Standards and Service Limits
Engine Electrical System (R18A1 engine)
STANDARDS AND SERVICE LIMITS - ENGINE ELECTRICAL (R18A1 ENGINE)Item Measurement Qualification Standard or New Service Limit Ignition coil Rated voltage 12V Firing order 1-3-4-2 Spark plug Type NGK:IZFR6K11S
DENSO:SKJ20DR-M11SGap 1.0-1.1 mm (0.039-0.043 in.) - Ignition timing At idle Check the red mark M/T (in neutral) 8±2° BTDC A/T (in N or P position) 8±2 ° BTDC Drive belt Tension Auto-tensioner Alternator Output At 13.5 V and normal engine temperature 90 A Coil (rotor) resistance At 68°F (20°C) 1.84-2.10 ohms Slip ring O.D. 22.7 mm (0.89 in.) 21.2 mm (0.83 in.) Brush length 19.0 mm (0.75 in.) 5.0 mm (0.20 in.) Brush spring tension 3.3-4.1 N (0.34-0.42 kgf, 0.75-0.93 lbf) Starter Output 1.0 kW Commutator mica depth
M/T0.50-0.80 mm (0.020-0.031 in.) 0.2 mm (0.008 in.) A/T Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) Commutator O.D.
M/T28.0 mm (1.10 in.) 27.0 mm (1.06 in.) A/T Brush length
M/T14.0-14.5 mm (0.55-0.57 in.) 9.0 mm (0.35 in.) A/T Brush spring tension 13.7-17.7 N (1.40-1.80 kgf, 3.09-3.97 lbf)
Engine Electrical System (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - ENGINE ELECTRICAL (K20Z3 ENGINE)Item Measurement Qualification Standard or New Service Limit Ignition coil Rated voltage 12V Firing order 1-3-4-2 Spark plug Type NGK:IFR7G11KS
DENSO:SK22PR-M11SGap 1.0-1.1 mm (0.039-0.043 in.) - Ignition timing At idle Check the red mark 8±2° BTDC Drive belt Tension Auto-tensioner Alternator Output At 13.5 V and normal engine temperature 105 A Coil (rotor) resistance At 68 °F (20 °C) 3.2-4.0 ohms Slip ring O.D. 14.4 mm (0.57 in.) 14.0 mm (0.55 in.) Brush length 10.5 mm (0.41 in.) 1.5 mm (0.06 in.) Brush spring tension 3.2 N (0.33 kgf, 0.7 lbf) Starter Output 1.0 kW Commutator mica depth 0.40-0.50 mm (0.016-0.020 in.) 0.15 mm (0.006 in.) Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) Commutator O.D. 28.0-28.1 mm (1.102-1.106 in.) 27.5 mm (1.083 in.) Brush length 11.1-11.5 mm (0.44-0.45 in.) 9.0 mm (0.35 in.) Brush spring tension 13.7-17.7 N (1.40-1.80 kgf, 3.09-3.97 lbf)
Engine Assembly (R18A1 engine)
STANDARDS AND SERVICE LIMITS - ENGINE ASSEMBLY (R18A1 ENGINE)Item Measurement Qualification Standard or New Compression Pressure Check the engine with the starter cranking Minimum 880 kPa (9.0 kgf/cm2, 128 psi) Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi)
Engine Assembly (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - ENGINE ASSEMBLY (K20Z3 ENGINE)Item Measurement Qualification Standard or New Compression Pressure Check the engine with the starter cranking Minimum 930 kPa (9.5 kgf/cm2, 135 psi) Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi)
Cylinder Head (R18A1 engine)
STANDARDS AND SERVICE LIMITS - CYLINDER HEAD (R18A1 ENGINE)Item Measurement Qualification Standard or New Service Limit Head Warpage - 0.08 mm (0.003 in.) Height 114.95-115.05 mm (4.526-4.530 in.) - Camshaft End play 0.050-0.250 mm (0.002-0.010 in.) 0.4 mm (0.02 in.) Camshaft-to-holder oil clearance 0.045-0.084 mm (0.0018-0.0033 in.) 0.15 mm (0.006 in.) Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.) Cam lobe height Intake, primary 35.754 mm (1.4076 in.) - Intake, secondary A 35.358 mm (1.3920 in.) - Intake, secondary B 36.027 mm (1.4184 in.) - Exhaust 35.813 mm (1.4100 in.) - Valve Clearance (cold) Intake 0.18-0.22 mm (0.007-0.009 in.) - Exhaust 0.23-0.27 mm (0.009-0.011 in.) - Stem O.D. Intake 5.48-5.49 mm (0.2157-0.2161 in.) 5.45 mm (0.215 in.) Exhaust 5.45-5.46 mm (0.2146-0.2150 in.) 5.42 mm (0.213 in.) Stem-to-guide clearance Intake 0.02-0.05 mm (0.0008-0.0020 in.) 0.08 mm (0.003 in.) Exhaust 0.05-0.08 mm (0.0020-0.0031 in.) 0.11 mm (0.004 in.) Valve seat Width Intake 0.85-1.15 mm (0.033-0.045 in.) 1.6 mm (0.06 in.) Exhaust 1.25-1.55 mm (0.049-0.061 in.) 2.0 mm (0.08 in.) Stem installed height Intake 67.2-67.4 mm (2.646-2.654 in.) 67.7 mm (2.665 in.) Exhaust 58.4-58.6 mm (2.299-2.307 in.) 58.9 mm (2.319 in.) Valve spring Free length Intake 55.31 mm (2.178 in.) - Exhaust 56.97 mm (2.243 in.) - Valve guide I.D. Intake 5.51-5.53 mm (0.217-0.218 in.) 5.55 mm (0.219 in.) Exhaust 5.51-5.53 mm (0.217-0.218 in.) 5.55 mm (0.219 in.) Installed height Intake 18.25-18.75 mm (0.719-0.738 in.) - Exhaust 18.25-18.75 mm (0.719-0.738 in.) - Rocker arm Arm-to-shaft clearance Intake 0.019-0.050 mm (0.0007-0.0020 in.) 0.08 mm (0.0031 in.) Exhaust 0.019-0.050 mm (0.0007-0.0020 in.) 0.08 mm (0.0031 in.)
Cylinder Head (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - CYLINDER HEAD (K20Z3 ENGINE)Item Measurement Qualification Standard or New Service Limit Head Warpage - 0.05 mm (0.002 in.) Height 103.95-104.05 mm (4.093-4.096 in.) - Camshaft End play 0.05-0.20 mm (0.002-0.008 in.) 0.4 mm (0.02 in.) Camshaft-to-holder oil clearance No. 1 journal 0.030-0.069 mm (0.001-0.003 in.) 0.15 mm (0.006 in.) No. 2, 3, 4, 5 journals 0.060-0.099 mm (0.002-0.004 in.) 0.15 mm (0.006 in.) Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.) Cam lobe height Intake, primary 32.791 mm (1.2910 in.) - Intake, mid 35.534 mm (1.3990 in.) - Intake, secondary 32.678 mm (1.2865 in.) - Exhaust, primary 32.772 mm (1.2902 in.) - Exhaust, mid 34.768 mm (1.3688 in.) - Exhaust, secondary 32.661 mm (1.2859 in.) - Valve Clearance (cold) Intake 0.21-0.25 mm (0.008-0.010 in.) - Exhaust 0.25-0.29 mm (0.010-0.011 in.) - Stem O.D. Intake 5.475-5.485 mm (0.2156-0.2159 in.) 5.445 mm (0.214 in.) Exhaust 5.450-5.460 mm (0.2146-0.2150 in.) 5.420 mm (0.213 in.) Stem-to-guide clearance Intake 0.030-0.055 mm (0.0012-0.0022 in.) 0.08 mm (0.003 in.) Exhaust 0.055-0.080 mm (0.0022-0.0031 in.) 0.11 mm (0.004 in.) Valve seat Width Intake 1.25-1.55 mm (0.049-0.061 in.) 2.00 mm (0.079 in.) Exhaust 1.25-1.55 mm (0.049-0.061 in.) 2.00 mm (0.079 in.) Stem installed height Intake 44.0-44.5 mm (1.73-1.75 in.) 44.7 mm (1.76 in.) Exhaust 44.1-44.6 mm (1.74-1.76 in.) 44.8 mm (1.76 in.) Valve spring Free length Intake NIPPON HATSUJO:
47.57 mm (1.8728 in.)- CHUO HATSUJO:
47.58 mm (1.8732 in.)Exhaust NIPPON HATSUJO:
49.64 mm (1.954 in.)- CHUO HATSUJO:
49.63 mm (1.954 in.)Valve guide I.D. Intake 5.515-5.530 mm (0.2171-0.2177 in.) 5.55 mm (0.219 in.) Exhaust 5.515-5.530 mm (0.2171-0.2177 in.) 5.55 mm (0.219 in.) Installed height Intake 15.2-16.2 mm (0.598-0.638 in.) - Exhaust 15.5-16.5 mm (0.610-0.650 in.) - Rocker arm Arm-to-shaft clearance 0.025-0.052 mm (0.0010-0.0020 in.) 0.08 mm (0.003 in.)
