Honda Civic 1996 1998 User Manual

General

Information

Paint Godes

Chassis

ldentification

Warning/Caution

Under-hood

Control

Lift and

Lift
Floor

Towing

and

Number

Emissions

Label

Support

and Safety

Jack

..........

Points

Stands

Label

.'.'..'.....'..'..'.."

Locations'..'.'.

Locations

.'..".'..'..'.'.'.".'

....,..................

'.'....' 1-29

1-2
1

"

1-21

'..'..'

......1'25

1-21
1'28

-2O

Chassis

and

Paint

Codes

U.S.

1996 Model

2HG: HONDA OF CANADA

l2-door

Hatchback)

000012AG

D16Y7: 1600

A4RA: 4-speed
S40 : s-speed Manual Transmission

SOHC 16-valves
Sequential Multiport
Fuel-injected Engine

Automatic Transmission

H: Alliston Plant, Ontario,

Destin.iions

Vehicle
and
Safety Standard Certification

ldentification

Federal Motor

Canada

Number

Vehicle

GY-16P
NH-503P
NH.583M
R-97

Midori Green Pearl
Granada Black Pearl
New Vogue
Roma Red

Paint

Silver Metallic

Code

COLOR
GY.l6P

t-z

.\a

U.S.

1996

Lino, Body 8nd

EJ6: CIVIC 4-door/D
EJ8: CIVIC 4-door/D'16Y8

Body Typo and Transmission

5: Sedan/s-speed

3: DX with
4: DX with ABS, EX
5: DX with ABS and
6: LX
7; LX with
8: LX with ABS

9:
Ch€ck Digit
Model Year

T: 1996

L: East Libertv. Ohio

S: Suzuka

H: Alliston Plant, Ontario, Canada

Model

Engine Typ€

Manual

Ay'C

Ay'C

LX with ABS and A,/C

Plant. Mie

JHM

Type

U.S.A.

Sedanl

EJ6

{4-door

l6Y7

A,/C

Plant,

Prefecture, Japan

52*TS

000001

D16Y7: 1600 SOHC 16-valves Sequential

Fuel-injected Engine

VTEC 16-valves Sequential

1500001-

ManualTransmission

: 5000001-

1000001-

Cyclone
Cypress
Frost White
Granada

New Vogue Silver Metallic
lsland Coral Pearl

D16Y8; 1600 SOHC

JAPAN:

: D16Yt, D16Y8-

U.S.A

4-speed Automatic Transmission

A4RA:
S40 : s-speed

: s-soeed ManualTransmission

S4C

A4RA {U.S.A.)
S40. SaC

B-73M
G-82P
NH-538
NH-503P
NH-583M
R-95P

Multipon

Multiport Fuel-injected Engine

D16Y7. D16Y8 - 1300001-

(JAPAN):

Paint Code

Blue Metallic
Green Pearl

Black Pearl

Vehicle ldentification Number
and Federal Motor Vehicle
Saf ety Sta ndard Cortif ication

COLOR

B.73M

1-i

Chassis

and Paint

Codes

U.S. 1996 Model

Lino, Body

Body Type

Chock Digit
Modol

Vehicle ldentification
and Federal
Safety Standard

and Engina
EJ6; ClvlCz-door/D16Y7
EJ7: ClVlC2-door/D16Y5
EJ8:

ClVlC2-door/D16Y8

and Tranrmission

3; OX with ABS,
4: DX with
5: DX with

and A"/C EX with

Year

T: 1996
L:

East Liberty,

Ay'C, HX
ABS

Typc

HX with

and Ay'C, HX with

Ohio Plant,

Motor Vehicle

Certif ication

(2-door

lHG

Type

ABS

with Ay'C,

ABS

EX

U.S.A.

Number

Coupe)

EJ6 12*TL

ABS

000001

D16Y5:

Dl6Y7:

D16Y8:

JAPAN:

U.S.A. : D16Y7.

