainshatt sth gear collar tength Mainshaft 1st gear collar length Mainshaft 1st gosr collar flange thicknoss 22.980 - 22.893 0.9047 - 0.9052), g5.978 35991 14163 — 1.4169) 31.975 31:91 (7.2589 - 1.2505) 30975 - 30.991 (1.2195 - 1.2201) 36.008 - 36.017 (1.4175 ~ 1.4180) 31.980 - 31,996 (1.2690 - 12600) 27.980 27.995 (1.1076 - 1.1021) 31975 ~ 31.991 (1.2589 - 12595) 31975 - 31.991 (1.2589 - 1.2595) 251991 - 26.000 (1.0233 - 1.0236) 27,980 27 993 (1.1016 - 1.1021) 481900 - 14.000 (015508 - 0.5512), 35.000 35.016 1.3780 - 13786) {th.000 - 41.076 (1.6142 — 1.6188) ‘38000-38076 (1.4961 ~ 1.4967) 136.000 ~ 38.016 (1.4961 - 1.4967) 38,000 - 38.016 (1.4961 ~ 1.4967) ‘32.000 — 23.016 1.2992 - 1.2998) 38.000 - 38.016 (1.4961 ~ 14967) 32.000 32.016 1.2598 - 12605) 438.007 ~ 18.020 (0.7089 ~ 0.7094) 29.000 23.033 (1.1417 ~ 1.1422) 27.000 27.021 (1.0830 - 1.0638) raat — 14.434 (0.5678 0.5883) 0.08 - 024 (0.003 - 0.009) 0.05 0,33 (0.002 ~ 0.0051) 0.05 0.135 (0.002 ~ 0.0053) 0.105 (0008-0020) 9.05 -0:13 (0.002 ~ 0.008%) 1.05 - 0.13 10.002 - 0.0083) 0.05 0.17 (0.002 - 0.007), 1.05 ~ 0.180.002 - 0.007) 0.10 -0.25 (0.004 0.010) 51.87 - 5190 (2.082 - 2.043) 45.00 45.03 (1.772 - 1.773), 27.00 -27.15 (1.063 - 1.068) Wear or damage 1 ' Wear or damage Wear or demage ‘Countershat distance collar length (281mm! ‘3897 ~ 39.00 (1.524 - 1.535) 38.02 - 38.05 (1538 - 1.897) 30.07 39.10 (1538 - 1539) 30.12 39.15 (1540-1541) 39.17 - 38.20 (1542-154) 3922-3025 (1544 1.548) 39.27 ~ 39.30 (1546-1547) 38.87 — 38.90 (1590-1530) 38.92 - 38.95 (1892-1533), ‘gear collar length ‘ear collar flange thickness Countershaft 1s gear collar length CCountershaft 1st gear collar flange thickness Subshatt th goar colar length Subshaft sth gest colar flange thickness Countershaft reve 145 ~ 148 (0571-0575) 24-26 (0.094 0.102) 145-14810571-0575) 24-26 (0.098 -0.102), 240 24.3 (0945-0949) 3.60 3.15 (0.118 0.124) ‘Wear or damage ‘Wear or damage Wear or damage ‘Wear or damege 3-24[— 2WD Automatic Transmission M24A (cont'd) — Section 14 Unit of length: mn fia) Thrust washer thickness ‘Mainshatt ath gear ‘Mainshaft ball bearing L. side Mainshaft 1st gear L side Mainshoft et gear Reid ‘Gountershoft Sed gear thrust washer thickness (355.52 mm) 357-360 (0.141 -0.142), 362-365 (0.148 0.148), 367 -3.70(0145 0.148), 372-375 (0.47 -0.148), 377-380 (0.148 0.150), 382-385 (0.151 0.152) | 387 -390,089-018) 4.45 ~ 485 (0.175 -0.179) 345-385 (0.136-0.140), | 1.45 ~150 (0.057 0.059), 3.43 - 350 (0.135 -0.138) 2573.00 0.117 -0.18 3.02 3.05 10.199 0.120) 307 -3:1010.121 0.122), 312-315 (0:123-0.128) 3.17 -3:20 0126 -0.126) 322-325 (0.127 -0.128), 327 -330(0.129 0.130, 3.32 -3.35 (0.191 -0.132) 337-3340 (0-123 0.1340), 3.42345 (0.135 0.138), 3.47 ~380 (0.197 - 0.138), 352-385 (0.139 0.140), 357-360 (0.141 0.142), [_ MEASUREMENT [STANDARD INEW) SERVICE LIMIT Transmission ‘Mainshat 2nd gear thrust washer thickness 347-350 (0.197 0.138) Wear or damaged (conta) 352-355 (0139 0.180) + ‘Weer ar damage ‘Wear or damage 7 Wear dr damage Wear or damage Wear or damage ‘Subshaft ath gear thrust washer thickness One-way clutzh contact area 1D. ‘Countershatt 1st gear Parking gear [299 20000.115-0.718) 83.339 - 83.908 (2.2810-3.2821) 66.685 - 65.608 (2.6258 - 7.6259) ‘Wear or damage t 1 Wear Or damage i pump driven gear LD. Oil pump shaft 0.0, 16.016 - 14.036 (0.5518 - 0.5525) 13.980 - 13.890 (0.5504 — 0.5508) Mainshatt fed pipe &, 0.0, 8357 ~ 898 (0.353 -0.364) 8.85 0.352) Mainshett feed pipe 8, 0.0 5.97 5.98 (02350-07354) 5.95 (0234) Countershaft feed pipe O.D, 797-798 (03198-02142) } 7.950313) Subshatt feed pipe 0.0 1977.98 (0.3138 0.3122) 7'3510:313) Mainshaft coating rng thickness 11980-1995 (0.0780-o.0788) | 80/0070) (23 mm and 35 ro) {| Mainshaft bushing 1. 6.018 -6.030.0.2959-0.2378) | 6.045 10.2300) ‘Mainshaft bushing ID. 9.000-9.015 103643 0.3548) | 9.030 10.256), Countorshatt bushing 1D. 8.000- 8.015 (03150-03356) | 03003161) Subshat bushing '. 8.000- 8.015 (03150-03356) | 020 (0.316%), Mainghaft sealing ring aroove width 2.025 - 2.060 (0.080 - 0.081), 2.080 (0.082), Regulator valve | Seoling ring contact. 135,000 - 35 025 (1.3780 1.3782) | 36.050 (13798) ody ‘Shitting device | Reverse shit fork finger thickness 590-600 (02732 0.236) a0 0213) ‘and parking brake | Parking brake ratchet pow! a Wear or other contol Parking brake gear — defect, ‘Throttle cam stopper height 27.0-27-1(1.083~ 1.067) Servo body Shite fork shaft bore 1D. 74.000 — 14.010 (0.5512 - 05576) Sif fork shat valve bore LO. 37,000 ~ 37.039 (1.4557 —1.4582)_| 97.045 (1.4586) Cit pume ‘il pump gear side clearance Drive | 0.03 0.05 0.001 - 0.002) ‘0.07 (0.003) Driven | 0.08 0.06 (0.0016 - 0.0024 0.07 (0.003) Oil pump gear-to-body clearance Drive | 0.210-0268 (0.0083-0.0108) | ——— Driven | 0.070 0.128 (0.0028 - 0.0049) Wear or damage Wear or damage (cont'a) 3-25Standards and Service Limits - 2WD Automatic Transmission M24A (cont'd) — Section 14 STANDARD (NEW? (MEASUREMENT Wiredia. | OD, Free Length No. of Coils Springs Regulator valve spring A 18007) 147 (058) | 88.13.4685 165 Di6y1, 1626 | Regulator valve spring A 1.81007) 147088) | 88.5 (3.408) 165 01582, D1587 Regulator valve spring B 1.81007) 9.6 (0.38) 44.01.73), 78 ‘Stator reaction spring 5510.22) 7264 (1.08) goair.18) | 2a Torque converter check valve spring 1.0 (0.08) 8.4 (0.33) 338 (1.33) 82 Modulator valve spring 1.210087) +7027) | 2720.07) | 80 ‘Australia model and Czecho/Slovakia 1.210.047), *7.010.276) | 26.311.038) 80 1628 engine modal Relief valve spring 1.11008) 86 (034) 37.1 0.48), 134 ‘Cooler check valve spring 1.0 (0.08) 4 (0.33) 33.8(1.33) 82 Governor spring A 1.00.08) 12.8 (0.74) 32.81.30), at Governor spring 8 0.9 0.04) 11.8 (047) 27.83.08), 60 0.80.04) 18 (0.47) 29.10.18) 80 2-3orifice control valve spring 0.9 (0.04) 6.6 (0.26) 324130 149 13 kick down valve spring 1.00.08) 6.6 (026) 29.91.18) wy 213-4 orifice control valve spring roo | 86034 519 (2.04) 138 2nd ON orifice control valve spring 0.9 (0.04) 8.0 (031) 24.1 (0.95) 36 Throttle valve A spring 1910.08) 8510.33) 2221087) 60 Throttle vaive A spring 1.9(0.08) 85 (0.33) 22.140.87) 55 Throttle valve A spring 1.10.08) 85 (0.33) 22.3087) 81 Throttle valve A spring 1.10.09) 85033) 2.31087) 16 Throttle valve B adjusting spring 0.8 (0.03) 62 (024) 301.18) 8 Throttle valve A adjusting spring 08 (0.03) 6210.24) 27 (1.08) 85 Throttle valve B spring 1.4 (0.08), 85 (0.33) 4150.69) 105, Throttle valve B spring 1.4 (0.08), 85 (0.33) 4150.63) n2 Throttle valve B spring 1.4 (0.08) 850.33) 41.61.68) 12a 1=2 shift valve spring 0.45 (0.018) 5.1 (0.20) 52.8 (2.08), 29 12 shift valve ball spring 0.45 (0.018) 4510.18) 10.7 (0.42) 127 2-3 shift valve spring 0.8 0.08) 7140.28) 65.3257) 321 2-3 shift valve ball spring 0.48 (0.018) 4510.18) 133 (0.52), 80 3-4 shift valve spring 0.9 (0.04) 8.6 (0.38), 32.51.28) 103 3A shift valve ball spring 05 (0.02) 4510.18) 131048) 14 ‘sthold accumulator spring 40016) | 2151085) 71:7 2.82) 83 ‘st accumulator spring A 2.6 (0.10) 24,310.86) 101,918.01) né | tt accumulator spring 8 2.3 (0.09) 991039 | 4901199) 46 2nd accumulator spring 35 (0.18) 221087) 7.03.0) O85 Std accumulator spring 2.6 (0.10) 11.5 (0.69) 8181360 8 4th accumulator spring 26 (0.10) 16 (063) 90.1 (385) 136 Lok-up shift valve spring 08 (0.08) 7.8 (0.30) 73.7 (2.90) Ey LLock-up timing valve spring 08 (0.031 68 (0.26) 6152.42) 278 Lock-up control valve spring 0.9 (0.08) 6.6 (0.26) 36.41.50) 233 Governor cut valve spring, 08 (0.03) 7.80.30) 445(0.78) 7 CPC valve spring 0.910.041 84 (0.33) 24.80.88), 98 Reverse control valve spring 0.6 (0.02), 7110.28) 401057) 100 3 2iming valve spring 1.20.08), 8600.38) 48.6(8.80) 47 ‘Servo control valve spring 0.9 10.08) 6.41025) 34.1 (1.34) vs 2 1 timing valve spring 0.6 0.02) 5.61022) 33 (1.30) no | 4th exhaust vaive spring 0.9 (0.04) 6.6 10.26) 43.31.70) 22 3-26 TrInside Diameter[— 4WD Automatic Transmission M25A — Section 14 Unit of nat: min (in) Pa tkgler, pid 2nd clutch presaure at 2,000 min- (rpm) [Dd position 3rd clutch pressure at 2,000 min (rom) [i position 4th elutch pressure at 2,000 min- irom) (D8 position ‘throttle fully closed £850 300 (859.0, 121 - 128) throtla more than 18 opened MEASUREMENT [STANDARD INEW) SERVICE UNIT | Transmission Capacity TUS ar, Imp at) 84 (68, 56) for overhaul fui 32 (3-4, 28) or fluid change Hydraulie | Line pressure at 2,000 min” pm) or[P) position | 860-900 (85-900, 121- 128), 800 18.0, 114) pressure cn | 500150,71) 45045, 67) throttle fully closed 800 (8.0, 114) throtle more than 38 opened Bnd clutch presse at 2000 min" om) postion | A50= BOO TEE=BO_TAT- T2B|__| woo (3a. Ta) Tet lth pressure at 2000 min pm) i ori) 880-900 (@5-80, 12128) | 60016. 14 poston Tethola cath presse 1,000 min oma] | BHD=BOOTRE-OS, aia | BOTAN. Ty pestton Theil B presse Throw faty dosed | 0 a Thole fly open | #50-900185-9.0, 121-126) | a001e0. 116 Teal speed min pm check wih car on level ground 2.600 2200-2900 Chic ‘hich inkl clerance Ta and | bas -005 08-033) — arian) 040-veo(oure 002) = fehola | 05 on(002- 003) = Cate return sing freetength tak Stonan Zann dna. 2rd,an | 30811201 mista tech | Stetiae Pater) ton se thickness ‘s8'200 00740078) Unt grooves worn out uth poe tekncss te 158-148 ner ces) Dcloraion { Escape et_| 198-208 (0077 00st) Bioortion ‘Giich end plate ices MARKY | 23-24 (0001 Goon Discoloration fencop at hola Mank2 | 24-28/0004—cose Marks | 23-284o009-c100 { mance | 28-27\o 02-0106) mance | 27-20(0100-0101 Marke | 28-28 (or10-on1m Mark? | 28-ao(ote—ane Make | So-atfore-o1za Marks | 31-a2\orze—oze Mank 10 | 82-83(o¥20-0130 Marci | 20-21 (0079 -o0es) Wane i2 | 21"22\0003-008n Mane 3 | 22-25 ae? —oost) Discoloration Cth ond pao ekness WARE —| 205-210 00H - 0.08) Discoloration | fevhot Wane? | 248-220(000-00en MARK 3 2.25 ~ 2.30 (0.089 - 0.091) | Manca | 235-240 0.009—c080 Nomane | 249-220 0.96~c0se) | Marke” | 28—280(0 100-000 anc? | 265-270 0.04 0.106 | Discoloration (conta) 3-27Standards and Service Limits MEASUREMENT ;— 4WD Automatic Transmission M25A (cont'd) — Section 14 STANDARD (NEW) SERVICE LIMIT Transmission Diameter af nedie bearing contact area ‘On mainshaft and stator shat (On mainshart 2nd gear ‘On mainshalt th gear collor (On mainshaft 1st gear collar On countershatt(Lside) On countorshat 3rd gear distance collar On eountorenat at gear On countershalt reverse gear collar On countorshalt te goar collar On subshaft(. side) On cubshatt sth goar collar On reverse idler gear shaft Inside diameter of needle bearing contact area | “on mainshaft 1st gear | Qhmainsnat 2nd gear (On mainshaft ath gear On countershaft tt gear | Oncounterenaft ra gear On countershaft sth gear On countershat reverse gear On subshat ah gear On reverse ilar gear On stator shaft side) On stator shaft (stator side) On reverse idler goar shaft holder End play Mainshaft 1st gear Mainshaf 2nd 9 Mainshaft th gear Countershatt 1 geo" Countershaft 3rd gear Countershatt sth gear Reverse idier gear Countershalt reverse gear Selector hub 0.0. Mainshat ath gear collar length Mainshatt 1st gear collar length Mainshatt 1st gear collar flange thickness 19.900 ~ 19.993 0.7866 - 0.7877) 35975 ~ 35.991 (1.4163 — 1.4169), 31.975 ~ 31.991 (12569 - 1.2695), 30975-30991 (1.2195 1.2207) 136.008 36.017 (1.4175 - 1.4180) 31.975 31991 (12569 - 1.2595), 27.980 - 27.993 (11016 1.1020) 29'980 - 29.93 (1.1803 - 1.1808), 31.975 - 31.91 (1.2569 - 1.2599), 27'99% - 28.00 (1.1020 - 1.1028) 29.980 - 29.993 (1 1803 — 1.3808) 42.990 14.000 (0 5508-05532), 36.000- 36.016 1.4173 1.4179) 4-000 - 41.018 (16142-16148), 38.000 - 38.016 (1.4961 ~ 1.4967), 38.000 - 38.016 (1.4963 - 1.4967), 38.000 ~ 38.016 1.4964 — 1.4967), 33.000 ~ 33.016 (1.2092 - 1.2098), 36.000 - 36.016 (1.4173 — 1.4179), 136.000 35.016 1.3780 - 13786) 48.007 - 18.020 (0 7088 - 0.7094) 26.000 26.013 (1.0236 - 1.0241) 24.000 24021 (0.9449 - 0.9487) 14.416 ~ 14.434 (05676 - 0.5683) 0.08 ~ 0.24 1.003 - 0.009) 9.07 - 0.18 (0.003 - 0.008), 0-008 (0 0.003) 04-045 (0.004 0.018) (0.07 ~0.18 (0.003 - 0.006) (0.07 ~0.15 (0.003 - 0.006) (0.05 ~ 0:18 (0.002 - 0.007) 0.10.45 (0.008 ~ 0.018), 51.87 -51.80 (2.042 - 2.083) 4850-4853 (1.8307 - 1.8319) 24.50 24.55 (0.9646 ~ 0.9665) 2.5~ 2.6 (0.098 0.102) Wear or damage | ) 1 Wear or damage Wear or damage t ' or damage Wear or demage Wear or damage _ Counisrahaft distance collar length 13.97 ~ 39.00 (7.694 - 1.836) 30102 - 39.05 (1.836 - 1.597) 38.07 - 38.10 (1538 1539) 39.12 38.15 (1540-158) 39.17 30.20 (1542-1543) 