Engine Block (R18A1 engine)
STANDARDS AND SERVICE LIMITS - ENGINE BLOCK (R18A1 ENGINE)Item Measurement Qualification Standard or New Service Limit Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.) Bore diameter 81.000-81.015 mm (3.1890-3.1896 in.) 81.070 mm (3.1917 in.) Bore taper - 0.05 mm (0.002 in.) Reboring limit - 0.25 mm (0.01 in.) Piston Skirt O.D. at 14 mm (0.55 in.) from bottom of skirt 80.980-80.990 mm (3.1881-3.1886 in.) 80.98 mm (3.186 in.) Clearance in cylinder 0.010-0.035 mm (0.0004-0.0014 in.) 0.05 mm (0.002 in.) Ring groove width Top 1.23-1.24 mm (0.048-0.049 in.) 1.26 mm (0.050 in.) Second 1.22-1.23 mm (0.047-0.048 in.) 1.25 mm (0.049 in.) Oil 2.005-2.020 mm (0.0789-0.0795 in.) 2.05 mm (0.081 in.) Piston ring Ring-to-groove clearance Top 0.045-0.070 mm (0.0018-0.0028 in.) 0.13 mm (0.005 in.) Second 0.035-0.060 mm (0.0014-0.0024 in.) 0.13 mm (0.005 in.) Ring end gap Top 0.20-0.35 mm (0.008-0.014 in.) 0.60 mm (0.024 in.) Second 0.40-0.55 mm (0.016-0.022 in.) 0.70 mm (0.028 in.) Oil 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.) Piston pin O.D. 19.960-19.964 mm (0.7858-0.7860 in.) 19.960 mm (0.7858 in.) Pin-to-piston clearance -0.004 to +0.003 mm
(-0.00016 to +0.00012 in.)0.006 mm (0.0002 in.) Connecting rod Pin-to-rod clearance 0.005-0.015 mm (0.0002-0.0006 in.) 0.02 mm (0.0008 in.) Small-end bore diameter 19.969-19.975 mm (0.7862-0.7864 in.) - Large-end bore diameter 48.0 mm (1.89 in.) - End play installed on crankshaft 0.15-0.35 mm (0.006-0.014 in.) 0.45 mm (0.018 in.) Crankshaft Main journal diameter 54.976-55.000 mm (2.1644-2.1654 in.) - Rod journal diameter 44.976-45.000 mm (1.7707-1.7716 in.) - Rod/main journal taper 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) Rod/main journal out-of-round 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) End play 0.10-0.35 mm (0.004-0.014 in.) 0.45 mm (0.018 in.) Runout 0.03 mm (0.0012 in.) max. 0.04 mm (0.0016 in.) Crankshaft bearing Main bearing-to-journal oil clearance 0.018-0.034 mm (0.0007-0.0013 in.) 0.045 mm (0.0018 in.) Rod bearing clearance 0.024-0.042 mm (0.0009-0.0017 in.) 0.055 mm (0.0022 in.)
Engine Block (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - ENGINE BLOCK (K20Z3 ENGINE)Item Measurement Qualification Standard or New Service Limit Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.) Bore diameter A or I 86.010-86.020 mm (3.3862-3.3866 in.) 86.070 mm (3.3886 in.) B or II 86.000-86.010 mm (3.3858-3.3862 in.) 86.070 mm (3.3886 in.) Bore taper - 0.05 mm (0.002 in.) Reboring limit - 0.25 mm (0.01 in.) Piston Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt No letter or A 85.980-85.990 mm (3.3850-3.3854 in.) 85.930 mm (3.3831 in.) Letter B 85.970-85.980 mm (3.3846-3.3850 in.) 85.920 mm (3.3827 in.) Clearance in cylinder 0.020-0.040 mm (0.0008-0.0016 in.) 0.05 mm (0.002 in.) Ring groove width Top 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.) Second 1.220-1.230 mm (0.0481-0.0484 in.) 1.25 mm (0.049 in.) Oil 2.005-2.025 mm (0.0789-0.0797 in.) 2.05 mm (0.081 in.) Piston ring Ring-to-groove clearance Top 0.045-0.070 mm (0.0018-0.0028 in.) 0.13 mm (0.005 in.) Second 0.040-0.065 mm (0.0016-0.0026 in.) 0.13 mm (0.005 in.) Ring end gap Top 0.20-0.35 mm (0.008-0.014 in.) 0.60 mm (0.024 in.) Second 0.50-0.65 mm (0.020-0.026 in.) 0.75 mm (0.030 in.) Oil 0.20-0.70 mm (0.008-0.028 in.) 0.80 mm (0.031 in.) Piston pin O.D. 21.961-21.965 mm (0.8646-0.8648 in.) 21.953 mm (0.8643 in.) Pin-to-piston clearance -0.005 to +0.002 mm
(-0.00020 to +0.00008 in.)0.005 mm (0.0002 in.) Connecting rod Pin-to-rod clearance 0.005-0.015 mm (0.0002-0.0006 in.) 0.02 mm (0.0008 in.) Small-end bore diameter 21.970-21.976 mm (0.8650-0.8652 in.) - Large-end bore diameter 51.0 mm (2.01 in.) - End play installed on crankshaft 0.15-0.30 mm (0.006-0.012 in.) 0.40 mm (0.016 in.) Crankshaft Main journal diameter No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal54.984-55.008 mm (2.1648-2.1657 in.) - No. 3 journal 54.976-55.000 mm (2.1644-2.1654 in.) - Rod journal diameter 44.976-45.000 mm (1.7707-1.7717 in.) - Rod/main journal taper 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) Rod/main journal out-of-round 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.) End play 0.10-0.35 mm (0.004-0.014 in.) 0.45 mm (0.018 in.) Runout 0.03 mm (0.0012 in.) max. 0.04 mm (0.0016 in.) Crankshaft bearing Main bearing-to-journal oil clearance No. 1 journal
No. 2 journal
No. 4 journal
No. 5 journal0.017-0.041 mm (0.0007-0.0016 in.) 0.050 mm (0.0020 in.) No. 3 journal 0.025-0.049 mm (0.0010-0.0019 in.) 0.055 mm (0.0022 in.) Rod bearing clearance 0.032-0.066 mm (0.0013-0.0026 in.) 0.077 mm (0.0030 in.)