A4RA : 4-speod
S40,
M4VA

1600 SOHC

Sequential Multiport
Fuel-injected

1600 SOHC

Sequential Multiport
Fuel-injected

1600 SOHC VTEC

Sequential
Fuel-injected

D16Y5 - 1300001-

D16Y8 - 15OOO01-

S4C: s-speed Manual

; Continuouslv

Transmission

A4RA :5000001-

s40,

s4c

M4VA: 1000001-

WEC-E 16-valves

Engine

16-valves

Engine

16-valves

Multiport

Engine

Automatic Transmission

Transmission

Variable

(CVT)

1-4

G-82P
NH.5O3P

NH-538
NH-583M
B-81
R.95P

Cypress
Granada Black
Frosl

New
Milano Red
lsland

Paint

Green Pesrl

White

Vogue Silver

Coral Pearl

Code

COLOR

G-82P

Pearl

Metallic

a

CANADA

1996 Model

l2-door

Hatchbackl

Line, Body and Engino

EJ6: ClVlC3-door/D16Y7

Body Type and

Digit

Check
Modol Ysar

T: 1996

H: Alliston Plant, Ontario, Canada

Vehicle ldentification

and Canadian Motor

Safety Standard

Typs

Transmission Type

Number

Vehicle

Certification

2HG EJ632*TH 000001

A4RA:,t-speed Automatic Transmission

:s-soeed Manual Transmission

S40

GY-T6P
NH-503P
NH.583M
R-97

Midori Green
Granada Black Pearl
New Vogue Silver
Roma Red

D16Y/ - 1700001

Pearl

Metallic

Paint Code

COLOR

GY.16P

1-5

Chassis and

Paint

Codes

CANADA

Lino, Body and Engino Typ6

EJ6: ClVlC4-door/D16Y7

Body Typo and Transmission Typo

5; Sedan/s-soeed Manual

4; LX with ABS
5: LX with ABS and A,/C
6: EX

7: EX with ABS
Check
Model Year

T: 1996

1996 Model

Digit

(4-door

lHG EJ653*TL 800001

Sedan)

D16Y7: 1600

Sequential Multiport
Fuel-injected Engine

A4RA; 4-speed Automatic Transmission
S40 : 5-soeed

A4RA:

5000001-

:1000001-

S40

16-valves

SOHC

ManualTransmission

L: Esst Liberty,

Ohio Plant, U.S.A.

Vehicle ldentification Number
and Canadian

Motor Vehicle

Saf ety Standard Gertif ication

B-73M
G-82P
NH-503P
NH-538
NH-583M

Cyclone Blue Metallic
Cypress Green Pearl
Granada Black Pearl
Frost White
New Vogue

Paint Code

Silver Metallic

COLOR

8.73M

w

1-6

.'rr

F'.i!

CANADA 1996

Lins, Body and Engine

EJ6:

ClVlC2-door/D16\'/

EJ8:

ClVlC2-doo./D16Y8

Body Typ6

3: Si

5: DX with ABS
Chock Digit
Model Yeat

T:

1996

Transmi3sion Type

and

with ABS

Model

1HG EJ6 12*TL 000001

Typa

(2-door

Coupel

1600 SOHC 16-valves

Sequential Multiport
Fuel-injected Engine

1600 SOHC WEC 16-valves

Sequential Multipon
Fuel-injected Engine

Transmission Number

Transmission l

A4RA I

s40, s4c:

Serial

A4RA

Numbor

4-soeed Automatic Transmission
s-soeed Manual Transmission

:

s40, s4c:

A4RA

-

5000001

L: East Liberty, Ohio Plant, U.S.A.

Vehicle ldentif ication
and Canadian

Motor Vehicle

Number

Safety Standard Certification

G-82P
NH-503P
NH-538
NH-583M
R-81
R-95P

Cypress Green
Granada Black Pearl
Frost White
New Vogue Silver
Milano Red
lsland Coral Pearl

Pearl

Paint Code

COLOR

NH-538

Metallic

1-7

Chassis

and

Paint

Codes

U.S.