39.22 30.25 (1544 1545) 39.27 ~ 39.30 (1.546 - 1.567), 38187 - 38.90 (1890 - 1.899) 13,92 ~ 38,95 (1.832 1.533) Couniershalt reverse gear collar length Countershaft reverse gear colar flange thickness Countershatt 1st gear collar length Countershatt 1st gear collar flange thickness Subshatt ath gear colar length Subshait ath gear colle length of needle bearing con: 145 1856 (0.5709 -0.5728) 2.45 2.55 (0.096 - 0.100) 445-1455 (0.5709 -0.5728) 2.45 ~2.55 (0.086 - 0.100) 24.0~28.1 (0985 - 0.989), 21.0-21.1 (0.8268 0.8307) ‘Wear or damage Wear or damage Wear or damage Wear or domage 3-28Transmission (conta | MEASUREMENT 7) Mainahatt 2nd gear thrust washer thickness [— 4WD Automatic Transmission M25A (cont'd) — Section 14 [STANDARD (NEW) ‘347-380 (0.137 0.138) 352-358 (0.138 0.140) 357-360 (0.141 0.142), 362-365 (0143-0148) 367-370 (0.185 0.146) 3:72-3:75 (0.147 ~ 0.148) 377-380 (0148 - 0-150) 32-385 (0.151 -0.152), 3.87 - 290 (0.153 -0.154), Unit of length: mn fia) SERVICE LMIT Wear or darmage Wor Or demage ‘Thrust washer thickness ‘Mainshaft ball bearing L. side (Mainshaft 1st gear L side Mainshot tat goae side TMainshait ath pear thrust washer thickness One-way elute contact aa LD. ‘Counterahatt tt goer Parking gear IMainshaft food pipe A, 0.0, ‘Mainshatt feed pipe 8, 0.0. Countorchaftfosd pipe 0.0, ‘Subshaft feed pipe 0D. Mainshatt sealing ring thickness Mainshaft bushing 10. Mainshaft bushing 1D. Countershatt bushing ID. Sulpehaft bushing LD Mainshatt sealing ring groove width Regulator valve body ‘Sealing ring contact LD. | Gountershaft Sra gear trust washor thickness 4.45 - 455 (0.175 -0.179), 2.95 3.05 (0.1181 - 0.1201) 4145 ~ 150 (0.057 ~ 0.658) 2.43250 10.096 ~ 0.098), ‘Wear or damage Weor dr domoge 287-290 0.113 0.18) 232-235 (0.115-0.116) 297-300 0.117.118) 3.02 305 (0.119 0.120), 3.07 -3.10 (0.121 -0.122) 342-3:15 (0.123-0.124) 3.17 - 3.20 (0.128 -0.126) 322-325 (0.127 -0.128) 327-330 (0.129 -0.1301 3.32336 (0.191 -0.132), 337-340 (0.133-0.134), 293-300 (0.115 0.118) 122,299 - 69.265 (2.2610 3.2821) 66.685 — 66.698 (2.6254 - 2.6259), 8.97 - 899 (0.383 0.354) 5.97 5.99 (07350-07358) 797-798 (03198-03142) 5.97 - 598 (07350-07350) 11980 1.995 (0.0760 0.0735) 8.018 - 6.030 (0.2368 0.2374) 9.000 ~ 9.015 (0.3543 0.3549), 8.000 - 8.015 (0.3180 0.3156) {8.018 - 6.030 (0.2369 - 0.2374) 2.025 - 2.060 (0,080 0.081) Wear or damage ' Wear 9 damage Wear ordamaoe Wear or damage 3.95 (0.352) 5.95 (0.234) 7.98 (9.313) 5.95 0.2349) 10 (0071) 6.045 0.2300) 9.030 10358), 8.030 (03161) 8.085 (02380) 2.080 (0.082), 35.000 ~ 36.025 (1.3760 1.3782) Shiting device tnd parking broke control Reverse shift fork fagar thickness Parking broke ratchet pawl Parking brake gear Theotle cam stopper height 590-600 (0982 - 0.736) 270-27. (1.063 ~1.067) "36.050 (1.3799) 5a0 0215) ‘Wear or other cefect (it pump driven a Oil pump shaft 0.0. 010, 44076 ~ 14.034 (0.5518 - 0.5525), 13.980 ~ 12990 (0.5508 0.5508) Servo body “Shift fork shal bore 1. A | 14.000 14.005 (05512 - 05510) 8 | 14.006 - 14010 (08514 ossi6) ¢ | 14011-14015 (osst6- 05518) - Shift fork shat valve bore LO. 37000 37.039 (1.4567 ~1.4562)_| 37.085 (1.4585) Oilpume (il pump gear side clearance ‘0.083 ~ 605 (0.00% ~ 0.002) (0.07 (0.003) Oil pump gear-to-body clearance Drive | 9.240 ~0:266 0.009 0.010) Driven | 0.063 ~ 0.085 0.002 0.003) ‘Wear or damage Wear or damage ‘conta 3-29Standards and Service Limits [- 4WD Automatic Transmission M25A (cont'd) — Section 14 MEASUREMENT | STANDARD NeW) SERVICE UNIT “naar ahah | Dimer of aed baarig coat ron S00) seoT5 2129-2.) | SARA 19) Brame at taperbeaingcantac aes 18960- tron0osees-ogeha) | teas\ocerl | Samte ot ive bevel gor conc ator _momiosea-osee | 2038 080 | Runowe | boro moe os i000) Fanaa dive] 1b. 35000-25021 (09849-09951) | 2500 0887 Eowtgeer Chara of eer beng conus arn Ssome-asore\iame— tae _| Sea8 0390) Trantor aven | Baclinsh 0.40075 (@00¢- 0008 Fas ith en Bevel gar Samar oftapor boning Transtar aiven gear edo | Setoa-aevisiiarioe 37s”) | Seaethayos cont ean texan cae Boer zoom iow=ron_| 278.100) STANDARD (NEW MEASUREMENT —~ — y ——| weds [09._| _Freetngih | No. oGale cn | Reguiorvake sina A vio) | wav@sm war a.aa) 735 rings | Regulstor valve spring B 1.8 10.07), | 9.6 (0.38) 44.0 (1.73), 75 Simtorreccon spina Siem | soantaner | Sngitaa g | Torq conver cack valve sng Mies) | “auwan | Seatnaa, et falta snng toes | Sway | Bangs, ws Bad erect vate spring asics | setean | Sense | Fd Soro once cont vake sing ssiean | eran | aeatnen » Fhrotie conor valve 8 sping ‘som | asoan | sansa we Thotlscontol vane Badhnwrsping | Osos) | away | anotiae, ¢ To Zonin vee epg sete | sean) aoainam ue 2 3hinvalve spp Seiooy | sean | Ssatnen os 3 ts vate sping Seiooy | teoan | sortean 35 fei estumultor og Seon | sar0sn | nawen sano {stholdseeumolstor spring airm | zaman | asses 38 {in erumalaor pring aii | ‘esr | fami | rae nd ecco sng Pom) | eres | Seas, 8 Sr accumulator sping Hom | iawan | eva | 3 tsegspconot ave xing aso, | “ewan | Matta at kak timing 8 ave sping asicon | sean | seri 21 eevee png tapos | Saosn | Bongo ro Cock sh vo soing iio | sitez | sieges | a3 EXEC conn ve eptog dsooy | sews, | artiem Bt oat rahe eave sng ties | sae | Sanaa | Modulator valve spring 0.9 (0.04) 8.6 (0.38) 18,2 (0.72) | 5.54 Serva conta wav ping tow) | sro | worn wes ftochauet valve sing asioon | coos, | dale iy sn dben ste eng ssiecn | _ecoas | szriran wee 3-30 STinside diameter-— Differential 2WD M/T $20 — Section 15 Unit of amar: mm Cin) Setring-o-bearing outer race MEASUREMENT STANDARD (NEW) SERVICE Lin | Final driven gear | Backlash ‘0.07 - 0.130 (0.0028 0.0051) | 0.1800.0077 Differential carrier | Pinion shaft bore diameter "8.000 - 18.018 (07087 - 0.7088) | —— Carrorto pinion shat clearance 0.033 0.047 (0.0005- 0.0019) | 0.095 (0.008 Driveshaft bore diameter 26.025 ~ 26.045 (1.0246 10254) | — 26.025 ~ 28.048 (1.1033 1.1041), Carrioeto-driveshat clearance 0.045~ 0.065 0.0018-o.0034) | 0.14 (0.006), Differential pinion | Backiash (0.05 0.15 (0.002 - 0.008) gear Pinion gear bore diameter 18.042 ~ 18.068 (0.7103 0.7113) Pinion gear-to pinion shaft clearance 0.055 - 0.095 0.0021 0.0037) | 0.150.006) (0-0.1(0- 0.008) ‘Aalst with shige -— Differential 2WD M/T Y21 — Section 15 MEASUREMENT STANDARD (NEW) SERVICE LIMIT Final driven gear | Backlash ‘6.080 0.146 (0.0035 - 0.0058) | 0-200 (0.008) Differential carrier | Pinion shai bore diameter 16.000 - 16.016 (0.7067 ~ 0.7085) | arriort0 pinion shaft clearance 0.013 - 0.045 10.001 - 0.002) 0.100.004) Driveshat bore diameter 28.000 - 28.021 (11024 - 1.1032), Carrier fo-driveanaft clearance 0.025- 0.066 10.0010-0.0026) _| 0.12 (0.005), Differential pinion | Backlash gear Pinion gear bore diemater Pinion gear-to-pinion shaft clearance 0.05 0.15 (0.002 —0.006) 16.042 ~ 16.066 (0.710-0.710) 0.055 ~ 0.095 0,002 - 0.0041, 0.15 0.0061 Seiring to bearing ower race ‘00.10 (0 - 0.004) ‘aust with shire (— Differential 2WD A/T M48A — Section 15 | MEASUREMENT ‘STANDARD (NEW! SERVICE LIMIT. Final driven gear_| Backlash ‘0.082 — 0.137 0.0032 0.0088) | 020.0079) Differntial carrier | Pinion shafi bore diameter 15.000 ~ 15.078 (0.5906 - 0.5913) | Corriertorpinion shaft clesrance 0.016 0.052 10.0006 0.0020) | 0.1 0.008 Driveshat bore diameter 26.005 ~ 26.025 (1.0238 ~ 1.0286) Carrier to driveshaft clearance 0.025- 0.063 (0.0010-0.0026) | 0.120.005), Diffrentiat pinion | Backlash (0.05 ~ 0.16 (0.002 — 0.006), gear Pinion gese bore diameter 15.081 ~ 18.061 (05922 - 0.59301 Pinion gear-to-pinion shaft clearance 0.057 ~ 0.095 0.0022--0.0037) | 0.180.006) ‘Set ringto-baaring outer race (0-0.15 00.006), ‘Aajust with shiew 3-31Standards and Service Limi [— Differential 2WD A/T M24A — Section 15 MEASUREMENT | ‘STANDARD (NEW) SERVICE Unrr [ Final driven goar | Backlash ‘a7 = 0.129 (0.0028 0.0083) | —— Differential earser | Pinion anal contact area 1D, 18.000 18.078 (15.6382 - 15.8580) | —— Carrierto-pinion clearance 0.013 0.047 (0.0005 0.0018) | 0.100.008) Driveshaft contact area 1D. 26.008 - 26,025 (7.0238 - 1.0248) | ——— Carrier-to-drveshat clearance (0.025 0.068 (0.0010 - 0.0028) | 0.120.005), | Batt bearing contact ares O.. | 40.002 - 20.018 (1.5749~ 1.5755) | ——— Bilferential pinion | Backlash 10.05 - 0.15 (0.002 - 0.008) — ear io, 18.041 18.061 (07103-07111) | —— | Finion gearto-pinion shat 6.054 ~ 0.090 (0.0021 - 0.0035) __| 0.15 (0.006) ‘Set ring to bearing outer race [o-018 100.008) [Aciust (— Front Different MEASUREMENT | 4WD Transmission — Section 15 STANDARD (NEW) SERVICE LMT Final driven gear | Backlash 0.071 0-129 0.0030 0.0050) | —— Differential earier | Pinion shaft bare diameter "18.000 — 18.018 (0.7087 - 0.7094) | —— | Set ingto-bearing outer race Carrier te-pinion shat clearance 10.016 0.052 (0.0008 0.0020) | 0.110.008 Drivershaft bore diameter 28008-28021 (1.1024 1.1022) | —— Carrierto-driveshaft clearance 0.025 0.086 0.0010 0.0028) | 0.12 (0.008), Ball bearing bore ciameter 40,002 - 40.018 (1.5749 ~1.5755)_| ——~ Differential pinion | Backlash ‘0.05 0.15 (0.002 0.008) = Pinion gear bore diameter 18.082 ~ 16.086 (07103 -0.7112) | —— Pinion goar-to-pinion shaft clearance dios8~ 0095 0.0029-0.0037) | 0.15(0000 ‘uit | 0-010 (0-0.000 Adivat a | 0-018 10 0006) (— Rear Different MEASUREMENT 4WD Transmission — Section 15 ‘STANDARD (NEW! ‘Differential carrier assembly Gileapacity 11.3 US at. 11 Imp ad for overhaul (1.1 US at, 0.9 imp at forall change 3-32Unit of length: mm tin (~ Steering — Section 17 th: mim ind (MEASUREMENT [STANDARD (NEW) ing whee! | Play at tearing whee! circumference o-1010-08) Starting load at steering whoa circumference Nika 1b) Monual steering 13-18113-18, 287-397) Power steering” Engine running Luo | Except 81642: 30 (3.0, 66) B16A2: 25 (25, 5.5) RHO | 25(25,55) Gearbox “gio of rack guide screw loosened MS | 50-10" {rom locked position pis LHD | 20° HD | 23° max Preload at pinion gear shaft Nim ikg-em, Ibin) MIS. | 0.5" 1.7 (6-17, 43~ 14.8) PIS | 06-1.1(6-11,521-8.55), | Pump | Pump pressure with valve closed THD | 8.000 9,000 (80 90, 1.198 72607 (oil temp /spoed: 40°C (105°F} mine HD | 5.500 6,500 (55 - 65, 782-924) Do not run for more than § seconds kPa tkgiom, psi - Powersieering | Recommended power steering fluid HONDA Power Stoaring Fluid V fluid Fluid capacity System LHD | 1.111.16,097), AUS at emp at HD | 10(7.08, 088) Reservoir | 0.40.42, 0.35) Power steering | Deflection with 100 N (70 a, 22 bs) ‘80 12.0 (0310.47) with used belt belt” between pulleys Except 016A9 | 80-9.5 (0240.37) wth new belt _ 01649 | 55-90 (0.22 0.35) with now belt “Tension measured with Bol tension gauge {350 500 35 ~ 50, 77 - 110) with used bot Nita bs) Except D1GA8 | 500 - 700 (50 70, 110-154) wth new belt Di6ag | 550~ 750 58 —75, 121 — 168) with new belt MIS: Manual steering, PIS: Power stesring *'Wnen vsing @ new belt, adjust deflection or tension to new valuas, Run the engine for § minutes then turn it off Readjust the deflection or tension to used belt values, 3-33Standards and Service Limits — Suspension — Section 18 MEASUREMENT |__stanoano ivews SERVICE LMT Wheel alignment | B16A2 Camber Front [sos Rear Leas 31 Coster Front ros Total toe Front 0220102008) = Rear 20:%4(0.08 38) = Front whee! Inward wheet | 30°27 = | turning angle __ Outward whaet_| 30°30" {= “WD except 81682 ] ‘Cambor Front oor ey a Rear wor 41° = Costar Front Vor — Total tos Front | 922003000 — Rear 2.0 *810.08°38 — Front whee! Inward best | 1022" = turning angle __ Outward wheel _| 33°30 — aw Camber Front ose y — Rear | 0°25" 1° — Costor Front ros" = Total toe Front 02010008) = Rear withow ass — | 20-48(008-48 — with ABS ons 0-3%9 — Front wheel Inward woot | 4322.2 — turning angle ___ Outward wheel _| 33°30 = Wheel im runout Aluminum wheel Axl ‘0-07 (06am) 20100 Racial 0-07 (0-003) 1510.05) Stoel wheel el 0- 1.010008) 2010.08) Radial 0-1010-0.08) 15 (008) Wheelboaring | End play Front 0-005 10- 0.002) — Rear { 0-005 10-0.002) 3-34-— Brakes — Section 19 Unit ofength: mm tind MEASUREMENT I STANDARD (NEW! SERVICE LIMIT Parking brake | Play in Ke 01 200 N (20 kg, &@ Ibs) lever Torco ‘To be locked when pulled | — lever 6" 10 notshes Foot brake padal | Pedal height wah floor mat removed MT | 1601630 1 AT | 165,650) Free play 1s tine~ 13968) ‘Master cylinder | Pieton to-pushrod clearance 0-04-0016) Diss brake Dize thickness Front 210827) 79 (0.748) 1s82,0138330 | 17 1087) 151059) Roar 91035) Bist) Disc runout Front 0.1 (0.008) Rear 0.1 (0.008) Dise parallelism Front and rear (0.015 0.0006) Front” 01382, 0138330 | 95037) 1.8 0.008), BI6A2, D16zZ7 (2WD} | 10.0 (0.30) 118 0.006), Others 9.0038) 18 (0.008), Rear 7510.03) 1.5 (0.008), ear brake dram | 1D. ZWD] 180 (7.08) 781 0.13) ‘two | 20078 2010.90) Lining thicknoss 2wo | 4510.18) 20 (0.08) swo | 4010716) | 2o%008 Brake booster | Characteristics at 200 N 20 kg, #4 Tbs) pedal force. ‘Vacuum mmig ting) | tine pressure kPa hgicw?, Be D16z7 (ewO) 20 7310 13.1, 186) without ABS. 3001118) 5.460 (58.6, 776) Z 500119.7) 8.300 83.0, 1.180) Br6a2 0.0) 1,310 (734, 186) ‘without ABS: 300(11.8) 5.450 (546,776) LC __| 500119:7) 7/850 (765, 1,088) Diez? (4WD) and | 010) 920 (92, 130) BISA? with ABS 200 (71.8) 5,570 (85.7, 792), 5001097) 8,740 (87.4, 1.249) Dise2, Dises30 | 0@ 11520 15.2, 216) 3011.8) 5.310 63.1, 755) 500 (19:7) 7/380 (78.8, 1,120) Others 00) }a,s20 115.2, 216) 20011.) 