Engine Lubrication System (R18A1 engine)
STANDARDS AND SERVICE LIMITS - ENGINE LUBRICATION (R18A1 ENGINE)Item Measurement Qualification Standard or New Service Limit Engine oil Capacity Engine overhaul 4.5 L (4.8 US qt) Oil change including filter 3.7 L (3.9 US qt) Oil change without filter 3.5 L (3.7 US qt) Oil pump Inner-to-outer rotor clearance 0.02-0.16 mm (0.001-0.006 in.) 0.20 mm (0.008 in.) Pump housing-to-outer rotor clearance 0.100-0.175 mm (0.0039-0.0069 in.) 0.20 mm (0.008 in.) Pump housing-to-outer rotor axial clearance 0.02-0.07 mm (0.001-0.003 in.) 0.12 mm (0.005 in.) Oil pressure with oil temperature at 176°F (80°C) At idle 70 kPa (0.7 kgf/cm2 psi) At 3,000 rpm 340 kPa (3.5 kgf/cm2, 50 psi)
Engine Lubrication System (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - ENGINE LUBRICATION (K20Z3 ENGINE)Item Measurement Qualification Standard or New Service Limit Engine oil Capacity Engine overhaul 5.5 L (5.8 US qt) Oil change including filter 4.4 L (4.6 US qt) Oil change without filter 4.2 L (4.4 US qt) Oil pump Inner-to-outer rotor clearance 0.06-0.16 mm (0.002-0.006 in.) 0.20 mm (0.008 in.) Pump housing-to-outer rotor clearance 0.15-0.21 mm (0.006-0.008 in.) 0.23 mm (0.009 in.) Pump housing-to-outer rotor axial clearance 0.035-0.070 mm (0.0013-0.0028 in.) 0.12 mm (0.005 in.) Balancer shafts, journal diameter No. 1 journal, front shaft 19.938-19.950 mm (0.7850-0.7854 in.) 19.92 mm (0.784 in.) No. 1 journal, rear shaft 23.938-23.950 mm (0.9424-0.9429 in.) 23.92 mm (0.942 in.) No. 2 journal, front and rear shaft 32.949-32.961 mm (1.2972-1.2977 in.) 32.93 mm (1.296 in.) Balancer shafts, journal taper 0.005 mm (0.0002 in.) max. - Balancer shafts, end play Front 0.063-0.108 mm (0.0025-0.0043 in.) 0.14 mm (0.0055 in.) Rear 0.063-0.108 mm (0.0025-0.0043 in.) 0.14 mm (0.0055 in.) Balancer shafts, shaft-to-bearing clearance No. 1 journal, front shaft 0.050-0.082 mm (0.0020-0.0032 in.) 0.10 mm (0.004 in.) No. 1 journal, rear shaft 0.050-0.082 mm (0.0020-0.0032 in.) 0.10 mm (0.004 in.) No. 2 journal, front and rear shaft 0.060-0.120 mm (0.0024-0.0047 in.) 0.15 mm (0.006 in.) Balancer shaft bearings, I.D. No. 1 journal, front shaft 20.000-20.020 mm (0.7874-0.7882 in.) 20.03 mm (0.789 in.) No. 1 journal, rear shaft 24.000-24.020 mm (0.9449-0.9457 in.) 24.03 mm (0.946 in.) No. 2 journal, front and rear shaft 33.021-33.069 mm (1.3000-1.3019 in.) 33.09 mm (1.303 in.) Relief valve, oil pressure with oil temperature at 176 °F (80 °C) At idle 70 kPa (0.7 kgf/cm2, 10 psi) min. At 3,000 rpm 300 kPa (3.1 kgf/cm2, 44 psi) min.
Engine Cooling System (R18A1 engine)
STANDARDS AND SERVICE LIMITS - COOLING SYSTEM (R18A1 ENGINE)Item Measurement Qualification Standard or New Radiator Coolant capacity (includes engine, heater, hoses, and reservoir) Use Honda Long Life Antifreeze/Coolant Type 2 M/T: engine overhaul 6.5 L (1.72 US gal) A/T engine overhaul 6.7 L (1.77 US gal) M/T: coolant change 5.2 L (1.37 US gal) A/T coolant change 5.3 L (1.40 US gal) M/T: engine overhaul 6.5 L (1.72 US gal) A/T engine overhaul 7.1 L (1.88 US gal) M/T: coolant change 5.2 L (1.37 US gal) A/T: coolant change 5.5 L (1.45 US gal) Reservoir Coolant capacity 0.4 L (0.11 US gal) Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi) Thermostat Opening temperature Begins to open 176-183°F (80-84°C) Fully open 203°F (951) Valve lift at fully open 8.0 mm (0.31 in.) min.
Engine Cooling System (K20Z3 engine)
STANDARDS AND SERVICE LIMITS - COOLING SYSTEM (K20Z3 ENGINE)Item Measurement Qualification Standard or New Radiator Coolant capacities (including engine, heater, hoses, and reservoir) Use Honda Long Life Antifreeze/Coolant Type 2 Engine overhaul 6.8 L (1.80 US gal) Coolant change 4.5 L (1.19 US gal) Reservoir Coolant capacity 0.4 L (0.11 US gal) Radiator cap Opening pressure 93-123 kPa (0.95-1.25 kgf/cm2, 14-18 psi) Thermostat Opening temperature Begins to open 169-176°F (76-80°C) Fully open 194°F (90°C) Valve lift at fully open 8.0 mm (0.31 in.)
Fuel System and Emission System (R18A1)
STANDARDS AND SERVICE LIMITS - FUEL AND EMISSIONSItem Measurement Qualification Standard or New Fuel pressure regulator Pressure with fuel pressure gauge connected 380-430 kPa (3.9-4.4 kgf/cm2, 55-63 psi) Fuel tank Capacity 50 L (13.2 US gal) Engine idle (USA models) Idle speed without load A/T (in N or P position), M/T (in neutral) 670 50 rpm Idle speed with high electrical load (A/C switch ON, temperature set to max cool, blower fan on High, rear window defogger ON, and headlights on high beam) A/T (in N or P position), M/T (in neutral) 710 50 rpm Engine idle (Canada models) Idle speed without load A/T (in N or P position), M/T (in neutral) 750 50 rpm Idle speed with high electrical load (A/C switch ON, temperature set to max cool, blower fan on High, rear window defogger ON, and headlights on high beam) A/T (in N or P position), M/T (in neutral) 750 50 rpm
Fuel System and Emission System (K20Z3)
STANDARDS AND SERVICE LIMITS - FUEL AND EMISSIONSItem Measurement Qualification Standard or New Fuel pressure regulator Pressure with fuel pressure gauge connected K20Z3 engine 330-380 kPa (3.4-3.9 kgf/cm2, 48-55 psi) Fuel tank Capacity 50 L (13.2 US gal) Engine idle Idle speed without load In neutral 750 50 rpm Idle speed with high electrical load (A/C switch ON, temperature set to max cool, blower fan on High, rear window defogger ON, and headlights on high beam) In neutral 750 50 rpm
Clutch System
STANDARDS AND SERVICE LIMITS - CLUTCHItem Measurement Qualification Standard or New Service Limit Clutch pedal Height from the floor 157 mm (6.18 in.) - Stroke 130-140 mm (5.12-5.51 in.) - Play 10-18 mm (0.39-0.71 in.) - Disengagement height from the floor 77 mm (3.03 in.) min. - Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.) Clutch disc Rivet head depth 5M/T model 1.35-1.95 mm (0.053-0.077 in.) 0.2 mm (0.01 in.) 6M/T model 1.65-2.25 mm (0.065-0.089 in.) 0.7 mm (0.03 in.) Thickness 5M/T model 7.8-8.4 mm (0.30-0.33 in.) 6.0 mm (0.24 in.) 6M/T model 8.3-8.9 mm (0.33-0.35 in.) 6.0 mm (0.24 in.) Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.) Height if diaphragm spring fingers Measured with clutch alignment disc, clutch alignment shaft, remover handle, and feeler gauge 0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.)