1997

Type

ol

Lino, Body

EJ6:

Body Typo

3: CX with Ay'C
4:

DX
5: DX with Ay'C
6: DX with ABS
7: DX with Ay'C

Digit

Chcck
Model Yoar

V; 1997

H; Alliston Plant,

Model

Vohicl€

Engino

and

ClVlC3-door/D16Y7

rnd Tranrmission Typc

(2-door

Typr

and ABS

Ontario, Canada

Hatchback)

2HG EJ6 32

*VH

1

00001

D16Y7i 1600 SOHC 16-valves

Sequential Multipon
Fuel-injected

A4RA: 4-sDeed
B4RA:
S40 :

A4RA: 600000'l-

B4RA: 6000001­S40 : 1000001-

NH.503P
NH.583M
Pg-l

4P

R-97

4-speed Automatic Transmission

s-speed Manual Transmission

Automatic Transmission

Engine

Granada Black Pearl
New Vogue
Dark
Roma Red

Silver Metallic

Amethyst Pearl

a

q

Vehicle ldentification

Federal

and
Safety Standard

Motor

Certification

Vehicle

Number

Paint

Code

COLOR

NH.583M

1-8

U.S.

1997 Model

l4-door

Sedanl

Body snd Engine

Lino,

EJ6: ClVlC4-door/D16Y/
EJ8: ClVlC4-door/D16Y8

Body Typo and

5: Sedan/s-sDeed

DX with Ay'C

3:
4: DX with ABS, EX

DX with ABS and Ay'C

5:
7: LX with Ay'C

with ABS

8: LX

9; LX with
Chock Digit
Modol Ycsr

V: 1997

L: East Libertv, Ohio
S: Suzuka
H: Alliston Plant. Ontario,

ABS

Plant, Mie Prefecture.

Typo

Trsnsmission Type

Manual

and

JHM

Ay'C

Plant, U.S.A.

Canada

EJ6 s2*VS

Japan

000001

Dl6Y/:

D16Y8: 1600 SOHC WEC

JAPAN: D16Y7, D16Y8

U.S.A. : D16Yt,

A4RA : 4-soesd Automatic Transmission

B4RA :
M4RA:
S40

A4RA

1600

Multiport Fuel-injected

Multiport

4-spe6d Automatic Transmission
4-speed Automatic

:s-speed Manual Transmission

(U.S.A.)

l$valves Sequentisl

SOHC

16-valves Sequential

Fuel-injected Engine

-

2300001-

Dl6Y8 - 2500001-

Transmission

:

6000001­B4RA {U.S.A.) : 6000001­M4RA UAPAN):

(JAPAN)

S40

B.73M
G-82P
NH-538
NH-503P
NH-583M
R.96P

2000001-

: 1000001-

Cyclone Blue Metallic
Cypress Green
Frost White
Granada Black
New Vogue Silver
lnza Red

Engine

Pesrl

Pearl

Metallic

Vehicle ldentification
and Federal
Safety

Standard

Motol

Vehicle

Certification

Number

Paint Code

COLOR

8.73M

1-9

Chassis

and Paint

Codes

U.S. 1997 Model

Vehicle

Manutaqturer,
Type

Line,

Body Typ€

Vehicle

Chsck Digit
ModelYear

Factory
Serial Number

Vehicle
and
Safety

ldentification

Make

and

ol Vehicle

lHG:

HONDA
MFG,, INC.
HONDA

vehicle

Body and Engine Type

EJ6;

ClVlC2-door/D16Y7
EJ7: ClVlC2-door/D16Y5
EJ8: ClvlC2'door/D16Ya

Transmission

and

1:

Coupe/s-speed
Ma nua I

2; Coupe/4-speed

Grade
2: DX, HX
3: DX with ABS, HX
4: DX with A,./C, HX
5: DX with ABS

and A'lC,

V: 1997

Code
L: East Liberty,

EX with ABS

AMERICA

OF

Passenger

Automatic,

with A,./C. EX

and A,iC, HX with ABS

Ohio Plant, U.S.A.

ldentification

Federal

Motor

Standard

Certification

(2-door

Number

'tHG

EJ6 14*VL

Type

CVT

with ABS

Number

Vehicle

Coupe)

000001

Engine Number

Engine

Type

D16Y5:

D16Y7:

D16Y8:

Serial Numb€r

JAPAN: Dl6Y5 - 2300001­U.S.A. : D16Y7, D16Y8

Transmission

Transmission

A4RA
B4RA : 4-speed
S40 :s-speed Manual
M4VA: Continuously

Serial Number

A4RA :

B4RA : 6000001­S40 :1000001­M4VA: 2000001-

1600 SOHC WEC-E

Sequential Multiport

Fuel-injected

1600 SOHC 16-valves

Sequential Multiport

Fuel-injected

1600 SOHC VTEC

Sequential Multipon
Fuel-injected Engine

Number

Type

: 4-speed Automatic

Automatic Transmission

Transmission

6000001-

16-valves

Engine

Engine

16-valves

-

2500001-

Transmission

Transmission

Variable

{CVT)

D16Y5 - 2300001

-

A4RA

6000001

a

a

1-10

G-82P
NH.5O3P
NH-538
NH.583M
R-81

Cypress Green Pearl
Granada Black Pearl
Frost White

New

Vogue Silver Metallic

N4ilano

Red

Paint

Gode

COLOR

G.82P

CANADA

1997

Model

(2-door

Hatchbackl

Line, Body lnd Engin€

EJ6; ClVlC3-door/D16Y7

Body Type and Transmission

H: Alliston Plant, Ontario,

Typo

2HG EJ6 32

Type

Canada

*VH

000001

D16fr:

A4RA: 4-speed Automatic Transmission
B4RA: 4-sDeed
S40 : s-sDeed Msnual

1600

Sequential
Fuel-injected Engine

16-valves

SOHC

Multiport

Automatic Transmission

Transmission

Vehicle ldentification
and Ganadian

Motor Vehicle

Number

Safety Standard Certification

NH-503P
NH.583M
PB-74P
R-97

Paint Code

NH-503P

G.anada
New Vogue Silver
Dark Amethyst Pearl
Roma Red

COLOR

Black Pearl

Metallic

1-11

7

Chassis

CANADA

Lino, Body and Engine Typs

EJ6: ClVlC4-door/Dl6Y7

Type

Body

5: Sedan/s-soeed Manual

4: LX With ABS

5: LX with ABS and ly'C
7: EX with ABS
8: EX with ABS

and Paint

1997 Model

and TEnlmLrion Type

and

Godes

(4-door

1HG EJ653+VL 800001

!y'C

Sedan)

D16\.t: 1600

Sequential Multiport
Fueliniected Engine

A4RA: 4-speed Automatic Transmission

84RA: 4-speed Automatic Transmission

S40 : s-sDeed Manual Transmission

SOHC

16-valves

L: East Libertv, Ohio Plant, U.S.A.

Vehicle ldentification

Number
and Canadian Motor Vehicle
Safety Standard Certif ication

B-73M
G.82P
NH-503P
NH-538
NH-583M

Paint

Code

Cyclone Blue Metallic
Cypress Green Pearl
Granada Black Pearl
Frost White
New Vogue Silver Metallic

COLOR

B-73M

1-12

v-

CANADA

1997 Model

(2-door

Coupel

Lino. Eody and

EJ6: CIVIC 2-doorlD16W
EJ8: ClVlC2-door/D16Yg

Body Type lnd Tran3mission

3: Si

DX with ABS

5:
6: OX
7: Si

Engins Type

with ABS

with ABS and

with ABS and Ay'C

Ay'C

lHG EJ6

Type

12*VL 800001

D16Y7: 1600 SOHC

Sequential
Fuel-injected

D16Y8: 1600 SOHC

Sequential
Fuel-injected

44RA: 4-speed
B4RA: 4-speed Automatic

:s-speed

S40

A4RA: 6000001­B4RA: 6000001­S40 :1000001-

16-vslves

Multiport

Engine

WEC 16-valves

Multipon

Engine

Automatic Transmission
Manual Transmission

Transmission

L: East Liberty,

Vehicle ldentif

and Canadian

Ohio Plant. U.S.A.

ication Numbel
Motor

Safety Standard

Vehicle

Certification

G-82P
NH-503P
NH-538
NH-583M
R-81

Paint Code

Cypress Green
Granada
Frost White
New
Milano Red

COLOR
NH-538

Pearl

Black Poarl

Vogue Silver Metallic

1-13

Chassis

and Paint

Codes

U.S. 1998

Line, Body

Body

Check Digit
Mod€l

and

EJ6:

ClvlC3-door/D16Y7

Type

and Transmission

3:

CX with Ay'C

4:

DX

5: DX

with Ay'C

6: DX

with ABS

7:

DX with

Year

W: 1998
H:

Alliston

Model

Engine

Ay'C

Plant.