6.380 (638, 907) 500(18.7) 8.370 (88.7, 1.261) 3-35Standards and Service Limits Pulleyto-preseure pate clearance [— Air Conditioning — Section 22 MEASUREMENT STANDARD (NEW) ie conditioning system SANDEN Lubricant type: SP 10 (P/N 28999 - P13 - 003) (For Refrigarant: HFC-124a (R-134a)) Engine type Dise7, 01821, | Lubricant capacity Condenser | 2012/3, 0.7) 1626, 01627, | me ilez Imp o:) Evaporator | 45 (1 12, 18) Diev Ling orhose | 10(13,0.4) Receiver | 1011/3, 04) ‘MATSUSHITA | Lubricant type: GUT0 FIN 38899 - POB - 008) (For RoTrigorant: HEC: 1348 (F-T34aN Engine ype D1261,.01382, | Lubricant capacity Condenser | 1511/2, 051 1363, 01882, | mi oz, Impox) Evoporator | 35(1 16,12) 01563, 015y2 Ling ornose | 10(13,0.4) Receiver | 1011/3, 04) NIPPONDENSO | Lubricant typa: NO~ OIL& (PIN 38809 PR7 - 003) [For Ralrigerant: HFC-134a (R-134—)) Engine type: Breaz Lubricant capacity Condenser ime (fier, Imp oz) Evaporator | 6012.20) Linger nese | 1011/3, 04) Receiver | 1000, 08) Compressor SANDEN Lubricant type: SP ~ 10 (PIN 38699 - P13 - 002) (For Refrigerant: HEC-124a (F-134a) Engine type: DISET, DISZ1, | Lubricant capacity me (loz, Imp o2) 12014, 42) 1626, 01627, | Field col resistance a 20°C (687F) 2065-298 Di6yt Paulloy to-presure plate clearance 0.5 = 0.18 (0.02 = 0,006) ‘MATSUSHITA | Lubricant type: GU10 (P/N 38899 - POS - 003) (For Refrigorant: HFC: 34a (F-13¢8)) Engine type 01281, 1382, | Lubrieanteapacity mf (for, Imp oz) 1404272, 49) (01962, 01562; | Field eoil resistance at 20°C (687) @ 316-350 ISB, DISY2\_| Pullay-to-prescure plate clearance | 0501 (0.020.000 NIPPONDENSO | Lubricant type: ND ~ OILS (PIN 38899 - PR7 - 003) (For Refigorant: HFC-134a (R-134a)) Engine type: Braz Lubricant capacity mf (foz. Imp o2) 120 08, 429 Stator coil resistance at 20°C (66"F) 34-38 (05 0.18 (0.02: 0.006) ‘Compressor belt™ Deflection with 98 N (10 kg, 22 Ibs) botwoen pulloys ‘85 10.5 (0.26 0.41) with used belt 5.0 7.010.202) with now be Beit tension N tka st Measured wih belt tension gauge {350 500 195 60, 77 1101 with used bol 600 - 800 (60-0, 132 ~ 176) with now belt “When using a new bal, adjust deflection or tension to new values: Run the engine for § minutes then turn i of Readjust deflection or tension to used belt valust 3-36-— Electrical — Section 23 Unit of lng: mi (in berwoon pulleys ‘Aornator bai | Detection with 100 N (10 kp, 22 Tbs) Excopt B16A2 16a? MEASUREMENT STANDARD (NEW) Tanition coil Rated vorage V 2 Primary winding resistance 9 at 20°C (68°F) 05-077) 06-08" Secondary winding resistance KE at 20°C (68°F) 144-216" 132-198" Spark plu Tyee ‘See Seation 23 pencewe iy 11-8 (0.088 Boe) igaition timing] Atiding “BTOC DiSBS (AT): 12°22 (Fed) BTOC 11382, B1389, 01822, D183 (MT), D15B4: 20° 2° (Red) BTOC Others: 16° 2" (Ree) BTOC 7.9 105 (0.28 0.41) with used bolt 55-80 (022-031) with new bat 50 7.0(0,20 0.28) with new belt "Tension measured with belt tension gauge 350 550 (5 60, 77 110) wth used bal Nika bet ‘Excopt B16A2 | 550-750 (65 -75, 121-165) with now belt B16A2 700 900 (78 = 90, 154 198) with now Belt ‘kernat ‘Guiput 135 Vathor A 70 (NIPPONDENSO) | Coil resistance rarer) @ 23 Slip ring 0. 44 (0967) 34.0 (0.551) Brush iength 105 (04 15 (0.08) Brush spring tension 9 (07! 330 (11.5) ‘Atornator ‘Output 135 V at hot A 70 mrTsusisn — | Coil wesistance rotor) 9 34-38 Slip ring 0. 227 (089), 2221087) Brush tength 20.00.79), 5.0 (020) Brush spring tension _g (ot) 300-450 (106-159) — “Aternator ‘uiput 135 athot A 20 (NIPPONDENSO) | Coil resistance (rotor) & 29. Slipring 0.. 14.4 (0567) 140 (0851) Brush length 305 (041) 1510.06) Brush spring tension 9 (oz) 300-360 (10.6- 12.7) “ Starter motor | Type Direc drive GHITACHIOS KW) | Mies depth 05-08 1002-003) 0.2 (0.008), Commutator runout 0-0.1(0-0.004), 04 0076) Eommutator 0.0 to00.878) 39.0.(1'538) Brush length 145-155 1057-080) 11.0043) Brush spring tension now) _N (kg, bs) 13113,29) we Stator motor | Type Gear reduction (warrsuBA Mica depth 0.408 (0.016.020) | 0.15 0.006) HOW, 124W, | Commutator runout 0-002 (00.001), 0.05 0.002) saw) Commtator 0.0. 28.0 28.1 (1.102 ~1.108) 27.5 (1.083) Brush Iona rorw,r2ew | 143-167 (086-058) 351037) aakw 188-162 (062-068) 1101043), Brush spring tension (now) TokW, 12k | 185-235 (185-235, 4.15.2) Nk, 185) Tanw 16-18 (18-18,35-40) = Siarormator | Type “Gear reduction (NIPPONDENSO | Mlea depth 05-08 (0020.03) 020.008) 1oKRW. 124) | Commutator runout 0-002 (0-0.001), 0.05 0.002) Commutator 0.0. 299-200(0.177 -1.180 29.00.16) Brush Tength 1oKW 130-135 (081-0383), 850039) s2kw 350-155(059-0611 30.0 (0.3 Brush spring tension new) voKW 18-24(18-24, 40-53) Nika, tbs a2kw 13-20(13-21.28-45) = Fr DI2BT, D182, D19B9, 01589, DIEZ? engines +2: 1582, 01987, 01821, D16A7, D16A9, 01625, 01627, D16Y1, B16A2 engines *3: When using a new beit, adjust deflection or tension to new belt values. Run the engine for 5 minutes then turn it of Readjust deliection or tension to used belt values. 3-37Design Specifications frems ernie eNousH nores DWENSIONS | Overallengtm 7080 1605in | Broo KO, KY aDNe 4060 mm Yetain | ForFinland onty ‘a70 mm worn | ka 1975 mm worn | wv | Overt wah “896 mm $67 Overall height 1346 mn son 1355 mm sain | KY | weotnase sr mm rain Track Front 4478 mn $83 Rear 468 mm Sain | Ground clearance 460 mn cain | 450 mim S3in | excape vei mode! I with CATA, Somting capacity Excopt care with 816A2 engine Five 6) Cre win B30ad engine Fourth DIMENSIONS] Overa Tenet TA mim Waain | BxcepeK0, x “0 | 4438 men 138i | Forfinand only 305 mm Yaoin | kaRv Overat wits 1885 mm cern Sreral noah 135mm Sclin | awo 1380 mm Bm | ee Bain | wo Whestbase watin | Track Front san awo sein ino. Was8 main Ground eearance ‘eo mm aan 480 mm Sain | Except EI model wwtn CATA Seating cxpacty Except care with 81642 engine five (9) Goren B16A0 engine Fou | 3-38European Model rem METRIC ENGUSH Notes door Hatchback WEIGHT | Corb weigne ox wr 355K Bible | KG KEKE 960 kg 2m6ibs | KS x wr 970k3, 2238 ibs | KG (Austria) vei wt 975 kg 29 tbs | KG, KF,KE 980 3 2retibs | KS oxi wr 965 63, 2rzribs | KG 9708 2iasibs | KS ar 995 5, 296105 | KG, KF 11000 ks 22205 tbs | KS. isi wr 920 9 2.161 bs | KG, KF, KE, KW 985 9 2a72 Ibs | KS ar 10109 2.227 bs | KG, KF, KE, KW To1s kg 2238 Ibs | KS si Mr 1015 ig 2238 Ibs | KG, KF 1030 kg 2am tbe | KE 11020 «9 2461s | KS ar 11045 «9 2303tbs | KG, KF 11060 «3 2337s | KE 11050 «9 2315ibs | KS vii wr 1100 kg 2a2sibs | KG KF. KW 4108 ka 2assios_| Ks ‘Weight distributions (FrontResr) Dx wr 5801375 kg 1.28827 tos | KG, KF, KE 505375 ka 120027 bs | KS x we 5951975 kg s3t2Re7 Ibe | KG KE vei wt 60075 kg 329077 os | KG. KF, KE 605975 ka 33477 tbe | KS oxi wr 5901375 kg 113017827 bs | KG, KF 59595 kp vatzear tbs | KS at 520375 ka 13677827 bs | KG, KF 525975 ko Ya7a27 be | Ks’ si wr 605/375 «9 1i3a1827 bs | KG, KF, KE, KW 10375 «3 1345827 bs | Ks ar 935/575 kg 114007827 bs | KG, KF, KE, KW 40/375 9 waria27 bs | Ks si wr 925/390 9 1137a7860 163 | KG, KF 035/395 9 saooe7i os | KE 930/390 k3 | 1389/@501n | KS ar (55/380 ko 114447860 be | KG, KF (555/395 ko sac07e71 os | KE 660/300 k3 114857860 Ibs | KS vn wr (595/405 kp 115327883 bs | KG, KF, KW. 700,408 ke 11497693 be | KS Tax: pormisebie weight (EC Ox 11380 kp 3,042 bs EX, VEI, OX), LSI, VI 11460 3 3.219 Ibs Si 11500 ko 3.310 bs 3-39Design Specifications European Model rem merRic ENGLISH NoTes oor Sedan WEIGHT ] Curb weight vei mit | 1010%9 aaa be | KG KE KF | torsta Zante | Ks oxi wr ‘ooo 43 2aosibe | Ke 1005 9 Zari | KS ar 1030 3 Zinio | ke 11035 ko Zzarioe | KS tsi ww rorsto 223i Ibe | KG, KE, KF, KW 1020 22ilos | KS an ‘as ko 2aotioe | KG,KE,KE, KW 10 ks 23s | Ks esi wr 11050 ko 2aisioe | KG, KE, KEW 1088 Zari | KS at 11020 ks Zaire | KG, KE, KE, ‘oes to Zanatoe | KS | Siwith ARS wr 1068 kg 2a toe | KG, KE, KE, KW ovo t9 2as0lbe | KS ar 408 t9 Zarelbe | KG, KE, KF, KW 00 «3 Zazsibs | KS vm wr v0 49 Zorstoe | KG. KE, KF, KW visto Zeetee | KS sri wrt 100g Zeiatee | Ke at eo b9 Zeer ioe _| Ke ‘Weight distributions FrontRea) ver mt | oosisoskg | 134993 ibe | KG. KE, KF 10408 ig | tases ibe | KS oxi mr | sosnoskg | 1312 be | KG soowosks | Yza03iee | KS at | ezawosky | aramssins | Ke | csawosig | e051 | KS tsi mT | 610/405 kg 1/345/893 bs | KG, KE, KF, KW. Givcostp | tasemoates | KS at | gaayeosicg | Naraogibe | KG. KE, KF, KW. Sesii08 kg | Sazzieesioe | ks esi wt | sonez0 kg | Vano26ie | KG. KE, KF, KW 25/420 iq | ta0o926ibe | ks av | Geanzons | Kassaze toe | Ke, Re, Re, ew ceszokg | iteanaeibe | KS Esiwith ABs mr | Beaeastg | diavvaay ibe | KG, KE, KF, KW cesveaskg | tazasaribe | KS a | Srowstg | tarraar ibe | KG. KE, KF, KW sroaskg | taanaorts | KS va wr | Foseasig | Vssuasatos | RG. KE, KE, KW Trowaskg | seuscoibe | | KS ISI mt | esieseg | sasenozsies | KG am | sosusseg | ssanoasios | Ke ‘Max, Permisaibe Weight ‘Ve Oxi Ls 1300 ig 3207 bs esi 132049 3373 be ESi with ABS: | 1,545 kg, 3,406 Ibs vi 1520 kg 3.361 be Ars Yeu Boros 3-40Except European Model rem METRIC ENGLISH Notes door Hatchback WeIGHT Carb waight x wr 71000 Ke 22051] KO cu tw 1013 5 2233 1b | Ka aT 10394 2201 Ibs | KO vi wr 11081 ke 231s | Ka ar 1077 ka 237s | KO 1.5L MT 9939 . 2reoibs | KY ar LoTsks 2293 Ibe | KY x Mr 11008 kg 2222Ibs_ | KY ar 11078 kg 2266 Ibs_| KY ‘Weight distributions (Frontiear x wr 6101390 ke sszveeo tbs | Ka cu wr 6197398 ke 113957869 bs | KO. ar 847392 ko ansress tbe | KO. vn mr 9/612 ky 114097808 bs | KO. at 65/612 kg Yasewos ibs | Ka seb wr 611/382 5 ‘sereizibs | KY AT 63378 kg vseqe35 bs | Kv ca mr 624/388 9 sreea7 bs | KY AT 68/380 3 siazeea5 bs_| KY WEIGHT Gor weight Ver wr 708 ke Bide | KO cu wr 11086 ko 22a | KO aT Vor2kg 2206ibs | KO vi wr 11088 2308 I= | KO. at 1119 kg 2308s | KO seb mr O17 kg 22821 | KY AT 11037 ke 2288 Ib | KY 15x wr 41045 kg 2308ibs | KY Ar 11008 «9 23308 Ibs | KY si wr 11080 «3 2403Ibs | KY AT Asks 2iase be | KY ‘Weight diawibutions (rontReet Vel wr 634/408 ko gee02 tbe | Ko cu MT 626/420 ky 1380826 bs | KO. an 566/420 kg 1473928 bs | KO. vi wr eaaiate kg 1420979 Ibs | KO. AT 77/842 kg vasge7atbs | KO SEL Mr 6257382 ka Y37ABe ibs | KY aT 549/388 9 vas1ess ibs | Ky 15ex mr esaie12 kg V30q908 bs | KY aT 557/408 kg Vacgea9 bs | KY si wt B4aieat kg sasia72 bs | Ky AT 501495 kg 114999950 bs | KY 3-41Design Specifications rem |__ mere nousi ores ENGINE, Type Except B16A2, O16A9 | ‘Water-cooled, 4-stroke SOHC™' or “*': Except D18Z1. Sone vtec gesine ence Biezh bree, aren, o%6H0 waarcooieg, earake Ones oc | Al, Dlexd Son viEe= gassing engine | > Br8e1 O1825, Cinder Arangement ‘eyindarsnine, wanes revi Soren Stee Brows Sue isoxs1smm | 2gex26ein | “i Biene tabs, o1382 jaxieonm | daerzeei isos Bisse Orsay o%szr.piszz | teoxsesmm | Zsexasein + Bioas btons o1eze O1ezy oti | Jeoxanemm | baseasein Bonz | stoxtramm | Saaxsanin | disptnement ones 1.99em 79cuin rans, 01382 13eser Bocnn Drses bisa ovser,o1s2s,orsz2 | tandem tocen | DBisay,oreas,oteze orez7, orev | Yao Srocnmn Bond {essen Srdenin Compresion Rat orse os Brae, 999 30 teed bis8s, oer, pisza °8 Oreet 23 rear o8 Breas, oraz, orev 2 reas 3 rene 02 Vohe Tain cept 2162, 01649 | Bat riven vats par elindr Sone or sone ree sro82, 169 fat van, &vaten parent conch or bone vice Lsbction System forced snare sump. roeno por SiPumpDiepucoment Except 816az, Osean | ST aS 40 mina Breas 68: (or US at 58 mp auminte rons $30 (rr US ah et mp cumin ter Pup Oeplacerant at 600 mi ep) team S160, B18A9 | 1250 (182 US a 11 Imp anne ovens 1126 (118 US a 99 mp atmos reas oF (48 U8 9123p aiinuie | At @a00 min’ ‘rom Feel Reasired rast Lendedgestne wih as RON, | ALBEDO tahoe trom rae 01589, Leaded gecaiewin 91 