Manual Transmission and M/T Differential (5-speed)
STANDARDS AND SERVICE LIMITS - MANUAL TRANSMISSION AND M/T DIFFERENTIAL (5-SPEED)Item Measurement Qualification Standard or New Service Limit Manual transmission fluid Capacity Use Honda MTF Fluid change 1.4 L (1.5 US qt) Overhaul 1.6 L (1.7 US qt) Mainshaft End play 0.11-0.18 mm (0.004-0.007 in.) Adjust Diameter of bushing contact area 18.800-18.850 mm (0.7402-0.7421 in.) 18.75 mm (0.738 in.) Diameter of distance collar contact area 28.992-29.005 mm (1.1414-1.1419 in.) 28.93 mm (1.139 in.) Diameter of ball bearing contact area (clutch housing side) 25.977-25.990 mm (1.0227-1.0232 in.) 25.92 mm (1.020 in.) Diameter of needle bearing contact area 34.984-35.000 mm (1.3773-1.3780 in.) 34.93 mm (1.375 in.) Diameter of ball bearing contact area (transmission housing side) 24.987-25.000 mm (0.9837-0.9843 in.) 24.93 mm (0.981 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) Mainshaft 3rd, 4th, and 5th gear I.D. 39.009-39.025 mm (1.5358-1.5364 in.) 38.95 mm (1.533 in.) End play 3rd 0.06-0.21 mm (0.002-0.008 in.) 0.30 mm (0.012 in.) 4th 0.06-0.19 mm (0.002-0.007 in.) 0.28 mm (0.011 in.) 5th 0.06-0.14 mm (0.002-0.006 in.) 0.23 mm (0.009 in.) Thickness 3rd 27.02-27.07 mm (1.064-1.066 in.) 26.95 mm (1.061 in.) 4th 25.52-25.57 mm (1.005-1.007 in.) 25.45 mm (1.002 in.) 5th 22.42-22.47 mm (0.883-0.885 in.) 22.35 mm (0.880 in.) Mainshaft 4th and 5th gear distance collar I.D. 29.014-29.024 mm (1.1423-1.1427 in.) 29.03 mm (1.423 in.) O.D. 34.989-35.000 mm (1.3775-1.3780 in.) 34.94 mm (1.376 in.) Length 
click to open the imageA 48.97-49.03 mm (1.9279-1.9303 in.) - B 22.53-22.56 mm (0.887-0.888 in.) - MBS distance collar I.D. 25.00-25.10 mm (0.984-0.988 in.) 28.02 mm (1.103 in.) Length 24.03-24.08 mm (0.946-0.948 in.) - Countershaft Diameter of needle bearing contact area (clutch housing side) 34.000-34.015 mm (1.3386-1.3392 in.) 33.95 mm (1.337 in.) Diameter of distance collar contact area 38.987-39.000 mm (1.5349-1.5354 in.) 38.94 mm (1.533 in.) Diameter of ball bearing contact area (transmission housing side) 26.020-26.033 mm (1.0244-1.0249 in.) 25.97 mm (1.022 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 35 mm shim-to-bearing inner race clearance 0.04-0.10 mm (0.0016-0.0039 in.) Adjust Countershaft 1st and 2nd gear I.D. 48.509-48.525 mm (1.9098-1.9104 in.) 48.58 mm (1.913 in.) End play 1st 0.06-0.21 mm (0.002-0.008 in.) 0.25 mm (0.010 in.) 2nd 0.06-0.14 mm (0.002-0.006 in.) 0.23 mm (0.009 in.) Thickness 1st 27.42-27.47 mm (1.080-1.081 in.) - 2nd 26.42-26.47 mm (1.040-1.042 in.) - Countershaft 1st and 2nd gear distance collar I.D. 39.00-39.01 mm (1.5354-1.5358 in.) 39.02 mm (1.536 in.) O.D. 44.489-44.5 mm (1.7515-1.7520 in.) 44.44 mm (1.750 in.) Length 1st 21.53-21.58 mm (0.843-0.849 in.) - 2nd 26.53-26.56 mm (1.044-1.046 in.) - Reverse idler gear I.D. 18.016-18.043 mm (0.7090-0.7104 in.) 18.08 mm (0.712 in.) Gear-to-reverse gear shaft clearance 0.032-0.077 mm (0.001-0.003 in.) 0.14 mm (0.006 in.) Synchro ring Ring-to-gear clearance Ring pushed against gear 0.655-1.334 mm (0.026-0.053 in.) 0.4 mm (0.016 in.) Shift fork Finger thickness 1-2 6.7-6.9 mm (0.26-0.27 in.) - 3-4,5 7.4-7.6 mm (0.29-0.30 in.) - Fork-to-synchro sleeve clearance 0.35-0.65 mm (0.014-0.026 in.) 1.0 mm (0.039 in.) Reverse shift fork Finger width 14.7-14.9 mm (0.579-0.587 in.) - Fork-to-reverse idler gear clearance 0.20-0.60 mm (0.007-0.024 in.) 1.2 mm (0.047 in.) Shift arm I.D. 14.013-14.058 mm (0.552-0.553 in.) - Shift arm-to-shift piece clearance 0.20-0.61 mm (0.008-0.024 in.) 0.7 mm (0.028 in.) Shift arm-to-shift lever clearance 0.013-0.085 mm (0.0005-0.0033 in.) - Select lever Finger width 14.85-14.95 mm (0.585-0.589 in.) - Change lever O.D. 13.941-13.968 mm (0.549-0.550 in.) - Interlock to select lever clearance 0.032-0.136 mm (0.001-0.005 in.) - Shift piece I.D. 14.000-14.068 mm (0.5512-0.5539 in.) - Shift piece groove width 16.00-16.20 mm (0.630-0.638 in.) - Shift piece finger width 15.9-16.0 mm (0.626-0.630 in.) - Shift piece-to-shift fork clearance 0.2-0.5 mm (0.008-0.020 in.) - M/T differential carrier Pinion shaft contact area I.D. 18.010-18.028 mm (0.7091-0.7098 in.) - Carrier-to-pinion shaft clearance 0.027-0.057 mm (0.0011-0.0022 in.) 0.1 mm (0.004 in.) Driveshaft contact area I.D. 28.025-28.045 mm (1.1033-1.1041 in.) - M/T differential pinion gear Backlash 0.05-0.15 mm (0.002-0.006 in.) - I.D. 18.042-18.066 mm (0.7103-0.7113 in.) - Pinion gear-to-pinion shaft clearance 0.059-0.095 mm (0.0023-0.0037 in.) 0.15 mm (0.006 in.) 80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing 0-0.10 mm (0-0.0039 in.) Adjust
Manual Transmission and M/T Differential (6-speed)
STANDARDS AND SERVICE LIMITS - MANUAL TRANSMISSION AND M/T DIFFERENTIAL (6-SPEED)Item Measurement Qualification Standard or New Service Limit Manual transmission fluid Capacity Use Honda MTF Fluid change 1.5 L (1.6 US qt) Overhaul 1.7 L (1.8 US qt) Mainshaft End play 0.11-0.17 mm (0.004-0.007 in.) Adjust Diameter of bushing contact area 20.80-20.85 mm (0.819-0.821 in.) 20.75 mm (0.817 in.) Diameter of distance collar contact area 31.984-32.000 mm (1.2594-1.2598 in.) 31.93 mm (1.257 in.) Diameter of ball bearing contact area (clutch housing side) 27.977-27.990 mm (1.1015-1.1020 in.) 27.92 mm (1.099 in.) Diameter of needle bearing contact area 38.984-39.000 mm (1.5348-1.5354 in.) 38.93 mm (1.533 in.) Diameter of ball bearing contact area (transmission housing side) 27.987-28.000 mm (1.1019-1.1024 in.) 27.93 mm (1.100 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) Mainshaft 3rd, 4th, and 5th gear I.D. 44.009-44.025 mm (1.7326-1.7333 in.) 44.08 mm (1.735 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 23.92-23.97 mm (0.941-0.944 in.) 23.80 mm (0.937 in.) Mainshaft 6th gear I.D. 40.009-40.025 mm (1.5752-1.5758 in.) 40.08 mm (1.578 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 23.92-23.97 mm (0.941-0.944 in.) 23.80 mm (0.937 in.) Mainshaft 4th and 5th gear distance collar I.D. 32.00-32.01 mm (1.2598-1.2602 in.) 32.02 mm (1.261 in.) O.D. 38.989-39.000 mm (1.5350-1.5354 in.) 38.94 mm (1.533 in.) Length click to open the imageA 51.95-52.05 mm (2.045-2.049 in.) - B 24.03-24.08 mm (0.946-0.948 in.) - Mainshaft 6th gear distance collar I.D. 28.00-28.01 mm (1.102-1.103 in.) 28.02 mm (1.103 in.) O.D. 34.989-35.000 mm (1.3775-1.3779 in.) 34.940 mm (1.3756 in.) Length 24.03-24.08 mm (0.946-0.948 in.) - Countershaft Diameter of needle bearing contact area (clutch housing side) 35.000-35.015 mm (1.3780-1.3785 in.) 34.95 mm (1.3760 in.) Diameter of distance collar contact area 39.937-39.950 mm (1.5723-1.5728 in.) 39.883 mm (1.5702 in.) Diameter of ball bearing contact area (transmission housing side) 30.020-30.033 mm (1.1819-1.1824 in.) 29.97 mm (1.180 in.) Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.) 35 mm shim-to-bearing inner race clearance 0.04-0.10 mm (0.0016-0.0039 in.) Adjust Countershaft 1st and 2nd gear I.D. 52.010-52.029 mm (2.0476-2.0484 in.) 52.08 mm (2.050 in.) End play 0.06-0.16 mm (0.002-0.006 in.) 0.25 mm (0.010 in.) Thickness 1st 22.92-22.97 mm (0.902-0.904 in.) 22.87 mm (0.900 in.) 2nd 27.92-27.97 mm (1.099-1.101 in.) 27.87 mm (1.097 in.) Countershaft 1st and 2nd gear distance collar I.D. 39.95-39.96 mm (1.5728-1.5732 in.) 39.97 mm (1.574 in.) O.D. 46.989-47.000 mm (1.8499-1.8504 in.) 46.94 mm (1.848 in.) Length 1st 23.03-23.08 mm (0.907-0.909 in.) - 1st 28.03-28.08 mm (1.104-1.106 in.) - Reverse idler gear I.D. 20.016-20.043 mm (0.7880-0.7891 in.) 20.90 mm (0.832 in.) Gear-to-reverse gear shaft clearance 0.036-0.084 mm (0.0014-0.0033 in.) 0.16 mm (0.006 in.) Synchro ring Ring-to-gear clearance Ring pushed against gear 0.70-1.49 mm (0.028-0.059 in.) 0.4 mm (0.016 in.) Double cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) Outer synchro ring-to-gear clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) Triple cone synchro Outer synchro ring-to-synchro cone clearance Ring pushed against gear 0.70-1.19 mm (0.028-0.047 in.) 0.3 mm (0.012 in.) Synchro cone-to-gear clearance Ring pushed against gear 0.50-1.04 mm (0.020-0.041 in.) 0.3 mm (0.012 in.) Outer synchro ring-to-gear clearance Ring pushed against gear 0.95-1.68 mm (0.037-0.066 in.) 0.6 mm (0.024 in.) Shift fork Finger thickness 7.4-7.6 mm (0.29-0.30 in.) - Fork-to-synchro sleeve clearance 0.35-0.65 mm (0.014-0.026 in.) 1.0 mm (0.039 in.) Reverse shift fork Finger width 13.4-13.7 mm (0.527-0.539 in.) - Fork-to-reverse idler gear clearance 0.20-0.59 mm (0.007-0.024 in.) 1.3 mm (0.051 in.) Shift arm I.D. 13.973-14.000 mm (0.5501-0.5512 in.) - Finger width 16.9-17.0 mm (0.665-0.669 in.) - Shift arm-to-shift fork clearance 0.2-0.5 mm (0.007-0.020 in.) 0.62 mm (0.024 in.) Select lever Finger width 14.85-14.95 mm (0.585-0.589 in.) - Change lever Shaft-to-select lever clearance 0.05-0.25 mm (0.002-0.010 in.) 0.50 mm (0.020 in.) Groove width 15.00-15.10 mm (0.591-0.594 in.) - Shaft-to-shift arm clearance 0.013-0.070 mm (0.0005-0.0028 in.) 0.1 mm (0.004 in.) M/T differential carrier Pinion shaft contact area I.D. 18.010-18.028 mm (0.7091-0.7098 in.) - Carrier-to-pinion shaft clearance 0.027-0.057 mm (0.0011-0.0022 in.) 0.1 mm (0.004 in.) Driveshaft contact area I.D. 28.025-28.045 mm (1.1033-1.1041 in.) - M/T differential pinion gear Backlash 0.05-0.15 mm (0.002-0.006 in.) - I.D. 18.042-18.066 mm (0.7103-0.7113 in.) - Pinion gear-to-pinion shaft clearance 0.059-0.095 mm (0.0023-0.0037 in.) 0.15 mm (0.006 in.) 80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing 0-0.10 mm (0-0.004 in.) Adjust
Automatic Transmission and A/T Differential
STANDARDS AND SERVICE LIMITS - AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL (1 OF 3)Item Measurement Qualification Standard or New Service Limit Automatic transmission fluid Capacity Use Honda ATF-Z1 Fluid change 2.4 L (2.5 US qt) Overhaul 5.9 L (6.2 US qt) ATF pressure Line pressure At 2,000 rpm in P or N position 900-960 kPa (9.2-9.8 kgf/cm2, 130-140 psi) 850 kPa (8.7 kgf/cm2, 120 psi) 1st clutch pressure At 2,000 rpm in 1 position 890-970 kPa (9.1-9.9 kgf/cm2, 130-140 psi) 840 kPa (8.6 kgf/cm2, 120 psi) 2nd clutch pressure At 2,000 rpm in 2 position 890-970 kPa (9.1-9.9 kgf/cm2, 130-140 psi) 840 kPa (8.6 kgf/cm2, 120 psi) 3rd clutch pressure At 2,000 rpm in 3rd gear in D3 position 890-970 kPa (9.1-9.9 kgf/cm2, 130-140 psi) 840 kPa (8.6 kgf/cm2, 120 psi) 4th clutch pressure At 2,000 rpm in 4th gear in D position 890-970 kPa (9.1-9.9 kgf/cm2, 130-140 psi) 840 kPa (8.6 kgf/cm2, 120 psi) 5th clutch pressure At 2,000 rpm in 5th gear in D position 890-970 kPa (9.1-9.9 kgf/cm2, 130-140 psi) 840 kPa (8.6 kgf/cm2, 120 psi) Torque converter Stall speed Check with vehicle on level ground 2,670 rpm 2,520-2,820 rpm Clutch Clutch end-plate-to-top disc clearance 1st 1.62-1.82 mm (0.064-0.072 in.) - 2nd and 4th 0.7-0.9 mm (0.028-0.035 in.) - 3rd and 5th 0.93-1.13 mm (0.037-0.044 in.) - Clutch return spring free length 1st 36.0 mm (1.42 in.) 34.5 mm (1.36 in.) 2nd and 4th 39.4 mm (1.55 in.) 37.4 mm (1.47 in.) 3rd and 5th 45.15 mm (1.778 in.) 43.0 mm (1.69 in.) Clutch disc thickness 1st, 3rd, and 5th 1.94 mm (0.076 in.) - 2nd and 4th 1.96 mm (0.077 in.) - Clutch plate thickness 1st, 3rd, 4th, and 5th 1.6 mm (0.063 in.) When discolored 2nd 2.0 mm (0.079 in.) When discolored Clutch waved-plate height 1st, 3rd, and 5th clutches 0.07-0.20 mm (0.003-0.008 in.) 0.05 mm (0.002 in.) 1st, 3rd, and 5th clutch end-plate thickness Markl 2.1 mm (0.082 in.) When discolored Mark 2 2.2 mm (0.086 in.) When discolored Mark 3 2.3 mm (0.090 in.) When discolored Mark 4 2.4 mm (0.094 in.) When discolored Mark 5 2.5 mm (0.098 in.) When discolored Mark 6 2.6 mm (0.102 in.) When discolored Mark 7 2.7 mm (0.106 in.) When discolored Mark 8 2.8 mm (0.110 in.) When discolored Mark 9 2.9 mm (0.114 in.) When discolored 2nd and 4th clutch end-plate thickness Mark AC or AM 2.1 mm (0.082 in.) When discolored Mark AD or AN 2.2 mm (0.086 in.) When discolored Mark AE or AP 2.3 mm (0.090 in.) When discolored Mark AF or AQ 2.4 mm (0.094 in.) When discolored Mark AG or AR 2.5 mm (0.098 in.) When discolored Mark AH or AS 2.6 mm (0.102 in.) When discolored Mark AJ or AT 2.7 mm (0.106 in.) When discolored Mark AK or AU 2.8 mm (0.110 in.) When discolored Mark AL or AV 2.9 mm (0.114 in.) When discolored ATF pump ATF pump thrust clearance 0.03-0.06 mm (0.001-0.002 in.) 0.07 mm (0.003 in.) ATF pump gear-to-body clearance Drive gear 0.210-0.265 mm (0.008-0.010 in.) - Driven gear 0.070-0.125 mm (0.003-0.005 in.) - ATF pump driven gear I.D. 14.016-14.034 mm (0.5518-0.5525 in.) When worn or damaged ATF pump driven gear shaft O.D. 13.980-13.990 mm (0.5504-0.5508 in.) When worn or damaged Stator shaft Needle bearing contact I.D. Torque converter side 27.000-27.021 mm (1.063-1.064 in.) When worn or damaged ATF pump side 29.000-29.021 mm (1.1417-1.1426 in.) - Sealing ring contact area I.D. 29.000-29.021 mm (1.1417-1.1426 in.) 29.05 mm (1.144 in.) Reverse