Type

and ABS

Ontario.

(2-door

2HG EJ6

Typ€

Canada

Hatchbackl

*WH

32

1

00001

D16Y7:

B4RA;

S40 :
B4RA:

S40 : 1000001-

NH.592P

NH-583M
PB-74P
R-97

1600

SOHC 16-valves
Sequential
Fuel-injected

4-speed

s-speed
7000001-

Automatic
Manual

Multiport

Engine

Transmission

Transmission

Flamenco
New
Dark Amethyst
Roma

Black

Vogue

Red

Silver

Pearl

Metallic

Pearl

t

Vehicle

ldentification
and Federal
Safety

Standard

Motor

Vehicle

Certif icataon

Number

Paint

Codo

COLOR

NH.583M

{i"

1-14

U.S. 1998 Model

(4-door

Sedanl

Line, Body and Engine Type

EJ6: CIVIC4-door/D16Y7
EJ8: ClVlC4-door/D16Y8

Body Type and Transmission

5: Sedan/5-speed

Manual

JHM

Type

EJ6

52*WS

000001

Engino Typ€

D16Y/:

D16Y8;

JAPAN:
U.S.A : D16Y7, Dl6Y8 - 3500001-

84RA : 4-soeed Automatic Transmission
M4RA: 4-sDeed
S40 : s-soeed

B4RA

M4RA

S40

'1600

SOHC 16-valves Sequential

Multiport Fuel-injected Engine

1600 SOHC

Multiport Fuel-injected Engine

D16Y7. D16Y8 - 3300001-

(U.S.A.)

(JAPAN):

(JAPAN)

VTEC 16-vslves S€quential

Automatic Transmission
Manusl Transmission

: 7000001-

3000001'

: 1000001-

DX with A"/C

3:
4: DX With ABS, EX
5: DX with
7: LX with A,/C
8: LX with ABS
9: LX with ABS and

L: East Liberty, Ohio Plant, U.S.A.

S: Suzuka

H: Alliston Plant, Ontario, Canada

000001: JAPAN, U.S.A.
500001: CANADA

ABS

Plant, Mie Prefecture, Japan

Vehicle ldentification

and

Ay'C

Ay'C

Numbel
and Federal Motor Vehicle
Safety Standard Certification

8.73M

NH-578
NH-592P
NH.583M
R.96P

Paint Code

Cyclone
Cypress Green
Taffeta White
Flamenco Black Pearl
New
lnza Red Pearl

COLOR

8.73M

Blue Metallic

Vogue

Silver

Pearl

Metallic

1-15

I

Ghassis

U.S.

1998

Lin.,

Body

EJ6:
EJ7:
EJ8:

Body Type

and Paint

Model

and Engina

ClVlC
ClVlC2-door/D16y5
ClVlC2-door/Dt6y8

and Transmbsion

1:Coupe/s-speed

Manual

2:

Coupe/4-speed

3: DX with
4: DX
5; DX

and Ay'C.
Chack Digit
Model

Year

W: 1998
L: East

Vehicle
and Fedoral

Safety

ABS,
with !VC,
with ABS

EX

Liberty,

ldentification

Motor

Stsndard

(2-door

Typo

2-door/Dt

Automatic.

HX

with ABS

HX

with A,/C.

and

Ay'C,

with

ABS

Ohio

Plant,

Number

Vehicle

Certifi

1HG

6y7

Type

HX with

U.S.A.

cation

Codes

Coupe)

EJ6 12+WL

CVT

EX

ABS

000001

Engine

Engins

Serial

Number

Typ€

D16Y5:

D16Yr:

D16Y8:

JAPAN:
U.S.A.