RON, | AE7.80 mint se mners ‘rom 128201882 b1522 | Unleaded gosta 8) RON rae rset prevt ‘rtiaher Breze 1627, BIOAE | Premium ulead geatne wth SS RON. or var reas feamiumigaaesgoctine vith | eens ON or hgher’® rear Looded gvaina with 91 RON. rmgher STARTER TiakeTvp6 Ost TATACHIOWee rive, 08RW wisn ester, 1010, kw and 4 ‘ippoNDENsOIGsn redeston, 19 4, Normal out "2hw. gow, Tonw 2h ah Norma Votoge av fourRetng 20 sconde Brecon of Rotation Clocaine ave tom goa ond Want MiTAC os kw are ite MnSUBA okW,.124W Bate "Sits tan Ferd ree wPrONDENSO 10 aw destn fate 1ahw Bi ste 5: Unleaded gasoline with 91 F.O.N. or higher may also be used, *6; Premium unleaded gasoline with 95 .O\N. or higher may also be used. 3-42rem METRIC ENGLISH NoTes | cuter ‘Type MT ‘Single plate dry, diaphragm spring Clutch Facing Area wr Carpureted engine teem a8 exin Pett enpne exept B18A2 Teens Benin BiaaZ engine esom Sewn TRANEMISSON | Type WaT] Syrenronzea epee forward, 1 vevese | 7 Exon RS Arawo | “Uagcedasoratewitnioscop cuteh, | KS reverse Dee onty Aran Etecvonialy controled segeed suomi, reverse Primary Reduton Gear 1. ato Diese Manoal Transmission Engin Type piasi Draee| fore Dises| —|ovezy|_ Joezr Bisse] oxs25| eo jxeze= eo farsa Braga) [over raze rea Disag | Gear Rao is ‘200 | 3280 aso |3as0 [3am [a0 dea | 1900) 1761 | 1.900 | 1.900 | nea | 205 ara {aso | va | 1250 | 1280 | tee | case i dis | 0305 | gsr [ozs | ogee | 1307 an O50 |:702 | 071 [ors [anes [oars fimverse _|189)188| 3183 | S18 | 00 | 000 Final Reduction oor aio [450] 3722) 4250] 4250] cae | 425s 129] Tyee Eni heivaigear | Tatamale Fansranon Eine Toe brass, | bases, | Biase, | Brae? | orezee | orezr reas | ovezee wor Otay Gear Ratio i aaa | 2000 | 200 | 2528 pa tase | iS | tase | Lee a tear | cans | Oars | oar i aco | ore | cee | a7 ase | aoe | tose | Qase Fin! Reduction Gear novo [T39a7 | “asss [4300 ae Tyee Single lial gear conta 3-43Design Specifications (cont’d) mem meTRIC ENGLISH NoTes aR Cooling Capacity ‘SANDEN 3351 beat 13.290 8TUm | RHO CONDITIONING 3.838 heath aszz05Tum | LHO MATSUSHITA 3.851 heath 15,270 BTU/s NIPPONDENSO 3.851 kealh ws2708TUm | ‘Compressor TyperMako ‘SerolUSANDEN Except 81642, No. of Cylinder Disa, D1sz1 Copacity 85.7emiirev | 5.22 cuinirev Max. Speed 10,000 mir (ror) Lubricant Type ‘SP10 Lubeieant Capacity 120me “flo, £2 imp ot Compressor TypelMako Vane rotary/MATSUSHITA Dise2, DISZi No.of Cylinder 3 Capacity ‘s0cmev | 8.18 cusnvtev Max. Speed 18,000 mi (pm) Lubricant Type Suro Lubricant Capac 140 me 4213 02, 43 imp oe Typeiake ‘SwashplateINIPPONDENSO Breaz No.of Cylinder 10 Capacity 185.3emiirev | 9.47 cuin/rew Max. Speed 7,600 min" (rpm) Lubricant Type ND-OILE Lubricant Capacity rome" | 4 flor, 42 Imp oF [Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Sirocco fan Arav Motor Input 200) 12 max. Speed Control ‘speed Max. Capacity 30mm | 15.188 cu-n Temp. Control Type. Aime Compressor Type | Bev single pte, poty-V bat drive Chute Power Consumption | a2Wmac/i2V SANDEN _ = ___towmexi2v Except SANOEN. Roivigorant Type (R380 Quantity 19.4 4002 3-44Design Specifications mem mermic | ENGLISH NOTES ‘STEERING SYSTEM | Tyne PS Power assisted, rack and pinion | ws Rack and pinion Overall Ratio vn PS Ho: 178 RHD: 16.5 Except VTi PIS LHD: 175 RMD: 17.0 ms LHD: 19.0, HD: 19.0 Turns, Lockto-lock VTi PS UO: 33 HD: 3.1 Except VTi PIS HO: 35 RHO: 35, ws. LHD: 39 RUD: 39 Stoaring Whee! Except VT and VTi 375 mm 1a8in Diameter Vel 380 mm 150in vii 311 mm 148 in ‘SUSPENSION | Type Front and Rear independent double wishbone, coil spring | shock Absorber Front and Rear copie, hydraule nitrogen gas filles WaEEL ‘Camber ALIGNMENT Front vn 0°05" WD except VTi O00 | “wo | ons es vi “075 WO except VTi “or20" wo “025 | caster Front 2wo eo wo 05" Toe | “Front omm cin Rear '9 2.0mm 0.08 in NO with ABS: ‘Omm ain BRAKE SYSTEM | Type Front | Poweressisted slVadjusting vatiated die | Rear [Power esiste eoltajusting sai dae or drum Ped and Lining Surface Ares Unit: men in Front | 358eméx2 seqinx2 | Disedia, 190175) 32 0m? 87 sqinx2 | Dise gis, 19175), 515 ome x2 Bosqinx2 | Diseeia, 211183), Rear | 210¢mex2 328 sqinx2 | Discdia, 208 18.2) 502 em’ x2 Fasqinx2 | Dumb. 1800.) 67.2 om’ x2 to4sninx2 | DrurmtD, 200173) Parking Brake ‘Type _| mechanial actuating oor two wheel brakes TRE ‘Size ond Pressure oo tro information label see pege 1-18) | 3-45Design Specifications | In the Under-dash Fuse Box 7.5.A,10 A 15SA, 20,308 Indicator Lights Ilumination and Pilot Lights Heater illumination Lights oar Fog Light 3-46 s2v-1.2W, 14W, 084 Ww WBV-14W, 12, 086 W 12V-091 W,0.56W, LED 12V-1.8W v_2iw Europesn, KB and KP models2-door Hatchback:Maintenance Lubrication Points .... Maintenance Schedule ...Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, installation, etc.) contained in each section. No. LUBRICATION POINTS LUBRICANT 1 | Engine API Service Grade: SF, SG or SH fuel efficient oil - | SAE Viscosity: See chart below 2 | Transmission Manual API Service Grade: SF or SG SAE Viscosity: 10 W—30 or 10 W—40 _| ‘Automatic | Honda Premium Formula or DEXRON® IL Automatic transmission fluid (ATF) Brake Line Brake fluid DOTS or DOTA Clutch Line Brake fluid DOTS or DOTS Steer 1d grease PIN 08733 B070E Shift lever pivots (Manual transmission) Grease with molybdenum disulfide Release fork (Manual transmission) 3 4 5 | Power steering gearbox : os 7 8 Steering boots 9 | Tailgate hinges and latches (2-door Hatchback) 10 | Steering ball joints 11 | Select lever (Automatic transmission! 12 | Pedal linkage 13 | Brake master cylinder pushrod 14 | Trunk hinges and latch (4-door Sedan) 15 | Door hinges upper and lower 16 | Door opening detents 17 | Fuel filler tid 18 | Engine hood hinges and engine hood latch 19 | Clutch master cylinder pushrod 20 | Throttle cable end 21 | Rear brake shoe linkages Urea Grease UM264 PIN 41211—PY5—305, Multi-purpose grease 22 | Caliper Piston seal, Dust seal, Caliper pin, Piston Silicone grease 23 | Power steering system (For cars with P/S) Honda power steering fluid-V 24 | Rear differential (4WD only) Honda Premium Formula or DEXRON® II Automatic transmission fluid (ATF) 28 | Air conditioning compressor Compressor oil: NIPPONDENSO: ND-OIL8 P/N 38899—PR7—003 MATSUSHITA: GU10 P/N 38899~Po8—003 SANDEN: SP-10 P/N 38899—P13—003 (For Refrigerant: HFC-134a (R-134al) Recommended Engine Oi) API Service Grade: SF, SG or SH fuel efficient oil Select the oil for the car according to this chart, CAUTION: Used engine oll may cause skin cancer if speatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis stil advisable to thoroughly wash your hands with soap and water as soon as possible +1: Excopt B16A2, 01609 engines *2: BI6A2, DI6A9 engines ‘Ambient tomporature rangessadhy s018INq1B0 104 feu luaisAs Buluonpuod sy YRlm 189 104 2, ‘worshs Buls9936 19mog YI 8109 104 5, faumo aut 03 Buypiosde Aijeanoed avop 2q pinous {Jona} 1UeIO09 pue 4Ly ‘I}o euIBue) 6129 AEp 03 AEG + seusorsno ayy Aq yenuew 1 i T ‘lepow Ueedo.ng UNA LOR 103 eetionesado 43uado @yoyo 7 sjepow ueadoung 104 | pus wersés jonuos amno1yy, 1 ‘uone|iuan aseaqueI9 annisog t 1 1 8 a a a a i 1 ' o H a ett) | |e ee TeUaAUGD OpATeIRD INOW 8189 104 8 8 a a u TeuoAUGD SAAleIES yyMn 8189 104 ' 1 ' i 1 sjapow ueedoung ueu sa\R0 104 Sujuun vontu6) tu9}8A6 jonUOD pue 1 1 Slapow uesdoing 104 ema efelel[slels[s[elele TeuanuOD ORAEIWO InoyM 189 105 8 u Jayanuon andrereo yum $189 404 nyo weds u ¥ ¥ u ue|e00 auiBug 1 1 i i i SuaRDeUUOD puB Saou WaISAS BUIOGD i i und save u u 169 Bua (¢.s088eidwoa Sjy * ,Bujbais Jomod ZOIeUIRIY) tt ' y ' u ‘suonpuoo pue vojsua; 319g o a De ‘sjapou Weadoing UeU JOO 104 1 7 1 i H sjapow weadoung 104 soueieaja amen u 4 a u u ‘sj9pow weadoung ueyt MIO 104 u u u Siapow weadoang 204 io woysswwsueNL Ssiiuow 970 (S9j 900°9) WH OOOTOL Avena Boe Kou ‘epOu Weadoung UeK TAIRO 104 ‘SaUoW Zi 70 (S9qW 900'9) Hy OOO'OL Alana BoeyKay sjapow weadoung 104 Wy No pue yo ouibug ozt | ao: [ 96 | va | zz | 09 | sv | v¢ | vz | a ‘squow oz [aor | e6 | va | zz | 09 | av | ve | vz | zi | son oo0' x a oz | os: | oat | ovt | ozi | oot | os | 09 | ov | oz 1 000'r x | 20 (san 40) wry Q90'L x pars jeALou ALN 8 SOWAIOS Maintenance Schedule ‘Aress090u j1 999jdou 10 s1ed01 “dn yy “asnipe j9 ‘uonsedsul ayy stoedsuj=| uejg=9 90 = mereworsks o4euq 201: ‘81 ‘lepow $y 40} adeoxe ‘AjU0 seumoejnuew Aq papueUIWOde ’s} lworshs Buuses 19mog yum $189 404 2 ‘SuiUOW Z1 10 (SN 0O0'S) WH GO0'O! NBNe 19edsu) a iv Tl'—']'[?[+]+yv+y fe 7s SuGHI9BuU0S Pue Sas0y “UoNUR) BujORIS Mog i 1 1 1 [ot si00q pus xoqiee6 ‘spus poi-an uoNDun) Buvaaig | a ‘siu@uoduios ojsuadsng ; i (uetianuos ope qua 8120 103) Pielys 1e9y s0uenuod andere) ee [UoR|puOD pus WiE}SAS YeNeUXG 50504 eunssord yBiy worsks oye19 HOOFRUY ita ‘= woneiedo Wieishs ye ¥0OrRUY rio ‘Soul pue Ses04 o¥eI a (ee Sev Buppniouy pny eg f i 1 t ‘one1ado @ye1q Bupieg ‘SBulUy pus SiepuyAa jaaur “SUInUp & ‘sped pue siedyeo ‘Sosip oe19 1804 T ‘siadyeo pue sosip 6ye1q 1u01y 1 8 v t ttrto e a H q i q 1 q merfeferfi ‘syIvOUW Z1 20 (S544 OO0'S) WH OOOO! 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BuLMO}/O} O4L suompuog Bung exenes Bequie seBuassed yum 120 104 1409%3 5 SUS WIA 8189 404 “35 vonensi6a Bult ds a0ejda1 pue warshs roadsuy W814 81894 OF s-luaishg 1urensoy jeruowarddng ‘eamni88 hiond voye edsuy onu09 Jo BseuqUeeID ‘218 ‘Sejpuey 109 Ce (suoneiado preoqusep Gers “@SION) @nUP 1801 Mot tata ‘BuiWow! Zi 40 (s=qW 000"S) WH 000'O! “BauoW Zi 19 (Foy O00"R) WH OOO'O! 3yom Apoq pue SabeWEP IIe eeq WBlipesy pue UOReIedO SIMBA e1eds Buipnjouy) aunsseid pue seam “wompuod sour jana woods ‘Kione ads u a u | a | a (epou GAP) 19 1eNUaLa4pIp ey epetedye pry pa yaya ~uonpucs Asneg ozt | eo | 96 | ve | zz | 09 | av | 9¢ | ve | a wou oz | sor | 96 | ve | zz | 09 | av | oe | vz | zr | som ooo x et uD 154 sowoD Jonoyoiye ‘synuoU jo soquInu Tey 4048 oz | ot | 091 | ovt | ozt | oor | 08 | 09 | ov | oz 191 000'L x | 20 (sayus 10) un} 090"L x Peis lenwenu! oun 1e eanwOg ‘Avwsso09u }1 90001 10 wedo1 “dn ‘yanipe ‘ues ‘vonsedsui zoyyy oedsuj=| uedIQ=] eoeidey=y 4-6Engine Engine Removal/Installa Engine Lubrication Intake Mai Outline of Model Changes ‘The 01822 engine has been adopted. Compare to D1SB3 engine. Main difference is exhaust manifold. The 01587 engine has been adopted. Compare to D1SB2 engine. Main clfference is intake manifold ‘The D16Y1, D16Z9 engines have been adopted. For the service procedures, refer to the procedures for 1626 engine.Engine Removal/Installation Outline of Model ChangeEngine Removal/installation 5-2SIDE ENGINE MOUNT: 1821, 01626, 01627 wo), DIY engines: | | | Except 01521, D1626, D1627 WD), D161 engines: Torque Specifications: 4,101.25 mm 60 Nem (6.0 kg-m, 43 lb-ft) Replace. B:12x1.25 mm 60 Nem (6.0 kg-m, 43 Ibe) Replace ©: 14x15 mm 85 Nem (8.5 kg-m, 61 lb-ft) Replace. D:12x 1.25 mm 65 Nem (6.5 kg-m, 47 lb-ft) E:10x1.25mm 39 Nim (3.9 kg-m, 28 lb-ft) F:12x1.25 mm 75 Nem (7.5 kg-m, 54 lb-ft) 6:10 1.25 mm 45 Nem (4.5 kg-m, 33 lb-ft) H:12x1.25 mm 85 Nem (8.5 kgm, 61 lb-ft) 121.25 mm 65 Nem (6.5 kg-m, 47 lb-ft) Replace. J: 101.25 mm 53 Nem (5.3 kg-m, 38 lb-ft) Replace. (cont’a} 5-3Engine Removal/installation r (cont'd) ‘Mount and Bracket Bolts/Nuts Torque Value Specifications: D16Z7 (4WD) engine: al | REAR MOUNT: ‘anismission Moun i 8 ag 5-4SIDE ENGINE MOUNT: Torque Specifications: 101.25 mm 60 Nem (6.0 kg-m, 43 lb-ft) Replace B: 12x 1.25 mm 660 Nem (6.0 kg-m, 43 Ib-ft) Replace. ©: 14x15 mm 80 Nim (8.0 kg-m, 58 lb-ft) Replace. D:12% 1.25 mm, 65 Nem (6.5 kg-m, 47 Ib-tt) E: 10x 1.25 mm 39 Nim (3.9 kg-m, 28 lb-ft) F:12x1.25 mm 175 Nem (7.5 kg-m, 54 tb-ft) 6:10 1.25 mm 45. Nim (4.5 kg-m, 33 lb-ft) H: 12 1.25 mm 85 Nem (8.5 kg-m, 61 Ib-ft) kk 10x 1.25 mm 55 Nem (5.5 kg-m, 40 lb-ft) Replace, J: 12x 1.25 mm 65 Nem (6.5 kg-m, 47 lb-ft) Replace. K: 101.25 mm 53 Nem (5.3 kg-m, 38 lb-ft) Replace, (cont'd) 5-5Engine Removal/Installation r (cont'd) ‘Mount and Bracket Bolts/Nuts Torque Value Specifications: B16A2 engine: ‘TRANSMISSION MOUNT: RIGHT FRONT MOUNT:SIDE ENGINE MOUNT: Torque Specifications: 10x 1.25 mm 60 Nem (6.0 kg-m, 43 Ib-ft) Replace B: 12x 1.25 mm 60 Nem (6.0 kg-m, 43 Ib-ft) Replace. ©: 14x15 mm 85 Nem (8.5 kg-m, 61 lb-ft) Replace. 0:12 1.25 mm 65 Nem (6.5 kg-m, 47 lb-ft) 12x 1.25 mm 75 Nem (7.5 kg-m, 54 lb-ft) 10% 1.25 mm 45 Nem (4.5 kg-m, 33 lb-ft) 6:12 1.25 mm 85 Nm (8.5 kg-m, 61 Ib-tt) Hi: 12x 1.25 mm 65 Nem (6.5 kg-m, 47 lb-ft) Replace. cont'd) 5-7Engine Removal/Installation r- (cont'd)Engine Lubrication Engine Oil Replacement ... Outline of Model ChangeEngine Oil t Replacement 1. Warm up the engine. 