shift fork Fork finger thickness 5.90-6.00 mm (0.232-0.236 in.) 5.40 mm (0.213 in.) Park gear and pawl - When worn or damaged Servo body Shift fork shaft bore I.D. 14.000-14.010 mm (0.5512-0.5526 in.) When worn or damaged Shift fork shaft valve bore I.D. 37.000-37.039 mm (1.4567-1.4582 in.) 37.045 mm (1.4585 in.) Regulator valve body Sealing ring contact I.D. 29.000-29.021 mm (1.1417-1.1426 in.) 29.05 mm (1.144 in.) Mainshaft Diameter of needle bearing contact area At stator shaft 22.984-23.000 mm (0.905-0.906 in.) When worn or damaged At 5th gear collar 32.975-32.991 mm (1.298-1.300 in.) When worn or damaged At 3rd gear 46.983-46.999 mm (1.8497-1.8503 in.) When worn or damaged I.D. of gears 5th gear 37.000-37.016 mm (1.456-1.457 in.) When worn or damaged 3rd gear 52.000-52.019 mm (2.047-2.048 in.) When worn or damaged End play 5th gear 015-0.27 mm (0.006-0.106 in.) - 3rd gear 0.04-0.10 mm (0.002-0.004 in.) - 40 x 63 mm thrust washer thickness No. 1 3.750 mm (0.1476 in.) When worn or damaged No. 2 3.775 mm (0.1486 in.) When worn or damaged No. 3 3.800 mm (0.1496 in.) When worn or damaged No. 4 3.825 mm (0.1506 in.) When worn or damaged No. 5 3.850 mm (0.1516 in.) When worn or damaged No. 6 3.875 mm (0.1526 in.) When worn or damaged No. 7 3.900 mm (0.1535 in.) When worn or damaged No. 8 3.925 mm (0.1545 in.) When worn or damaged No. 9 3.950 mm (0.1555 in.) When worn or damaged No. 10 3.975 mm (0.1565 in.) When worn or damaged No. 11 4.000 mm (0.1575 in.) When worn or damaged 5th gear collar length 60.4-60.5 mm (2.380-2.381 in.) - 5th gear collar flange thickness 3.70-3.85 mm (0.146-0.152 in.) When worn or damaged Sealing ring thickness 1.91-1.97 mm (0.0752-0.0776 in.) 1.86 mm (0.0732 in.) Width of sealing ring groove 2.025-2.060 mm (0.0797-0.0811 in.) 2.080 mm (0.0819 in.) 3rd clutch feed pipe O.D. 7.97-7.98 mm (0.3138-0.3142 in.) 7.95 mm (0.313 in.) Feed pipe bushing I.D. 8.000-8.015 mm (0.3150-0.3156 in.) 8.030 mm (0.3161 in.) Countershaft Diameter of needle bearing contact area At torque converter housing 33.504-33.517 mm (1.3191-1.3196 in.) When worn or damaged At 5th gear 32.986-32.999 mm (1.287-1.299 in.) When worn or damaged Reverse selector hub 35.983-35.999 mm (1.4167-1.4173 in.) When worn or damaged I.D. of gears 5th gear 39.000-39.016 mm (1.535-1.536 in.) When worn or damaged Reverse gear 42.000-42.016 mm (1.6535-1.6542 in.) When worn or damaged End play 5th gear 0.64-0.87 mm (0.025-0.034 in.) - Reverse gear 0.10-0.25 mm (0.0039-0.0098 in.) - Reverse selector hub width 29.25-29.45 mm (1.1516-1.1595 in.) - Collar, 33.2 x 40 x 26 mm length 25.95-26.00 mm (1.022-1.024 in.) - Reverse selector hub O.D. 55.87-55.90 mm (2.200-2.201 in.) When worn or damaged Secondary shaft Diameter of needle bearing contact area 1st gear 30.986-30.999 mm (1.2199-1.2204 in.) When worn or damaged 2nd gear 42.986-42.999 mm (1.6924-1.6929 in.) When worn or damaged 4th gear collar 34.975-34.991 mm (1.3770-1.3776 in.) When worn or damaged I.D. of gears 1st gear 38.000-38.016 mm (1.4961-1.4967 in.) When worn or damaged 2nd gear 49.000-49.016 mm (1.9291-1.9298 in.) When worn or damaged 4th gear 41.000-41.016 mm (1.6142-1.6148 in.) When worn or damaged End play 1st gear 0.04-0.12 mm (0.002-0.005 in.) - 2nd gear 0.04-0.12 mm (0.002-0.005 in.) - 4th gear 0.10-0.22 mm (0.004-0.009 in.) - 31 x 54 mm thrust washer thickness No. 1 3.925 mm (0.1545 in.) When worn or damaged No. 2 3.950 mm (0.1555 in.) When worn or damaged No. 3 3.975 mm (0.1565 in.) When worn or damaged No. 4 4.000 mm (0.1575 in.) When worn or damaged No. 5 4.025 mm (0.1585 in.) When worn or damaged No. 6 4.050 mm (0.1594 in.) When worn or damaged No. 7 4.075 mm (0.1604 in.) When worn or damaged No. 8 4.100 mm (0.1614 in.) When worn or damaged No. 9 4.125 mm (0.1624 in.) When worn or damaged No. 10 4.150 mm (0.1634 in.) When worn or damaged No. 11 4.175 mm (0.1644 in.) When worn or damaged No. 12 4.200 mm (0.1654 in.) When worn or damaged No. 13 4.225 mm (0.1663 in.) When worn or damaged No. 14 4.250 mm (0.1673 in.) When worn or damaged No. 15 4.275 mm (0.1683 in.) When worn or damaged No. 16 4.300 mm (0.1693 in.) When worn or damaged No. 17 4.325 mm (0.1703 in.) When worn or damaged 43 x 54.5 mm thrust washer thickness No. 1 2.900 mm (0.114 in.) When worn or damaged No. 2 2.925 mm (0.115 in.)u When worn or damaged No. 3 2.950 mm (0.116 in.) When worn or damaged No. 4 2.975 mm (0.117 in.) When worn or damaged No. 5 3.000 mm (0.118 in.) When worn or damaged No. 6 3.025 mm (0.119 in.) When worn or damaged No. 7 3.050 mm (0.120 in.) When worn or damaged No. 8 3.075 mm (0.121 in.) When worn or damaged No. 9 3.100 mm (0.122 in.) When worn or damaged No. 10 3.125 mm (0.123 in.) When worn or damaged No. 11 3.150 mm (0.124 in.) When worn or damaged No. 12 3.175 mm (0.125 in.) When worn or damaged No. 13 3.200 mm (0.126 in.) When worn or damaged 4th gear collar length 32.9-33.0 mm (1.295-1.299 in.) - 4th gear collar flange thickness 3.75-3.90 mm (0.148-0.154 in.) When worn or damaged Sealing ring thickness 1.87-1.97 mm (0.074-0.078 in.) 1.82 mm (0.072 in.) Width of sealing ring groove 2.025-2.060 mm (0.0797-0.0811 in.) 2.080 mm (0.0819 in.) Clutch feed pipe O.D. 2nd clutch 6.97-6.98 mm (0.2744-0.2748 in.) 6.95 mm (0.2736 in.) 4th clutch 11.47-11.48 mm (0.4516-0.4520 in.) 11.45 mm (0.4508 in.) Clutch feed pipe bushing O.D. 2nd clutch 7.018-7.030 mm (0.2763-0.2768 in.) 7.045 mm (0.2774 in.) 4th clutch 11.500-11.518 mm (0.4528-0.4553 in.) 11.530 mm (0.4539 in.) ATF guide collar I.D. at sealing ring contact area 21.200-21.221 mm (0.8346-0.8355 in.) 21.25 mm (0.8366 in.) Idler gear shaft End cover bearing contact area 30.003-30.013 mm (1.1812-1.1816 in.) When worn or damaged Cotters thickness 1.39-1.42 mm (0.0547-0.0559 in.) - Reverse idler gear Reverse idler gear shaft O.D. at needle bearing contact area 14.99-15.00 mm (0.5902-0.5906 in.) When worn or damaged I.D. 20.001-20.014 mm (0.7874-0.7880 in.) When worn or damaged I.D. of reverse idler gear shaft contact area on transmission housing 14.800-14.818 mm (0.5827-0.5834 in.) - I.D. of reverse idler gear shaft holder 14.800-14.824 mm (0.5827-0.5836 in.) When worn or damaged