B4RA
S40 :s-speed
M4VA:

1600

Sequential
Fuel-injected

1600

Sequential
Fuel-injected

1600

Sequential
Fuel-inject€d

Numbor

D16Y5

: D16Y7,

: 4-speed

Continuously
Transmission

B4RA;7000001-

S40

:1000001-

M4VA:

4000001-

SOHC VTEC-E

Multipon

Engine

SoHC

16-valves

Multiport

Engine

SOHC

WEC

l6-vatves

Multipon

Engine

-

3300001-

-

016Y8

Automatic
Manual

350OOO1-

Transmissron

Transmission

Variable

(CVT)

D16Y5

t6-vatves

-

3300001

1-16

NH-592P
NH-578
NH.583M
R-81

Cypress
Flamenco

Taffeta

New

Vogue

Milano

Paint

Code

Green Pearl

Black

Pearl

White

Silver

Metsllic

Red

COLOR

G-82P

CANADA 1998 Model

l2-door

Hatchbackl

Vehicle

Manufactur€r. M!ke and

Typ€ ot V6hicle

Lins, Body 8nd Engino Typo
Body

Vchiclo

Chock Digit
Modol Yoar

Factory

Sarial Number

ldentification Number

2HG: HONDA

MFG., INC.
HONDA Passenger
vehicle

EJ6:

ClVlC3-door/Dl6Yt

Typo and Transmi$ion Typ6

3: Hatchbacld5-speed

Manual

4: Hatchbacl(4-speed

Automatic

G18d.

2:

CX

3: CX-G

W;1998

Codo

H: Alliston Plant,

OF CANADA

Ontario, Canada

2HG EJ6

32

*WH

000001

D16Y7: 1600

B4RA: 4-speed

S40
B4RA: 7000001-

S40

SOHC 16-valves
Sequential Multiport
Fuel-injected

Automatic Transmission

:s-speed

:1000001-

Manual Transmission

Engine

Vehicle ldentifi cation Numbsr
and Canadian Motor
Srfoty Standard

Vchicle

Certifi cation

Paint Code

COLOR

NH.592P

Flamenco Black Peafl
New Vogue
Dark Amethyst Pearl
Roma Red

Silver Metallic

1-17

T

Chassis

CANADA

Vehicle

and Paint

1998

ldentification

Model

Number

2HG

Codes

(4-door

+W

EJ6 53

Sedan)

H

900001

,
\-

Manutacturei.
Type

Line. Body

Body Type

Vehicle

Chock Digit
Model

Factory

Serial

Vehicle

of

2HG:

HONDA

MFG., INC,
HONDA Passenger
vehicle

JHM:

HONDA
LTD.
HONDA Passenger
vehicle

and Engine Type

EJ6:

ClVlC4-door/Dl6Y7

and Transmission

5: Sedan/s-speed

6:

Sedan/4-speed
Automatic

Grade
0: EX
3: LX

4:

LX with
5: LX with
7: EX with

8: EX

with ABS

Yoar

W:

1998

Code
H: Alliston
S:

Suzuka Plant,

Numb6r

800001-:

900001-:

Make and

OF

MOTOR CO..

ABS
ABS

and A,/C

ABS

and Ay'C

Plant,

Ontario,

Mie

JAPAN
CANADA

CANADA

Type

Manual

Canada

Prefecture,

Jaoan

D16Y7: 1600

3750001-:

3700001-: JAPAN

Transmission

Transmission

B4RA

: 4-speed
M4RA:
S40 :

Ssrial

Number

(U.S.A.)

B4RA
M4RA

(JAPAN)

S40

B.73M
G.82P
NH.592P
NH-s78

NH.583M

SOHC 16-valves
Sequential
Fuelinjected

U.S.A.