2. Drain the engine oil (OIL PAN DRAIN PLUG washer 485 Nm (65 kgm, 23 Ib-F) Replace. Do not avertighten. 3. Reinstall the drain plug with a new washer, and refill with the recommended oil Requirement | API Service Grade: SF, SG or SH ‘Change Every 10,000 km (6,000 miles) or 6 (12%) months, +3; European models Capacity # (US at, Imp at as ‘After engine] Atchange eoeereaae overhaul including filter DIAG engine 4345.38) | 3668,32) BI6A2 engine 436142) | 40(42,35) Except DI6A9, Biaar eaten 4.0142,35) | 33(35,29) Engine Oil SAE Viscosity for Outside Temperature Ranges. — 30-8010 29390’ 800+ Ambiont temperature ranges “1: Except D16A7, D16A9, B18A2 engine “2; DIBA, DIGAS, BIBA2 enginesIntake Manifold/Exhaust System Intake Manifold Replacement Exhaust Manifold Replacement .. [ Outline of Model Change + The D1522, 01587 engines have been adopted.Intake Manifold - Replacement NOTE: Use new gaskets and O-rings when reassembling. 1587 engine: o-nincs 8x 1.25 mm 2aNm (24 kom, Ths INTAKE MANIFOLD BRACKETS 841.25 mm 2aNm ies kg-m, be 9-2 INTAKE MANIFOLD Replace iferacked or INTAKE MANIFOLD ifrmating surfaces are GASKET damaged, Replace, ‘O-RINGS CP — Replace FAST IDLE VALVE Be careful not te damage.Exhaust Manifold (- Replacement NOTE: Use new gaskets and now self-locking nuts when reassembling, CAUTION: In handling @ metal gasket, care should be taken not to bend it or damage the contact surface of the gasket. 1522 engine: ‘OXYGEN SENSOR 841.25 mm 45 Nm (65 kom, 22m (22 kg Same ewe Bo coraful net to damage. EXHAUST MANIFOLD EXHAUST MANIFOLD N cover 101.25 mm 32Nm (3.2 kgm, 23K Replace 6x 1.0mm $ {ONm(1okgm, CATALYTIC CONVERTER HoXuer aera) 7A Replace. ) SSELF-LOCKING NUT = 81.28 mm a convenren “7 cover seeLooke NUT \ ghsner 10x 1.25 mm exaust **?! Bim Shon, prea y Bx 1.25 mm Replece. 24 Nem (2.4 kg-m, om 9-3SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If Fuel and Emissions maintenance is required) ‘Some model versions of the Civic include a driver's airbag, located in the steering wheel hub. In addition, the KB model has a front passenger's airbag located in the dashboard above the glove box. There are two types of SRS: ‘Type II (SRS unit is part of the airbag assembly), which is used for models without front passenger's airbag (all except KB model), and Type ill (SRS unit is not part of the airbag assembly, and has built-in sensors), which is used for models with front passenger's airbag (KB model). Information necessary to safely service the SRS is included in this Shop Manual. Items marked with an asterisk (*} on the contents page include, or are located near, SRS compo- nents. Servicing, disassembling or replacing these items will require special precautions and tools, and should therefore be done by an authorized Honda dealer. "To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. ‘© Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal jury caused by unintentional activation of the airbags. ‘* Do not bump the SRS unit. Otherwise, the system may fail in case of 9 col ‘when the ignition switch is ON ill) (SRS Type Ill) ‘© All SRS electrical wiring harnesses are covered with yellow insulation. Related components are located in the steering column, front console, dashboard, dashboard lower panel, and, in case of the KB model, in the dash- board above the glove box. Do not use electrical test equipment on these circuits. '* Service work nearby and in the areas listed below may affect the SRS and must therefore be performed by an authorized Honda desler ion, or the jebags may deploy ‘SRS Type Wl: + Stoering whee! (Be careful not to bump the steering wheel as the SRS unit (sensors), inflator, ete. are located init) + Behind the dashboard + Under-dash fuseirolay box SRS Type Il + Steering wheel + Behind the dashboard + Under-dash fuseirelay box + Front console + Car stereo units and other accessories + AC heaterFuel and Emissions Carbureted Engine [ Outline of Model Changes) $$ i “The 01522 engine has been added for KO model, refer to D1282 engine in the base Shop Manuals. Fuol-Injected Engine ‘Special Tools lanition Output Signal 1128 Component Locations ‘Atmospherie Pressure (PA) Senor os 1130 Inde nn sn Idle Control System ‘System Description Idle Speed Setting ...... semanas MBL Vacuum Connections 4 Pulseenonien Electrical Connections wrens WE Fuel Pressure [D15B2 engine] essen 11-32 Troubleshooting Main Relay . ve 1188, Selfediagnostic Procedures 9 oaks ores PGM-FI Control System Throttle Body vas Troubleshooting Flowcharts pauses Coan aie Electronic Control Unit (ECU) me Exhaust Gas Recirculation System Oxygen Sensor - awe fre Fuel Supply System wa Manifold Absolute Pressure (MAP) Sensor 123 Outline of Model Chang + The special too! (SCS short connector) has been added + The D15B7 engine has been added for KO, KB model + The D161 engine has been added for KO model, refer to D16Z6 engine. + The D1628 engine has been added for KB model, refer to D16Z6 engine. + The Electronic Control Unit (ECU) (Except 01882 engine} has been modified, and changed following trou bleshooting flowchart: — Oxygen Sensor — Fuel Supply System — Atmospheric Pressure (PA) Sensor Exhaust Gas Recirculation System (D1821 engine) = Idle Speed Setting +The main wire harness (SCS, Ignition Output Signal, Main Relay circuit) has been changed + The main wire harness (MAP sonsor circuit) has been changed for B16A2 engine. + The fuel pressure has been changed for 01582 engine. + The throttle body disassembly has been changed. + The throttle body has been modified for B16A2 engine,Special Tools rt.no. | TootNumber | Dasrnion ty | _ Remarts I O7PAZ~0010100 | _SCS Short Connector 1 - 11-2Component Locations Index D15B7 engine: MaNtFouD ABSOLUTE (ar) SEN PURGE CONTROL Mroubheshootr, SOLENOID VALVE 98 11 (Except KO model) THRoTTLe page 11.23, ANGLE SENSOR INTAKE AIR TEMPERATURE (TA) SENSOR TDC/CRANK/CYL SENSOR (Guilt into the DISTRIBUTOR) GniTer UNIT (Guilt into the DISTRIBUTOR? coouar Lock-UP CONTROL ‘TEMPERATURE Sousonaes SOLENOID VALVE AB (Twisenson Frrcbheshootng ‘wm poge na 11-3System Description Vacuum Connections D15B7 engine: MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR. PURGE CONTROL SOLENOID VALVE (Except KO model) ( ‘CHARCOAL CANISTER FRONT OF VEHICLE PRESSURE REGULATOR 11-4D15B7 engine: COOLANT [libs “TI eNaINE @ OxvGEN (0s) seNsOR @ FUEL TANK @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (B AIR CLEANER @ COOLANT TEMPERATURE (TW) SENSOR, @ RESONATOR @ INTAKE AIR TEMPERATURE (TA) SENSOR {i CATALYTIC CONVERTER ® ELECTRONIC AIR CONTROL VALVE (EACV) (@ PCV VALVE @ FAST IDLE VALVE | CHARCOAL caNisTER @ FUELINJECTOR {® PURGE CONTROL DIAPHRAGM VALVE @ PRESSURE REGULATOR ie TWO-WAY VALVE ® FUEL FILTER {i FUEL CUT VALVE (@ FUEL PUMP 2% PURGE CONTROL SOLENOID VALVE (Except KO model} 11-5System Description Electrical Connections [Except D15B2 engine] MAIN RELAY peice | (ae = janvier | matai} 4 a BrzcvLM | INs2 As} SZ. | i =e mzas | Ne, | roc senson [ BreToCM | inseaz} — 8% | BIS CRNK P | RANK SEN | | ew ||| roetp unr | —_foro gt EAGV one | | CHECK ENGINE LIGHT | || SPEED SENSOR __“"_1 g9 vse WARN AIS} —o | ig i | CHECK. fe Connecron -—+To arc swireH —_ ACC As a ests a LET] RELAY DATA UN Laie RADIATOR FAN RELAY Connector [Z| S10" fav Tommie) FANG ar} AC ATORESNSSLAY _| mrrcuuten [> % cooLANT aie ‘TEMPERATURE ercisw | = swirch pane . tes aoa | arisa ara} Tt ar — ‘BAATDS | ATISBAIYarrLocKUP| | A/T LOCK-UP jconTROL onTROL 'Soueno> SOLENOID VALVES. VALVE A thie tos pases 7 BACK UP (75 A)Y [08 oanow @ BATTERY (60 Al* shirt posmTION| = @1G oA) SonsoLe ON] PAN 03 bs] INDICATOR. @ STOP. HORN (20 AI" swine \ @ECU IISA = ACG (5) 115.4) BACK-UP LIGHTS (10 A) rc | @ REAR DEFROSTER RELAY an HEATER MOTOR RELAY 11-6 COOLING FAN MOTOR RELAY (75 A) @ STARTER SIGNAL (75.8) {8 OPTION (50 a)" G INTERIOR LIGHT (75 A) *: UNDER-HOOD FUSE/RELAY BOXSC prevect | _vneF 16 727 CONTROL tt ozevece map Benson| swnoTne| | : INGLE | E {—__fonom [Sieh iourren SENSOR a) four | | (016A | bet ima St | ower nace | : DioviL | een vaive (P| = (xcopt D1887, D16A7, (01821 engine Di2eGRL scopt DISBY, D1GA7, 2 wine) “FT SENSOR| 1} zl} IGA, D16A9 engine! (Except 1587, [VALVE as DIGA7, DIGAS, “TIMING OIL —2—foavin VIS Ad} ot Dieagengine) PRESSURE | pg oH. 7001 SoLENO oe | PRESSURE - cy SwircH = t 4} wesw ovat enghail see (01821 engine) tasenson |__| ESAT} —ggnino oS} DIBTA SOLENOID VALVE bore tw viene a] TW SENSOR Pas Ao} oe ao PURGE CONTROL SOLENOID VALVE eee Modan |_haewTeNT totowo. ‘ReGC Ate +} — 1] EN — TANATOR D140; atte {0 model | Sone + | bec orsz1 eves] eraine) lover v8~ Ses cchh ones { ‘Ag HTCNTL TERMINAL LOCATION. 11-7System Description Electrical Connections [D15B2 engine] MAIN RELAY. |_|] I man secon a L nae os io | AL {| rweaenank | ‘SENSOR aA — — runce curr | ||| MAP ‘SOLENOID VALVE SAson |, | SoteNe a { ~ er ano valve Sensor asieth | SOLENO} VaLve manor us inet Srey —+ Sensor me T the wel 7 tonto, = cuuren| senvice | cree SOLENOD VALVE RELAY Sonnecron =} — ale caetk enone arr | 6} wren mena | ee Seeds" weommen +) sexo sores coe | uh Taam minanienn tHe women eo eso) ey ene FUSES TO nn SEES BATTERY (20 A) © REAR DEFROSTER RELAY (000000000 Jf 0000000000 Jf 00000000] Sic woar HEATER MOTER RELAY 200000000 ff 0000000000 ff 00000000 | @ecu isa COOLING FAN MOTOR RELAY (7.5 A ACG (8) (15.4) ® BACK-UP LIGHTS (10 A) mamma ema cwaTene CACC EAD aD ACK UP ea ‘SF UNDER-HOOD FUSEIRELAY BOK TERMINAL LOCATION 11-8Troubleshooting oak Self-diagnostic Procedures. ———$£—_—_____________ |. When the Check Engine light has been reported on, do the following 4, Connect the SCS short connector to Service Check Connector as shown (The 2P Service Check Connector is locat- fed under the dash on the passenger side of the car). Turn the ignition switch on. ue HD: DATA LINK DATA LINK CONNECTOR (27) CONNECTOR cP) Nove note Do mot attach Bo not attach jumper wit. jumper wire cs sHont connécTon o7PAz~ 0010100, a SERVICE CHECK shvice check a CONNECTOR (2) Sonnecron a) 2, Note the CODE: the Check Engine light indicates a failure code by the length and number of blinks. The Check Engine light can indicate simultaneous component problems by blinking separate codes, one after another. Problem codes 1 through 9 are indicated by individusl short blinks. Problem codes 10 through 48 are indicated by { series of long and short blinks. The number of long blinks equals the first digit, the number of short blinks equals the second digit. Sometimes the first blink is dificult to see; always count the blinks at least twice to verify the code. Nore: ‘Two Trip Detection Method To prevent false indications, the Two Trip Detection Method is used for the Or sensor, fuel metering-related EGR system self-diagnostic functions. When an abnormality occurs, the ECU stores it in its memory. When the same abnormality recurs after the ignition switeh is turned OFF and ON again, the ECU informs the driver by lighting the Check Engine light. However, to ease troubleshooting, this function is cancelled when you short the service check connector. The (Cheek Engine light will then blink immediately when an abnormality occurs, (cont'd) 11-9Troubleshooting r- Self-diagnostic Procedures (cont'd) —£$@@--——H\————— IL ECU Reset Procedure 1. Turn ignition switch off 2. Remove the BACK UP fuse (7.5 A) from the under-hood fuselrelay box for 10 seconds to reset the ECU. NOTE: Disconnecting the BACK UP fuse also cancels the radio preset stations and the clock setting. Make note of the radio presets before removing the fuse so you reset them, BACK UP FUSE ‘UNDER-HOOD FUSE/RELAY Box IIL Final Procedure {this procedure must be done after any troubleshooting) 1, Remove the SCS Short Connector. NOTE: If the SCS Short Connector is connected and there are no CODE stored in the ECU, the Check Engine light will stay on, 2. Do the ECU Reset Procedure 3, Sot the radio proset stations and the clock setting. 