STANDARDS AND SERVICE LIMITS - AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL (2 OF 3)Item Measurement Qualification Standard or New Wire Diameter O.D. Free Length No. of Coil Main valve body spring (see MAIN VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY) Cut valve B spring 0.8 mm (0.031 in.) 9.9 mm (0.290 in.) 27.3 mm (1.074 in.) 8.0 Shift valve A spring 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7 Shift valve C spring 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7 Relief valve spring 1.0 mm (0.039 in.) 9.6 mm (0.378 in.) 34.1 mm (1.343 in.) 10.2 Lock-up control valve spring 0.6 mm (0.024 in.) 7.1 mm (0.280 in.) 31.2 mm (1.228 in.) 11.2 Cooler check valve spring 0.85 mm (0.033 in.) 6.6 mm (0.260 in.) 27.0 mm (1.063 in.) 11.3 Shift valve D spring 0.8 mm (0.031 in.) 5.6 mm (0.220 in.) 28.1 mm (1.106 in.) 15.9 Servo control valve spring 0.8 mm (0.031 in.) 9.9 mm (0.290 in.) 27.3 mm (1.075 in.) 8.0 Regulator valve body spring (see REGULATOR VALVE BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY) Stator reaction spring 4.5 mm (0.177 in.) 35.4 mm (1.394 in.) 30.3 mm (1.193 in.) 1.92 Regulator valve spring A 1.9 mm (0.075 in.) 14.7 mm (0.579 in.) 80.6 mm (3.173 in.) 16.1 Regulator valve spring B 1.6 mm (0.063 in.) 9.2 mm (0.362 in.) 44.0 mm (1.732 in.) 12.5 Torque converter check valve spring 1.2 mm (0.047 in.) 8.6 mm (0.339 in.) 33.8 mm (1.331 in.) 12.2 Lock-up shift valve spring 1.0 mm (0.039 in.) 6.6 mm (0.260 in.) 35.5 mm (1.398 in.) 18.2 1st accumulator spring B 2.4 mm (0.094 in.) 12.2 mm (0.480 in.) 35.0 mm (1.378 in.) 7.7 1st accumulator spring A 2.4 mm (0.094 in.) 18.6 mm (0.732 in.) 50.1 mm (1.972 in.) 6.7 4th accumulator spring 2.5 mm (0.098 in.) 14.6 mm (0.575 in.) 29.9 mm (1.177 in.) 4.9 Servo body spring (see SERVO BODY DISASSEMBLY, INSPECTION, AND REASSEMBLY) Cut valve A spring 0.9 mm (0.035 in.) 9.9 mm (0.390 in.) 22.3 mm (0.878 in.) 6.9 Shift valve B spring 0.8 mm (0.031 in.) 7.1 mm (0.280 in.) 23.7 mm (0.933 in.) 9.7 5th accumulator spring A 2.5 mm (0.098 in.) 16.6 mm (0.654 in.) 46.9 mm (1.846 in.) 7.8 5th accumulator spring B 1.9 mm (0.075 in.) 10.0 mm (0.394 in.) 38.5 mm (1.516 in.) 10.6 2nd accumulator spring A 1.8 mm (0.071 in.) 14.6 mm (0.575 in.) 43.8 mm (1.724 in.) 7.9 2nd accumulator spring B 1.85 mm (0.073 in.) 9.4 mm (0.370 in.) 32.5 mm (1.280 in.) 8.7 3rd accumulator spring A 1.8 mm (0.071 in.) 14.6 mm (0.575 in.) 43.8 mm (1.724 in.) 7.9 3rd accumulator spring B 1.85 mm (0.073 in.) 9.4 mm (0.370 in.) 32.5 mm (1.280 in.) 8.7
STANDARDS AND SERVICE LIMITS - AUTOMATIC TRANSMISSION AND A/T DIFFERENTIAL (3 OF 3)Item Measurement Qualification Standard or New Service Limit A/T differential carrier Pinion shaft contact area I.D. 18.010-18.028 mm (0.709-0.710 in.) - Carrier-to-pinion shaft clearance 0.027-0.057 mm (0.001-0.002 in.) 0.1 mm (0.004 in.) Driveshaft contact area I.D. 26.025-26.045 mm (1.024-1.025 in.) - Carrier-to-driveshaft clearance 0.045-0.086 mm (0.002-0.003 in.) 0.12 mm (0.005 in.) Final driven gear backlash (References) 0.085-0.142 mm (0.003-0.006 in.) 0.2 mm (0.008 in.) A/T differential pinion gear Backlash 0.05-0.15 mm (0.002-0.006 in.) - I.D. 18.042-18.066 mm (0.7103-0.7113 in.) - Pinion gear-to-pinion shaft clearance 0.059-0.095 mm (0.002-0.004 in.) 0.12 mm (0.005 in.)
Steering (Electronic Power Steering System)
STANDARDS AND SERVICE LIMITS - STEERING (EPS)Item Measurement Qualification Standard or New Steering wheel Rotational play measured at outside edge with engine running 0-10 mm (0-0.39 in.) Starting load measured at outside edge with engine running 34 N (3.5 kgf, 7.7 lbf) Gearbox Angle of rack guide screw loosened from locked position 7 ° ± 3°
Steering (Hydraulic Power Steering System)
STANDARDS AND SERVICE LIMITS - STEERING (POWER STEERING)Item Measurement Qualification Standard or New Steering wheel Rotational play measured at outside edge with engine running 0-10 mm (0-0.39 in.) Starting load measured at outside edge with engine running 34 N (3.5 kgf, 7.7 lbf) Gearbox Angle of rack guide screw loosened from locked position 15° ± 5° Pump Output pressure with shut-off valve closed 7,850-8,550 kPa (80-87 kgf/cm2, 1,140-1,240 psi) Power steering fluid Capacity
Use Honda Power Steering FluidFluid change 0.26 L (0.27 US qt, 0.22 lmp qt) System overhaul 0.8 L (0.85 US qt, 0.70 lmp)
Suspension System
STANDARDS AND SERVICE LIMITS - SUSPENSIONItem Measurement Qualification Standard or New Service Limit Wheel alignment Camber Front 0°00' ± 30' Rear (without "C" marks on the rear upper arm) -1° 30'+1° 05' -0° 45' Rear (with "C" marks on the rear upper arm) -0° 45'+1° 05' -0° 45' Caster Front 7°00'±1° Total toe-in Front 0±2 mm (0±0.08 in.) Rear 2+2-1mm (0.08+0.08 -0.04 in.) Front wheel turning angle (DX, DX-G) Inward 40°06' ± 2° Outward 31 °55' (Reference) Front wheel turning angle (Except DX, DX-G) Inward 38° 46' ±2° Outward 31 ° 14' (Reference) Wheel Steel wheel runout Axial 0-1.0 mm (0-0.04 in.) 2.0 mm (0.08 in.) Radial 0-1.0 mm (0-0.04 in.) 1.5 mm (0.06 in.) Aluminum wheel runout Axial 0-0.7 mm (0-0.03 in.) 2.0 mm (0.08 in.) Radial 0-0.7 mm (0-0.03 in.) 1.5 mm (0.06 in.) Wheel bearing End play Front 0-0.05 mm (0-0.002 in.) Rear 0-0.05 mm (0-0.002 in.)
Brake System
STANDARDS AND SERVICE LIMITS - BRAKESItem Measurement Qualification Standard or New Service Limit Parking brake Distance traveled when lever pulled with 196 N (20 kgf, 44 lbf) of force 8 to 10 clicks Brake pedal Pedal height (carpet removed) M/T model 153 mm (6 in.) A/T model 158 mm (6 1/4 in.) Free play 1-5 mm (1/16-3/16 in.) Brake disc Thickness Front (except Si) 20.9-21.1 mm (0.82-0.83 in.) 19.0 mm (0.75 in.) Front (Si) 24.9-25.1 mm (0.98-0.99 in.) 23.0 mm (0.91 in.) Rear 8.9-9.1 mm (0.35-0.36 in.) 8.0 mm (0.31 in.) Runout - 0.04 mm (0.0016 in.) Parallelism - 0.015 mm (0.0006 in.) Brake pad Pad thickness Front (except Si) 9.6-10.2 mm (0.38-0.40 in.) 1.6 mm (0.06 in.) Front (Si) 9.0-9.7 mm (0.35-0.38 in.) 1.6 mm (0.06 in.) Rear 8.3-9.4 mm (0.33-0.37 in.) 1.6 mm (0.06 in.) Rear brake (drum brake) Brake drum I.D. 199.9-200 mm (7.870-7.874 in.) 201 mm (7.91 in.) Brake shoe lining thickness 4.0 mm (0.16 in.) 2.0 mm (0.08 in.)
Air Conditioning System
STANDARDS AND SERVICE LIMITS - AIR CONDITIONINGItem Measurement Qualification Standard or New Refrigerant Type HFC-134a(R-134a) Capacity of system 400-450 g (14.1-15.8 oz) Refrigerant oil Type SP-10
(P/N 38897-P13-A01 or 38899-P13-A01)Capacity of components Condenser 50 mL (1 2/3 fl.oz, 1.8 lmp oz) Evaporator 40 mL (1 1/3 fl.oz, 1.4 lmp oz) Each Line and hose 10 mL (1/3 fl.oz, 0.4 lmp oz) Compressor 75-85 mL (2 1/2-2 5/6 fl.oz, 2.6-3.0 lmp oz) Compressor Field coil resistance At 68 °F (20 °C) 3.15-3.45 ohms Pulley-to-pressure plate clearance 0.35-0.65 mm (0.014-0.026 in.)