Multiport

Engine

Number

B4RA

Type

Automatic
4-speed
s-speed ManualTransmission

(JAPAN):3000001-

Automatic

: 7000001­:

1000001-

Transmissron

Transmission

Cyclone Blue
Cypress
Flamenco

Taffeta

New Vogue

Green Pearl

Black

White

Silver Metallic

Metallic

Pearl

-

7000001

Paint

Vehicle
and

Canadian

Safety

Standard

ldentification

Motor

Vehicle

Certification

Number

Code

COLOR

B-73M

1-18

t

a

CANADA

1998

Model

1HG EJ6

(2-door

GouPe)

*W

12

L 800001

Line, Body and

EJ6:
EJ8: ClvlC2-door/D'16Y8

Type and Tlansmission

Body

Vehicle Grade

2: DX, Si
3: Si
5: DX with

DX with

6:
7: Siwith

Digit

Check

Yoar

Modsl

W: 1998

L: East Libertv,

Engin€ Type

ClVlC2-door/D16Y/

with ABS

ABS
ABS and AVC

ABS and

Ohio Plant.

A,/C

TyPe

U.S.A.

D16Y7: 1600 SOHC

Sequential
Fuel-injected Engine

D16Y8: 1600 SOHC

Sequential

Fuel-injected

D16Y7: 3750001­D16Y8:3780001-

B4RA: 4-speed

:s-speed Manual

S40

7000001-

84RA:
S40 :1000001-

Automatic Transmission

16-valves

MultiPort

WEC 16-valves

Multiport

Engine

Transmission

Vehicle
and Canadian

ldentification

Motor Vehlcle

Safety Standard

Number

Gertification

G-82P
NH-592P
NH-578
NH.583M
R-81

Paint Code

Cypress
Flamenco
Taffeta

New Vogue Silver
Milano

COLOR

NH-578

Green Pearl

Black Pearl

White

Metallic

Red

1-19

ldentification

Number Locations

V6hicl6 ldontif ication
Numbor

lVlN)

\_

Transmission
Numb6r

t

1-20

Numb€l

*:.,

Y-

Warning/Caution

Label

Locations

A: CABLE

REEL CAUTION

REFER TO SERVICE

noNs.

a: DRIVER

THE AIRBAG INFLATOR
TALLY DEPLOYED, CAN
.

o
.

.

MODUTI WARNING

WARNING

DO NOT USE ELECTRICAL
ING DEVICES,
THEY CAN CAUSE
NO

SEnVICEABLE

8tE.

AIBBAG UPRIGHT

PLACE
FOIIOW SERVICE

A

MANUAL

SERIOUSLY

ACCIDENTAL DEPLOYMENT.

PARTS lNSlOE.

MANUAL INSTRUC'TIONS

FOR DETAILED

IS EXPLOSIVE

TEST EOUIPMENT OR

WHEN REMOVED.

AND, IF ACCIDEN.

HURT OR KILL

DO NOT OISASSEM'

INSTRUC.

CAREFULLY.

YOU.

PROB'

C: DRIVER MOoULE

DANGER
EXPLOSIVE/FLAMMABLE
CONTACT
AS COPPER,

IRRITATING GASES

AND
STORAGE
{l(x}"CI,
AL PROCEDURES
PLEMENT.

CONTAINS
NITBATE.

IF CONTENTS
EYE COI{TACT.
IF GASES
SEEK FRESH AIR. IN
ATTENNON.
KEEP OUT OF REACH OF

FOR PROPER HANDLING, STORAGE

POTSON

FIRST AID:

(FROM

DANGER

WITH ACID, WATER OR

LEAD OR MERCURY

TEMPERATURES

REFEi

POISONOUS SOOIUM

ARE SWALLOWED, INDUCE

FLUSIJ

ACIO OR

EVERY CASE, GET

HEAVY METALS SUCH

MAY PRODUCE HARMFUL

OR EXPLOSIVE COMPOUNDS.

MUST NOT EXCEED

TO

SERVICE

AZIDE AND

EYES w|TH WATER

WATER CONTACI)

CHILDREN.

AND DISPOS.

MANUAI- SRS

POTASSIUM

VOMMNG,

FOR 15 MINUIES.