11-10E' SELF-DIAGNOSIS INDICATOR BLINKS. ‘SYSTEM INDICATED PAGE (Except 1582 engine} PAGE (01582 engine) a eu 112 18 [a 1 [OXYGEN SENSOR _ 1118, 20 3 MANIFOLD ABSOLUTE PRESSURE (MAP SENSOR) 1128 | 5 | 11-26 zt CRANK ANGLE (GRANK SENSOR) a 5 COOLANT TEMPERATURE (TW SENSOR) a 7 ‘THROTTLE ANGLE 7 8 ‘TDC POSITION (TDC SENSOR) 8 No.1 CYLINDER POSITION (Cv SENSOR) — 0 INTAKE AI TEMPERATURE (TA SENSOR) 1 IMA SENSOR (O16A9 engine) i 42, EXHAUST GAS RECIRCULATION SYSTEM (EGR) qual "ATMOSPHERIC PRESSURE (PA SENSOR) nap {DIS57 engine, B1521/D1626 engine KS, mode 4 ELECTRONIC AIR CONTROL(EACV) 75 IGNITION OUTPUT SIGNAL ‘oars 76 FUEL INJECTOR (01882 engine) - 17 VEHICLE SPEED SENSOR — ae 78 TAT LOCK UP CONTROL SOLENOID VALVE AB 20 ELECTRICAL LOAD DETECTOR (ELD) 2 SPOOL SOLENOID VALVE 22 VALVE TIMING OIL PRESSURE SWITCH a — a OXYGEN SENSOR HEATER (01557, 1676, DT8z7, 8162 ena a LAF SENSOR HEATER (D15Z1 engine) a | FUEL SUPPLY SYSTEM (01862, 01587, D1EZ1, al Di6z6, D162, DIsZS, BIeAZ, O16V" engine @ TAF SENSOR (D1521 engine) = ‘© 'f codes other than those listed above are indicated, verify the code, If the code indicated is not listed above, replace the Ecu. © The Check Engine light may come on, indicating 8 system problem when, in fact, there is @ poor or intermittent electe- ¢al connection First, check the electrical connections, clean or repair connections if necessary ‘© The Chock Engine light and indicator ight may tight simultancously when the self-diagnosis indicator blinks 6, 7 and 17 Check the PGM-FI system according to the PGM-Fl control system troubleshooting, then recheck the (By india- tor light. '# The Check Engine light does not come on when there is @ malfunction in the Electric Load Detector circuits. However, it wil indicate the codes when the SCS Short Connector is connected. © For reference pages not listed with the respective Sell-Diagnosis Indicator Blinks, refer to base Shop Manuals. 11-11PGM-FI Control System [- Troubleshooting Flowchart — ECU Check Engine light stays on ‘comes on after two seconds, ‘connect the SCS to the service el short connector heck connector NOTE: When there is no code stored, the Check Engine light will stay on if the service check connec: tor is shorted, Connect the te: tween the ECU ine stort << piatn No “Turn the ign Measure voltage between Dé I+) terminal and 022 (-) terminal oe peas 113) Doss Check Engine ont YES Soca Toceguen |] Een >ASS[ Goto settaiagnostic procedures, Remove the SCS short connector Datel bast {rom the seve check connector. ou 7—L__Tern the inition switch OFF [Terie start the one | Jt harness be. nd connectors. ion ewitch ON, Is there appros (WWD model ves [Connect the SCS short connector | totha service check connector. V7 tava, Ropair short to and service check — Repair open ‘tween ECU I {Remove and inspect he ECU 115A) — Repair open [BRN wire between the ECU (D4) ‘tween service check connec NO body ground in hee Measure voltage between 4 (+) terminal and body ground. 3k connector. in BRN wire be- D4) and service 's there approx. 5 V? 8D model: 13 V2) in BLK wire be. _> NO Remove the SCS short connector rector, test drive the ea Engine light fora code, No cm the service check connector IeihetuseoK? > [essinmnsi Series test convester | ves ae ‘NOTE: Aner reotir,ceconnect the SCS short con (a page 149) and recheck the Check 11-12(rom page 11-12) Inspect the ACG (S) (15 A) fuse in | the under dean fuserely box nm Disconnect “A” connector from < temenseoK? > the ECU a (From page 11-12) urn tho ignition switch OFF. [ves Turn the ignition switch ON. Disconnect the 3P connector of CMAP saneor EGR valve it sensor (D15Z1 engines + Throwe angle sensor TIMA (D168 engine) Does Check Engine ight No romain ON? ves “Turn tho ignition ewitch OFF. Substitute » known-good ECU wo and recheck. If symptom/indica tion goes away, replace the orig pal ECU, Replace the sensor that caused the ight to go out, “Turn the ignition switch ON, Yes ep GRN/ORN wire between the ECU (A131 and Check Engine light. short to body ground in Check for continuity between body ground terminals 019, 020. ae | | yes wo Reconnect all the sensor connee Reconnect the the ecu, 1° connecter to “Turn the ignition itch ON. (To page 11-14) — Repair short to body ground Jn VELIRED or YELIGRN wir between ECU (D19) and MAP Repair short to body ground in VEL/WHT wire between ECU (020) and throttle angle ‘sensor of EGR valve lift sen er {D1821 engine) oF IMA {D164 engine). wire harness 2000000000000] 00000000}96096] 00000000090 ; oe eT con cont'd 11-13PGM-FI Control System [ Troubleshooting Flowchart — ECU (cont'd) (From page 11-13) [ measure voltage between body {round ang the following term re ee a) al indvidualy: A26, 82 (0000000000009 | 90900008 ]860008] 00000000000 t 126 D Leosthanrvr — Check main relay and wiring ves connectors at meln relay. Substitute a known-good ECU and recheck. If symptoringles 11-14Connect te the ee (see page ee “Turn the ignition switch ON. | the SCS shor connector | 19). 4 No. iine ight ne Ramage ST cienaamee rene] rs NOTE: When there is no code stored, the Check Engine Tight will stay on if the service check connector is shorted. - Troubleshooting Flowchart — ECU [D15B2 engine] fuse in Remove and inspect the ECU (15.8) telay box No ‘the under-hood <_Diatnecnsine sta? > = Tuen the ignition switeh OFF Remove the SCS short connector {390000000 J| 0000000000 J co000000 ees ti evs eae 900000080 f 0000000009 f 00000900 B04) er) Tiytostarthe engine ow Connect the test harness be. ‘the ECU and connectors ‘Turn the ignition switch ON. Me: ure voltage betw terminal and C12 (-)terminal. | n 820 fuse) __ torand G101 Repair short to body ground in sccsure vohage between 820 BRIN wire between the ECU (B20) ne ie Dentese ated land service check connector, = Repair open in BLK wi ‘ween service check ci Connect the SCS short connector ta the eervice check connector. {and body ground. ne T ves. — Repair open in BRN wire be Is there approx. § V7 tween ECU (B20) and service — —- heck connector. No Remove the SCS short connector ‘from the servica check connector, le the fuse OX? ves (o page 11-18) the fuse. hector, fst drive the car, Engine light for 2 code. (To page 11-10) ir, disconnect the SCS short con hd recheck the Check (cont'd) 11-15PGM-FI Control System (From page 14-18) Troubleshooting Flowchart — ECU [D15B2 engine] (cont'd) (€rom page 11-15) Turn the fai Disconnect the 3P connector of CMAP eonsor ‘Throttle angle tion goes awa nal ECU, = > = ves GRN/ORN wire betwoen the ECU Tuen the fgnition switch OFF. Does Check Engine light NO _| Replace the sensor that caused remain ON? the light to 90 out yes body ground in | (G6) and Check Engine waht wl from the ECU only, not the main a a 900000000 | 006000000 Jf c0000088 Sone 333338383 J esseesees [cesses 4 Continuity Check for cont inuity between body eround terminals C13, C15. sensor from the main wire hamess. Turn the ignition switch ON. Moasure voltage between 014 4) torminal and AZ6 vermin. ; YES |" Repair short in WHT wire be- <_tttese more han 0 Poa ween ECU (D14} and 0: sensor. [x0 ~ Measure voltage at the engine ‘Substitute a known-good ECU wire harness side of the Oven: and recheck. H symptom/ingiea- Sor connector between GAN ‘on goes away, replace the orii- Were and WHT ¢. ECU. ves ——_———} te we Replace Os sensor. No ‘open in WHT wire be: ‘tween ECU (D1) and O: sensor. Iwi is 0 tor open in GaNiWHT tween ECU (022) and 0: 1587, p1821, b1626, 01627, 81602 engine: tsa7, onszr engine: 0: SENSOR GAN War) WaT) ‘een oe cieanson O7LAA-PTS0101 " ee ‘O7LAA - PTSO101 Commercially available or ovat 002000 11-22Ei Self-diagnosis Check Engine light indicates code 3: An electrical problem in the Manifold Absolute Pressure (MAP) Sensor system. - Troubleshooting Flowchart — MAP Sensor [Except D15B2 engine] Self-diagnosis Check Engine light indicates code 5: A mechanical problem in the Manifold Absolute Prossure (MAP) Sensor system. The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECU. vacuum e- (oo = Check Engin ported on. — With the S65 short connector oureur conocted (page 1-5, CODE VourTace Sisindionted ee mas 30 Do the ECU Reset Procedure 2s tbage 11-10. 20 15 10) as 1 (in Hg) Gauce Start the engine and allow ito 0s eS tavine i. 700200300” «00 800 600700 (mmtig) Intermittent failure, system is OK ii this time (test drive may be is Check Engine ight on and does \,_NO_| hecassay) indicate CODE 3? heck for poor connection or = fone wires at MAP sonsor and ves ou. Turn theigniion switch OFF. | "Map SENSOR \ Disconnect the aP connector from tho MAP sensor [turn te ignition swten ON. | (Fo page 11-28) war” Grwwwat YeLsneD (conta) 11-23PGM-FI Control System (rom page 1123) Measure voltage between YEL/ RED (+) terminal ond body ‘round ae ves << _tetnore approx. 8 v7 No | Connect the test harness “D" Eonnetorto the ECU ony, not 0 | the main wire harness, Measure voltage between 19 (+) terminal and D2t (terminal ves

<_tetnoroappron 57> ves | tteasure vottage between WHT (6) terminal and GRNWHT tovenina st Us there approx. 5 V2 ves. [Turn the inition switch OFF. Reconnect the aP connector to the MAP soncor, \ — is Connect the test harness be: | twwoen the ECU and connector, — peel (To page 11-25) Repair open in GRN/WHT or GRN/BLU wire between ECU (21) and MAP sensor 11-24(From page 11-24) Turn the ignition switch OFF Connect the test harness “D" teonnector to the ECU only, not to tha main wite ames —__| Turn the ignition switch ON. Moature voltage between O17 (+) terminal ane 021 (2) termina. No ‘Substitute a known-good ECU (rom page 11-28) ‘Measure voltage betweon D17 (+) terminal and O21 (-) terminal SS retiree id ves —__|_ ‘Substitute # known-good ECU land recheck. If symptom/indice tion goes away, replace the origi- al ECU. av eal D7) Bare TosssoosoDIOD | SoGSOTTS [RUBEEBT FeaS STO 2000000000000 | 00000000 [690090] 00000000000 — Repair short in WHT or PNK/ WHT wire between ECU (D171, nd MAP sensor. — Repair open in WHT or PNK? WAHT wire between ECU (017), 7 ‘and MAP sensor (conta) 11-25PGM-FI Control System = Check Engine reported on — Wieh the SCS shor ‘connected (page 11 Sis indicated | CODE Do the ECU Reset Procedure {page 1-10), 1nd keep engine ls Check Engine light on and does S,,_NO iRindioate CODE 8? ves “Ture the ignition switeh OFF Remove the MAP sensor from throttle body. Connect a vacuum pump to the MAP sensor and apply vacutim = Noy Id vacuum? LJ ves | por tn theo (To page 11-27) [ Troubleshooting Flowchart — MAP Sensor (cont'd) itn f may be necessary) — Make Replace MAP sensor. 11-26(From page 14-26), —__|_. No Yes Stop the engine | Gannwst i cont harnaas be tween the ECU and connector, the ECU ondconnetor, __ “Turn the ignition switch ON, Measure voltage between D17 (+) terminal and 021 (+) trrinal sissies aE aan eeeee avr 17 (9) Dat fea 355550000050] 5000000 [OOTBOB] D0dd00CObO 9000000000000] 00000000 88] 00000000000 > aptace MAP sensor. ves 11-27PGM-FI Control System [- Troubleshooting Flowchart — Ignition Output Signal SGTT= LEE setr-tingnosis check Engin light indicetes code 16: A problem inthe Ignition Output Signal circuit ses. Soke = Check Engine reported on — With the ses ‘connected Do the ECU Reset Procedure | |L_tpage 11-10 NOTE: If the engine won't start, it may take 20 seconds of cranking to set the | code. ‘wires at igniter unit and Is Check Engine light on and does S, NO_| necessary) itindieate CODE 15? Chock for poor connections or Yes. “Turn the ignition ewitch OFF. Disconnect the 2P connector from the distributor ‘Measure voltage betwoon BLK! YEL (+1 terminal and body grounds pus BLK YEL (+) No_| Repair open in BLK/YEL wire be- ‘ween the 2P connector and ign tion suite, Yes. (To page 1128) 11-28(From page 11-28), Ten the ignition ewiten OFF, — v7 —— L 21 (6h Connect the test harness be: 200000000000. sesssonas ats Teaeacee thwoen the ECU snd connoctors. 26 (41 [| NN "Measure voltage batwoon A2t (+) terminal and A26 () termina jt — Replace the igniter uni = Repair open or short in VEL/ GAIN wire between igniter == W the VELIGAN wire w Substitute « known-good ECU ‘and ECU (21, 26, tho igniter may be dameged. id recheck. if symptom/indica- replace the origi @S500000000 20000000. 