Design Specifications
STANDARDS AND SERVICE LIMITS - DESIGN SPECIFICATIONSItem Measurement Qualification Specification DIMENSIONS: 4-door Overall length 4,489 mm (176.7 in.) Overall width 1,752 mm (69.0 in.) Overall height 1,435 mm (56.5 in.) Wheelbase 2,700 mm (106.3 in.) Track Front 1,499 mm (59.0 in.) Rear 1,528 mm (60.2 in.) Ground clearance 154 mm (6.1 in.) Seating capacity Five (5) DIMENSIONS: 2-door Overall length 4,440 mm (174.8 in.) Overall width 1,751 mm (68.9 in.) Overall height 1,359 mm (53.5 in.) Wheelbase 2,650 mm (104.3 in.) Track Front 1,499 mm (59.0 in.) Rear 1,526 mm (60.1 in.) Ground clearance 154 mm (6.1 in.) Seating capacity Five (5) WEIGHT Gross Vehicle Weight Rating: 4-door (GVWR) DX, DX-G, and LX 1,665 kg (3,671 lbs) EX 1,695 kg (3,737 lbs) Si See Gross Vehicle Weight Rating: 2-door (GVWR) DX, DX-G, and LX 1,645 kg (3,627 lbs) EX 1,665 kg (3,671 lbs) Si 1,725 kg (3,803 lbs) R18A1 engine Type Water cooled, 4-stroke SOHC i-VTEC gasoline engine Cylinder arrangement Inline 4-cylinder, transverse Bore and stroke 81.0 x 87.3 mm (3.19 x 3.44 in.) Displacement 1,799 cm3 (110 cu in.) Compression ratio 10.5 Valve train Chain drive, SOHC i-VTEC 4 valves per cylinder Lubrication system Forced, wet sump, with trochoid pump Oil pump displacement At 6,800 rpm 52.3 L (55.3 US qt, 46.0 lmp qt)/minute Water pump displacement At 6,000 rpm 104 L (110 US qt, 110 lmp qt)/minute Fuel required Regular UNLEADED gasoline with 87 Pump Octane Number or higher K20Z3 engine Type Water cooled, 4-stroke DOHC i-VTEC gasoline engine Cylinder arrangement Inline 4-cylinder, transverse Bore and stroke 86 x 86 mm (3.39 x 3.39 in.) Displacement 1,998 cm3 (122 cu in.) Compression ratio 11.0 Valve train Chain drive, DOHC i-VTEC 4 valves per cylinder Lubrication system Forced, wet sump, with trochoid pump Oil pump displacement At 6,000 rpm 54.3 L (57.4 US qt, 47.8 lmp qt)/minute Water pump displacement At 6,000 rpm 82 L (87 US qt, 72 lmp qt)/minute Fuel required Premium UNLEADED gasoline with 91 Pump Octane Number or higher STARTER Type Gear Reduction Nominal output 1.0 kW Nominal voltage 12 V Hour rating 30 seconds Direction of rotation Counterclockwise as viewed from drive end CLUTCH Clutch Single plate dry, diaphragm spring Clutch friction material surface area R18A1 engine model 221 cm2 (34.22 sq in.) K20Z3 engine model 174 cm2 (28.99 sq in.) MANUAL TRANSMISSION (5-speed) Type Synchronized, 5-speed forward, 1 reverse Primary reduction Direct 1:1 Gear ratio 1st 3.142 2nd 1.750 3rd 1.241 4th 0.969 5th 0.805 Reverse 3.230 Final reduction Type Single helical gear Gear ratio 4.111 MANUAL TRANSMISSION (6-speed) Type Synchronized, 6-speed forward, 1 reverse Primary reduction Direct 1:1 Gear ratio 1st 3.267 2nd 2.130 3rd 1.517 4th 1.147 5th 0.921 6th 0.659 Reverse 3.583 Final reduction Type Single helical gear Gear ratio 4.765 AUTOMATIC TRANSMISSION Type Electronically controlled automatic, 5-speed forward, 1 reverse, 3-element torque converter with lock-up clutch Primary reduction Direct 1:1 Gear ratio 1st 2.666 2nd 1.534 3rd 1.021 4th 0.720 5th 0.524 Reverse 1.956 Final reduction Type Single helical gear Gear ratio 4.437 STEERING (EPS) Type Rack and pinion with electrical power-assisted Overall ratio 13.62 Turns, lock-to-lock 2.65 Steering wheel diameter 360 mm (14.0 in.) STEERING (Power Steering) Type Hydraulic power assisted rack and pinion Overall ratio 13.73 Turns, lock-to-lock 2.67 Steering wheel diameter 360 mm (14.0 in.) SUSPENSION Type Front Independent strut with stabilizer, coil spring Rear Independent double wishbone with stabilizer, coil spring Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled TIRES Size of front and rear DX, DX-G P195/65+R 15 89H EX, LX P205/55R16 89H Si P215/45R17 89V or 215/45ZR17 91W Size of spare Except Si T125/70D15 95M Si (ABS model) T125/70D16 96M Si (VSA model) T135/80D16 101M WHEEL ALIGNMENT Camber Front 0° 00' Rear (without "C" marks on the rear upper arm) -1° 30' Rear (with "C" marks on the rear upper arm) -0° 45' Caster Front 7° 00' Total toe-in Front 0 mm (0 in.) Rear 2 mm (0.08 in.) Front wheel turning angle (DX, DX-G) Inward 40° 06' Outward (reference) 31° 55' Front wheel turning angle (except DX, DX-G) Inward 38° 46' Outward (reference) 31° 14' BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc Rear (disc) Power-assisted self-adjusting solid disc Rear (drum) Power-assisted self-adjusting solid drum Type of parking brake Mechanical actuating, rear wheels Pad friction surface area Front (except Si) 37.5 cm2 (5.81 sq in.) x 2 Front (Si) 33.8 cm2 (5.24 sq in.) x 2 Rear 20.6 cm2 (3.19 sq in.) x 2 Shoe friction surface area Rear 57.6 cm2 (8.93 sq in.) x 2 AIR CONDITIONING Compressor Type Scroll Capacity 77.1 mL (4.7 cu in.)/rev. Maximum speed 10,000 rpm Lubricant capacity 75 mL (2 1/2 fl-oz) Lubricant type SP-10 Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type Stabilized swirling flow Motor type 220 W/12V Speed control Infinite variable Maximum capacity 470 m3 (16.571 cu ft)/h Temperature control Air-mix type Compressor clutch Type Dry, single plate, poly V-belt drive Electrical power consumption at 68 °F (20 ° F) 42 W maximum at 12 V Refrigerant Type HFC-134a (R-134a) Capacity 400-450 g (14.1-15.8 oz) ELECTRICAL RATINGS Battery R18A1 engine, USA models 12V-45 Ah/20 HR (12 V-36 Ah/5 HR) K20Z3 engine, Canada models 12 V-47 Ah/20 HR (12 V-38 Ah/5HR) Fuses Under-hood fuse/relay box 100 A, 80 A,70 A, 50 A, 40 A, 30 A, 20 A, 15 A, 10A, 7.5 A Under-dash fuse/relay box 30 A, 20 A, 15 A, 10 A, 7.5 A Light bulbs Headlight high beam 12V-60W Headlight low beam 12V-51W Front side marker/parking/turn signal lights 2-door: 12V-28/5W (two filaments) Amber color
4-door: 12V-21/5W (two filaments) Amber colorRear turn signal lights 12V-21W Amber color Brake/Taillights 12V-21/5W (two filaments) Inner taillights 12V-5W (4-door) Rear side marker light 12V-5W High mount brake light 12V-21W (Except Si)
12V-LED (Si)Back-up lights 12V-21W License plate light 2-door: 12V-3 CP
4-door: 12V-5WCeiling lights 12V-5W Individual map light 12V-8W Trunk light 12V-5W Gauge lights 12V-LED (non-replaceable) Indicator lights 12V-LED, 14V-0.56W, 0.84 W Washer reservoir Capacity (USA models) 2.5 L (2.6 US qt) Capacity (Canada models) 4.5 L (4.8 US qt)
Body Specifications
4-door:
Fig. 1: Identifying Body Specifications (4-Door)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
2-door:
Fig. 2: Identifying Body Specifications (2-Door)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