90000000000.PGM-FI Control System - Troubleshooting Flowchart — PA Sensor [D15B7 engine, D15Z1/D16Z6 ——— engine (KS model)] DEES “LTTE Seltdiagnosis Check Engine light indicates code 13: A problem in the Atmospheric Pressure (PA) ABS CULL sensor. The PA sensor is built into the ECU. -eSI- 502) — Check Engine light has beon reported on — With the SCS short connector ‘connected (page 11-9). CODE $3 ie indicated Do the ECU Reset Procedures (page 11-10 NO_[ "Rep apa in BLK wire ‘and ves T [= fen 00 te Teen coca te ae renin 20S 6 = Turn the ignition switch ON. BLRIYEL terminal round = Replace ACG (5) (15 A) fuse, = Repair open in the BLK/YEL wre between the mein ley ratnence ssiieAusee” | auur see RESIN EAN He | BM Turn the anton swich to me - START It positon, aux: fo Tu posto awa vets oleae wr —* [ Mesture the vottage between yeu, | blunt Terninet ® and boy BR suey |_ sroend _ a sux) — Replace STARTER SIGNAL yeu MAIN __| | ~erane SoH <__ite niesvatoga > M| — Rept an oso in the ios: BLU IwN mite betes 7 the natn recy ana the STA | TER SIGNAL (7.5 A) fus (To page 17.26) (cont'd) 11-33Fuel Supply System r- Main Relay [Except D15B2 e: (rom page 11:33) ‘Turn the ignition switch of gine] (cont'd) Reconnect “A” connector to the ECU. Connect the main relay connec: = | ‘Turn the ignition switch ON. Measure the voltage between {A23 (-) terminal and the follow: Ing teres: A285 (+) 81 (4). | _ YES \ Lu ‘Turn the ignition switeh OFF a Connect the test harnoss be i tween the ECU and connector BoobosossssosoooTSoSS paDasssocnsl Biszonnact A” connector from Soceocsssecs | sococces aeeesel sscccosccce the ECU only, not the main wire | harness, Check for continuity between GRN/VEL terminal ® and A? tor —_ —_|____ ————___ < tinuity exist? GaniveL. ey tween ECU IA7) and main relay. ves — _ Bortery voltage? Aes ba 1 i 3oGGd00000068] da0005 90000000000 = Repair open in the YEL/BLK wire @ between the ECU {A26, B1) and main relay. = Replace main relay Battery voltage? az 23 (-) BsadoCOOOSOSO Dood000TOSTBGS] 6000000000, 20000000|999900] 00000000000 ‘Measure the voltage between AT G3} terminel and A23 (2) terminal suhen the ignition switeh i est turned ON for twa eeconde. ves (Check the main relay Substitute # known-good ECM and recheck. if Prescribed volt 11-34Air Intake System [ Throttle Body [Except D15B2 engine) AA ___________ Disassembly (All models) top screw is non-adjust smbly, adjust the throttl snd A/T throttle control cable for cars with A/T. A C Replace. Re Oe ‘conTRoL CABLE @ ® B1GA2 engine: ManiFoLD (MAP) SENSOR Troubleshooting, page 11.23 ANGLE I ‘O-RING os wi (0 kem, 7tb-A Fast IDLE VALVE 11-35Emission Control System - Exhaust Gas Recirculation System [D15Z1 engine] Troubleshooting Flowchart Self diagnosis Check Engine light indicates code 12: A problem in the Exhaust Ges Recirculation (EGR) systom. Sagas SOE = Check Engine light has been reported on. — With the SCS short connector connected (page 11-8), CODE ‘2s indiented, = | Do the ECU Reset Procedure tpage 11-10), TL Connect the SCS short connector to the service check connecior (see page 11-9). Road test necessary: Warm up the engine to normal operating temperature (cooling fan comes vacuum pume/ on meHOsE = GAUGE Drive the car on the road for ap- prox. 10 minutes. With tho tans mission in low geor, keep the fengine speed im the 1,700 2.500 range. Is Check Engine ight on and does indicate CODE 127 she engine ati the ate nove tom [__pumetgavgeto the hove J ves | Disconnect 2° connector from Ts there any vecuum? the control box and check the #16 hose for vacuum again. No ae CONTROL, Ws T Move the vacuum pumpigauge | tothe EGR valve. eqRvatve “| onw/s.u (To page 11-37) {To page 11-37) 11-36oo (From page 11-26) (rom page 11-36) 1 With the engine a, apy 200 | mmHg of vacuum to the EGR No ves the control box | Disconnect the 2P connector from [ Messure vottage betwoon BLK) | YELL ormina onthe main wire | hamess and body ground, ves Reconnect the vacuum pump! | ‘dauge to the M6 hose, | (To page 11-38) Does the engine stall or ran i rough Turn the jgnition switen OFF and | discanneet the "A" connector from the ECU ‘Check for continuity to ground on GRNIBLU wire of 2° connector panes j__ Exhaust Gas Recirculation System [D15Z1 engine] (cont'd) {From page 11-39) No [— oa O_{ “Replace the EGR valve ves Reconnect the #16 hose to the EGR valve. ‘and allow it ro ate. Connect 11 terminal to A26 ter minal with 3 jumper wire wo [Rapa pe nwa. wine remit [sneha set conet | Supettte known: good ECU We land recheck tion goos away. nal ECU. 11-40Manual Transmis: ion 2WD Manual Transmission $20. y21. AWD Manual Transmis: $22.2WD Manual Transmission $20 Transmission Assembly Removal Installation .. 13-2 13-6 Outline of Model Changes + The transmission mount, right front mount/bracket, and rear mount bracket have been modified. + Torque value of transmission mounting bolts have been changed. + Torque value of transmission mount bolt has been changed, + _Installed of transmission breather cap has been changedTransmission Assembly -- Removal = ks and safety stands are placed proper- ly (see section 1), ‘¢ Apply parking brake and block rear wheels so car will ‘ot roll off stands and fall on you while working un- dor it CAUTION: Use fender covers to avoid damaging painted surfaces. 1. Disconnect the negative {-) cable first, then the pos: itive (+) cable from the battery. 2. Remove the intake air pips, intake air duct and air cleanor housing assembly. 3. Drain transmission oil. [AIR CLEANER. INTAKE HOUSING. AIRPIPE ASSEMBLY INTAKE AIR DUCT 4. Disconnect the starter motor cables and transmis: sion ground wire, 5. Remove the engine wire harness clamp. 6. Disconnect the back-up light switch connector and speed sensor connector. BACK-UP LIGHT acne SWITCH CONNECTOR SENSOR CONNECTOR STARTER TRANSMISSION CABLES (GROUND WinE 7. Remove the clutch pipe bracket and slave cylinder. NOTE: Do not operate the clutch pedal once the slave eylinder has been removed cuuTen suave PIPE, CYLINDER, BRACKET 13-28. Remove the three transmission mounting bolts and lower starter mounting bolt, ‘TRANSMISSION MOUNTING BOLTS 9. Remove the driveshafts, intermediate shaft, and right damper fork Isee saction 16). NOTE: Coat all precision finished surfaces with clean engine oil or groaso. Tie plastic bags over the driveshaft ends, SET RING DRIVESHAFTS SELF-LOCKING NUT corrénpIN Replace, Feplace, 10. Remove exhaust pipe A. SELF-LOCKING NUT Replace. GasKers. Replace. casier /eussvncn SELF-LOCKING NUT ‘SELF-LOCKING NUT Replace. Replace. Remove the change rod and change extension, CHANGE ROD 8x20 mm SPRING PIN Replace. CHANGE EXTENSION PIN DRIVER, 8.0 mm (077440010600 (cont'd) 13-3Transmission Assembly r- Removal (cont'd) 12. Install the bolts in the cylinder head and attach a chain hoist to the bolts, then lift the engine slightly 10 unload the mounts. D16A9 engine: CHAIN HOIST RIGHT FRO: MOUNT/BRACKET ENGINE SPLASH SHIELD 14. Remove the front and rear engine stiffeners, and the clutch cover. | ctures J cover FRONT ENGINE REAR ENGINE 'STIFFENER STIFFENER 18. Place a transmission jack under transmission and @ jack stand under the engine 16. Remove the transmission mount. ‘TRANSMISSION MOUNT 13-417. Remove the rear mount bracket bolts and transmis- sion mounting bolts, ‘SPECIAL BOLT Replace. washer “7 Rear MOUNT BRACKET SPECIAL BOLT Replace. 18. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the tranemis: sion jack. 13-5Transmission Assembly - Installation 1. Install the dowel pins. DOWEL PINS Apply groase to the parts as shown. NOTE: Use only HONDA Genuine Urea Grease (UM264 (P/N 41211 ~ PYS — 308) Install the release bearing, release fork, and release fork boot, {Pin 4211 - PY — 308) RELEASE RELEASE FORK 4 Place the transmission on the transmission jack land raise itto the engine level Install the transmission mounting bolts and rear mount bracket bolts, SPECIAL BOLTS Replace. 1241.25 mm 1415 mm 65 Nem (635 Karr. 47 Wht) 85 Nem (85 harm, 61 bf) washers REAN MOUNT BRACKET ‘SPEGIAL BOLT Replace. Wxismm 85 Nem (8.5 kgm, 61 lb-ft) Raise the transmission, then install the transmission mount. NOTE: Torque the mounting bolt and nuts in the sequence shown, CAUTION: Chock that the bushings are not twisted or offset. © 12%1.25 mm 5 fern (6.8 kgm, 47 Wot) ‘TRANSMISSION MOUNT @ 122x425 mm 75 Nem (7.5 kgm, 54 FO 13-67 8 Install the clutch cover, then install the front and rear engine stiffeners, 6x1.0mm, 1aNmit2 kgm, Sib) FRONT ENGINE STIFFENER oturcH cover 281.25 mm 24 Nm 2-8 kor, Tien REXR ENGINE 'STIFFENER 101.25 mm 45m (45 kg-m, 33 A) Insta the right front mountibracket. Install the engine splash shield, SPECIAL BOLT oplace. 121.25 mm 65 Nem (65 kom, 47 If) <> fi2fyy mcr Front 7 MOUNT/oRACKET 822m =o Ropes 10% 1.28 mn {5m aS kgm, Biehl he EXTENSION PIN DRIVER, 8.0 mim ora ooroem” = ENGINE SPLASH SHIELD ve ex 20 mm a 10 Nem (1.0 kg-m, 7 Ib-ft) “ SHIFT ROD BOOT | eur | aa DOWN | (cont'd) Hote 10. Remove the chain hoist, then reinstall the distribu tor mounting bolt. (CHAIN HOIST DISTRIBUTOR MOUNTING BOLT 2% 1.25 mm 2aNkm (24 ko-m, 7st) 11. Install the change rod, the spring pin, and the clip, Note: ‘ Install the clip and the spring pin on the change joint as shown, ‘© Turn tho shift rod boot so the hole is facing down as shown, ‘© Make sure the shift rod boot is installed on the change rod. 12, Install the change extension. 1.25 mm CHANGE ROD 22Nim (22 kgm, 16 b-f) 13-7Transmission Assembly - Installation (cont'd) 13. Install exhaust pipe A. SELF-LOCKING NUT Replace, 31.25 mm 22.Nm (22 kom, 16 16-4) Gasket Roplace, EXHAUST PIPE A SELF-LOCKING NUT SELF-LOCKING NUT Replace Replace 1.25 mm 40% 1.25 mm Nm 1eko-e, 55 Nm (55 kom, be oe 14. Install the intermediate shat and driveshafts NOTE: Use the set rings with new ones. 415, Install the ball joint onto the lower arm. 16, Install the damper fork INTERMEDIATE SHAFT DRIVESHAFT. (oka, 2o lb) correnpin | 10125 mm Foplace. Aattm (6a kgm, 2b) 1241.25 em ‘Nem (5.0-6.0kg-m, SELF-LOCKING NUT 36-43 16 ft) Replace. 4251.25 mm 65 Nem (6.5 kom, 47 b-F) 17. Install the transmission mounting bolts and lower starter mounting bolt 10x125mm \ 45 Nm kom, 33 ib ‘TRANSMISSION MOUNTING BOLTS 3241.25 mm (65 Nem (6.5 kom, 47 tht) 18, Install the slave cylinder, then install the clutch pipe bracket. NOTE: Use only HONDA Genuine Urea Grease UM264 (PIN 41211 ~ PYS ~ 308). CLUTCH PPE BRACKET 22Nm (22 kgm, 16 -F) "¥5 ~ 308) 13-819. Connect the speed sensor, back-up light switch con ectors, transmission ground wire, and starter ca bles, NOTE: Whon installing the starter cable, make sure that the crimped side of the ring terminal is facing ‘out (see section 23) 20. Install the wire harness clamp. 8x1.25 mm 22.Nem 22 kgem, 16 It) 22, SPST eon BIS on 8x1.25 mm B8Nm(OSkam, STARTER TRANSMISSION pa) CABLES GROUND WIRE 21. Install the intake air duct, air cleaner housing a sembly, and intake air pipe. 6x 1.0mm AIR CLEANER. TONm(1Okgm, HOUSING Tb ASSEMBLY INTAKE INTAKE AIR DUCT AR PIPE 0) 22. Turn the breather cap so that the “F” mark points at {an angle of 30° towards the front of the car as shown, Front BREATHER CAP 23. Ref the transmission with ol 24. Connect the positive (+) cable first, then the negative () cable to the battery. 25. Check the clutch operation, 26. Shift the transmission and check for smooth opera- tion 27. Adjust ignition timing (see section 23) 28. Check the front wheel alignment (see section 18). 13-92WD Manual Transmission y21 Transmission Assembly Removal . Shift Fork Assembly Index . 13-12 Transmission Assembly Installation .... Outline of Model Changes. $$ @$A@aa$a a a + Tho transmission mount, right front mount/bracket, and rear mount bracket have been modified. + Torque value of transmission mounting bolts have been changed. + Torque value of transmission mount bolt has been changed, + The shift forks have been changed.Transmission Assembly - Removal Make sure jacks and safety stands are placed proper- Iy (see section 1), © Apply parking brake and bl will not roll off stands and under it CAUTION: Use fender covers to avoid damaging paint- ed surfaces, 1, Disconnect the negative (-) cable first, then the pos: itive (+) eable from the battery, 2. Drain the transmission oil, then reinstall the drain plug with a new washer. 3, Remove the intake air pipe, intake air duct, and the air cleaner housing assembly. AIR CLEANER INTAKE HOUSING AIRPIPE ASSEMBLY INTAKE AIR DUCT [sg >) TR, 6 7. Disconnect the back-up light switch connector and the transmission ground wire. Remove the lower radiator hose clamp from trans: mmission hanger B. LOWER RADIATOR HOSE CLAMP. BACK-UP LIGHT SWITCH CONNECTOR TRANSMISSION TRANSMISSION GROUND WIRE HANGERS. Remove the wire harness clamps. Disconnect the starter motor cables and the speed sensor connector. SPEED SENSOR WIRE HARNESS GONNECTOR CLAMPS. STARTER moror CABLES 13-128, Remove the clutch pipe bracket and the slave cylin der. NOTE: Do not operate the clutch pedal once the slave cylinder has been removed. SLAVE cuuten a eau CYLINDER BRACKET 9. Remove the three upper transmission mounting bolts and lower starter motor mounting bolt, STARTER ‘TRANSMISSION MoToR MOUNTING. MOUNTING BOLTS. pour 10. Remove the engine splash shield. ENGINE SPLASH SHIELD 11, Disconnect the oxygen sensor connector, then remove exhaust pipe A. oxycen ‘SENSOR ‘CONNECTOR GasKeTs Replace. asker Replace EXHAUST PIPE A, SELF-LOCKING NUT SELF-LOCKING NUT Roplace (cont'd 13-13Transmission Assembly 7 Removal (cont'd) 12, Remove the cotter pins and loosen the castle nuts, then separate the ball joints from the lower arm, (see section 18) 18, Remove the right damper fork. SELF-LOCKING NUT Replace. right COTTER PIN DAMPER —CASTLENUT Replace FORK 14, Remove the driveshafts and the intermediate shaft {s00 section 16) NOTE: Coat all the precision finished surfaces with clean engine oil or grease. Tie plastic bage over the ‘driveshaft ends. SET RING /o — Replace. SET RING Replace. pavéenast DRIVESHAFT SET RING INTERMEDIATE SHAFT Replace. 15. Remove the bolt, then disconnect the change exten: 16. Remove the clip and the spring pin, then disconnect the change rod. 8x22mm ‘SPRING PIN op. PIN DRIVER, 8.0 mm CHANGE EXTENSION 17. Remove the front and the rear engine stiffeners. FRONT ENGINE STIFFENER REAR ENGINE ‘STIFFENER 13-14Remove the clutch cover. Remove the right front mount/oracket. SPECIAL BOLT Replace. RIGHT FRONT MOUNT/BRACKET 20, Place a transmission jack under the transmission and a jack stand under the engine. 21. Remove the transmission mount ‘TRANSMISSION MOUNT Remove the rear mount bracket bolts and the trans: ‘mission mounting bolts, REAR MOUNT BRACKET 23, Pull the transmission away from the engine until it clears the mainshatt, then lower it on the transmis sion jack 13-15Shift Fork Assembly r- Index 7B Prior t0 reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. PIN DRIVER, 5.0 mm STH/REVERSE ‘SHIFT FORK. ‘SRO/4TH SHIFT FORK 5x22 mm ‘SPRING PIN Replace. 18T/2ND SHIFT FORK. STH)REVERSE SHIFT PIECE. 13-16Transmission Assembly ait} [ Installation 1. Install the dowel pins on the clutch housing 2. Apply grease to the parts a8 shown, then install the release fork and release bearing. NOTE: Use only HONDA Genuine Urea Grease UMa64 (PIN 41211 - PYS 308) 3. Install the release fork boot RELEASE FORK BOLT Dimon — SE Zw in ar2v1- Py -308) RELEASE BEARING newase Fork Boor (P/N 41211 - PY5 - 305) 4. Place the transmission on the transmission jack, and raise itto tho engine level 5. Install the transmission mounting bolts and the rear mount bracket bolts SPECIAL BOLT Replace 124125 mm hanson GNmiostom ai) ——astemiestom, abe : SD wesen EAR MOUNT Backer Raise the transmission, then install the transmission ‘mount. NOTE: Torque the mounting bolt and nuts in the ‘sequence shown, CAUTION: Check that the bushings a or offset. not twisted © 1241.25 mm 65m (65 kgm, abe ‘TRANSMISSION @ 1241.25 mm 75mm (75 kom, Balb-hy 7. Install the three upper transmission mounting bolts and lower starter motor mounting bolt a 32x1.25mm 65 Nem (6.5 kgm, 47 Ib) 101.28 mm 45 Nm (45 kom, 331b8) (cont'd 13-17Transmission Assembly -- Installation (cont'd) 8 Install the right front mountibracket. SPECIAL BOLT Foplace. 32% 1.25 mm (65 Nm 16.5 kgm, 47 Ib) RuGHT FRONT MOUNT/BRACKET 10 1.25 mom 45Nm (as kom, 0 9. Install the clutch cover. 8x129 mm BAN a ekgm, Dee 40. Install the front and rear engine stiffeners. REAR ENGINE Berzmm |) | STIFFENERS: 58 Nm 6.8 kom, ib) ey) 24Nm (24 kg-m, ib ax 125mm 2aNm 2.4 kgm, FRONT ENGINE 17 Ib) 1224.25 mm STIFFENERS 58 Nem (6.8 kam, abn Install the change rod, the spring pin, and the clip. NOTE: '* Install the clip and the spring pin on the change joint as shown, Turn the shift rod boot so the hole is facing down as shown. Make sure the shift rod boot is installed on the change rod. 12. Install the change extension. ax1zmm ] 2aNm (22m, Da ewe / ‘SHIFT ROD BOOT CHANGE can SPRING PIN 8 we 13-1813, Install the intermediate shaft and the driveshafts (see section 16) NOTE: Replace the set rings with new ones. DRIVESHAFTS, > SET RING Replace, INTERMEDIATE ‘SHAFT ser Aine Replace. 101.25 mm 40M (40 kgm, 23 1b-40 114, Install the ball joints onto the lower arm (see sec- tion 18) 15. Install the right damper fork (see section 18. 101.25 mm {44 hen (44 koe, 22 bf) SELF-LOCKING NUT = Replace. 65 Nem (65 kgm, abe casTLe Nuy 32x 125mm 50-60. (5.0-60 kgm, 36-431) cortén pin oO: 16, Install exhaust pipe A, then connect the oxygen sen oxycen ‘SENSOR ‘CONNECTOR GaskeTs Renlace Replace. SELF-LOCKING NUT Replace. 125mm eee EXHAUST PIPE A r6b-t SELF-LOCKING NUT SSELF-LOCKING NUT Replace, =F 3e 1.25 mm ents mm 28 hem (8 Kom ‘Nim (neko, 30 hm ihn 17. Install the engine splash shield. ENGINE SPLASH SHIELD (cont'd 13-19Transmission Assembly r Installation (cont'd) 18. Install the slave cylinder, then install the clutch pipe bracket NOTE: Use only HONDA Genuine Urea Grease: UM264 (P/N 41211 ~ PYS ~ 308}. cuutounre BRACKET x1.9.mm 30 Nem 9.0 kg-m,7 Wot) suave CYLINDER a 8x 1.25 mm aiait—pys-205) 228m 22kgm, semi 19. Connect the speed sensor connector and the starter motor cables, 20. Install the wire harness clamps, 6x 10mm SPEED TON m (1.0 kg-m, 7b) SENSOR CONNECTOR HARNESS CLAMPS. 21. Install the lower radiator hose clamp on transmis: sion hanger B. 22. Connect the transmission ground wire and the back-up light switch connector. 841.25 mm LOWER RADIATOR 22Nm(@2kgm, HOSE CLAMP remy BACK-UP LIGHT ‘SWITCH CONNECTOR TRANSMISSION TRANSMISSION GROUND WIRE HANGER B. 23. Install the air cleaner housing assembly, intake air duct, and intake air pipe. 6x1.0mm TON MIT Ok-m, AIR CLEANER. cea HOUSING INTAKE AIR DUCT ASSEMBLY iwraKe AIR PIPE 24, Refll the transmission with ll 28. Connect the positive (+) cable first, then the nega: tive (-) cable to the battery. 26, Check the clutch operation. 27. Shift the transmission, and check for smooth opere- tion 28. Check the front whee! alignment (see section 18}, 13-20[ 4WD Manual Transmission $22 Service Precautions Special Tools .. Transmission Assembly Removal .. Mlustrated Index Transmission Housing Removal .. e Mainshaft, Countershaft Assemblies Removal Transfer Shaft Bearing Replacement .. Transmission Reassembly .... Transmission Assembly Installation . Outline of Model Changes The transmission mount, right front mount/bracket, and rear mount bracket have been modified Torque value of transmission mounting bolts have been changed. + _The super-low shatt, 2~ 4 select lever, and transfer shaft have been changed.Service Precautions (4WD) This 4-wheel drive model is not equipped with the sys- ‘tem that mechanically shifts the drive system to the 2-wheel drive Therefore, perform the speedometer test by using the free rollers. Tip on use of free roller: '® Test cannot be made by using the chassis dy- namometer. © Do not operate the accelerator pedal, clutch, brake system and steering wheel quickly. The car can roll hard or dash out during the test which is very dan- gerous. ‘© Do not raise the speed more than 50 km/h. '® Do not use the free rollers continuously for more than 3 minutes at one try. ‘© Secure the car for safety. Attach the ropes to the car ‘ot to allow it to roll or dash out during the test. (Use the free rollers for the rear wheels) 1. Set each of the free rollers at the wheelbase and track of the car. NOTE: Be sure that the free rollers and speedome- ter tester rollers are sot parallel with each other. FREE ROLLER ‘SPEEDOMETER TESTER FRONT WHEEL REAR WHEEL SIDE oF ‘SPEEDOMETER TESTERS FREE ROLLERS WHEELBASE Set the positioning positionina uiné etches on the line. Move the car to set the front wheels on the speedometer testers and the rear wheols on the free rollers. Be sure that the wheels are set at the center of the speedometer testers and free rollers respec tively. CAUTION: Be sure that the front and rear wheels. are set at the center of the speedometer tester and {rae rollers securely, or the car can rall hard or dash, ‘out during the test, which is very dangerous. 3. Attach the ropes to the trailing hook and tie-down ff the car from rating) 4. hooks to secure the car (For prevention of the car from rolling hard or dashing out during the test). CAUTION: ‘© Be sure that the ropes attached to the car for prevention of rolling are not slack. Slack ropes do. not effectively secure the car and the car can roll during the test. © Attach the ropes to the car not t the bumper. ‘© Do not attach the ropes to any section other than, the specified section. erfere with ROPE (for prevention of the cat from dashing out) attach to the walling hook. FRONT }OPE (for prevention ROPE {for provontion of the car from rolling) ‘Attach to the talling hook. ‘Attach to the te down hook. Start the engine. With the gearshift lever in the 3rd ange on the manual transmission car or the gear. shift lever in the D1 or D2 position on the automatic, transmission car, start the car and raise the speed gradually. CAUTION: Take care not to exceed 50 kmih of speed and do not test for more than 3 minutes con- tinuously. After the test, slow down the car until it stops by applying the brake graduall 13-22Special Tools |__ Ret. No. Too! Number Description aty_| Page Reference @ 0746¢ - 0010100 ‘Snap Ring Pliors 1 | 1339,37 @ 07748 0010700 Outer Driver, 24 x 26 ram 1 | 13a ® 07749 - 0010000 Outer Handle A i | 1335 13-23Transmission Assembly Removal ly (eee section 1) Apply parking brake and block rear wheels so car ‘will not roll off stands and fall on you while working under it. CAUTION: Use fender covers to avoid damaging paint- ed surfaces. 1. Disconnect the negative (-) cable first, then the pos- itive (4) cable from the battery. 2. Drain the transmission il, then reinstall the drain plug with a new washer 3. Remove the intake air pipe, intake air duct, and the air cleaner housing assembly. [AIR CLEANER iTaKe HOUSING AIR ASSEMBLY INTAKE AIR OUCT 4. Disconnect the starter motor cables and the trans mission ground wire. 5. Remove the wire harness clamp. 6. Disconnect the back-up light switch and the speed sensor connectors. ‘SPEED wire BACK-UP LIGHT sensor HARNESS. SWITCH CONNECTOR CLAMP. CONNECTOR STARTER ‘TRANSMISSION MoToR GROUND WinE CABLES 7. Remove the clutch pipe bracket and the slave cylin- der. NOTE: Do not operate the clutch pedal once the slave cylinder has boon removed. CLUTCH PIPE suave BRACKET 13-248. Remove the cotter pins, then loosen the locknuts ‘and remove the select and shift cables. NOTE: Take care not to bend the cables when re- moveing from them and hang them by cable up to the body, 8. Remave the wire harness clump from the change cable bracket. wire COTTER Pin WARNES Replace, Locknut cLUMP CHANGE CABLE BRACKET 10, Remove the three transmission mounting bolts and starter motor mounting bolt, ‘STARTER MOTOR MOUNTING BOLT TRANSMISSION MOUNTING BOLT Remove the cotter pins and the loosen castle nuts, then separate the ball joints from the lower arm (see section 18). Remove the right damper fork SELF-LOCKING NUT Replace, Leg RIGHT Casi Siomen SASTIENGT Cohen iy FORK Roplace, 13. Remove the driveshafts and the intermediate shaft (see section 16} NOTE: Coat all precision finished surfaces with clean engine oil or greaso. Tio plastic bags over the driveshaft ends. SETRING Replace. SETRING ~ Replace. priveser > DRIVESHAFT Replace. INTERMEDIATE SHAFT (cont'd) 13-25Transmission Assembly - Removal (cont'd) 14, Remove exhaust pipe A. SELF-LOCKING NUT Replace. Gaskets. Replace. Replace. ‘SELF-LOCKING NUT Replace. ‘SELF-LOCKING NUT Replace. exausr PEA 16. Disconnect the No. 1 propeller shatt from the com: anion flange, NOTE: Mark the shaft and companion flange before disconnecting them. No.1 PROPELLER SHAFT 16. Install the bolts in the cylinder head and attach 9 chain hoist to the bolts, then lift the engine slightly 10 unload the mounts. 17. Remove the engine splash shield. 18, Remove the right front mountbracket. IGHT FRONT MOUNT/BRACKET ‘SPECIAL BOLT Replace, 13-2619, Remove the front and the rear engine stiffeners. 20. Remove the clutch cover mounting bolt. MouNTiNG BOLT ENGINE STIFFENERS 21. Place a jack under the transmission, then remove the transmission mount. ‘TRANSMISSION ur 22, Remove the rear mount bracket bolts and the trans- mission mounting bolts SPECIAL BOLT Foplace. sPectat Bout Replace. BRACKET 23. Pull the transmission away from the engine until it clears the mainshaft, than lower it on the transmis: sion jack 24. Remove the parts below as shown, eres aon reer ne z TRANSMISSION MOUNT BRACKET BACK-UP LIGHT swiTcH ‘TRANSMISSION’ HANGER, wabuer Replace. 13-27