ARE INHAI.ED,

PROMPT MEDICAL

2OO"F

SUP-

FOR

{cont'd)

1-21

Warning/Caution Label Locations

(cont'dl

o.E

l----_l

(

E

=-+:

)F

W

D: DRIVER INFORMATION: CANADA MODEI-

4!8q{Gt ALwAYs WEAR

.

THIS CAR IS EOUIPPED
FRONT SEAT PASSENGER
TAL RESTRAINT

.

IT IS DESIGNED TO

'

Exc6m CANADA CX

E: SRS INFORMATION: U.S. modol

youR

SEAT BELT

WITH A DRIVER AIRBAG AND

SYSTEM

AIFBAGT AS A SUPPLEMEN-

ISRSI.

SUPPLEMENT THE SEAT BELT.

9? mod.l)

{96,

cAunoN

TO AVOID

.

.
.
.
.
.
.

SERIOUS INJURY:

FOR

MAXIMUM SAFEW PROTECNON IN
CMSHES. YOU MUST
BELT.
DO NOT INSTALL REARWARD-FACING
ANY FRONT
DO NOT SIT OR LEAN
ANBAG.
DO NOI PLACE ANY
BETWEEN THE AIRBAG ANO YOURSELF.
SEE

TION AND EXPLANATIONS.
THE

INSTALLED.

TTIE DATE OF INSTALLATION

ER'S DOORJAMB,

PASSENGER SEAT POSITION.

THE

OWNER'S MANUAL FOR FURTHER
MUST

SRS

ALWAYS WEAR YOUB SAFETY

UNNECESSARILY CLOSE TO THE

OBJECTS OVEn THE AIRBAG OR

BE INSPECTED TEN YEARS AFTEN |l

IS SIIOWN OF THE DRIV.

ALL TYPES OF

CHILD SEATS IN

INFORMA.

|s

U.S. mod.l

WASNING

DEATH OR SERIOUS INJURY

A

.

CHILDREN 12 AND UNDER
AIRBAG.

.

THE BACK

.

NEVER PUT A REAR.FACING

FRONT.

.

SIT AS FAR BACK AS POSSIBLE FROM

.

ALWAYS

.

THE
INSTALLED.

.

THE OATE
ER'S DOORJAMB.

modell

198

(rcCUR.

CAN

CAN BE KII-LED BY THE

SEAT lS THE SAFEST PLACE FOB

USE SEAT BELTS AND CHILD RESTRAINIS.

SRS MUST BE INSPECTED TEN YEARS

INSTALLANON

OF

CHILD SEAT IN TIIE

THE AIRBAG.

IS SHOWN ON THE DRIV.

CHILDREN.

AFTER 1T IS

1-22

F: ASSISTANT INFORMATIONT

US MOOEL

{96,

97

modell

J: SRS WARNING IHOODI

AIRBAG SEE OTHER

U.S. model

AIRBAG
FLIP VISER

G: STEERING

NOTICE

TO

BEFORE REMOVING
BOLT.

H: MONITOR

NONCE

.
.

198

WARNING

OVER

COLUMN NOTICE

PREVENT SRS DAMAGE, REMOVE

CAUTION

NO

SERVICEABLE PAFTS INSIDE.

REFER

TO SERVICE MANUAL FOR DETAILED

SIDE.

modell

STEERING SHAFT CONNECTING

TtoNs.

I: FRONT

EXPLOSIVE/FLAMMABLE
CONTACT WITH
AS
FUL AND IFRITATING
POUNDS.
2OO"F
DISPOSAL PROCEDURES
SRS SUPPLEMENT.
POTSON
CONTAINS
NITRATE.
FIRST AID
IF CONTENTS ARE
EYE CONTACT, FLUSH EYES

UTES, IF GASES
INHALED,
MEDICAL ATTEiITION.

KEEP OUT OF REACI{

THE AIBBAG INFLATOR
TALLY OEPLOYED,
o

.
.

.

SEAT PASSENGER MODULE

DANGER

COPPER, LEAD OR MERCURY MAY PRODUCE

IlOO"CI.

WARNING

DO NOT USE El-ECTRICAL TEST
ING DEVICES.
THEY

CAN CAUSE ACCIDENTAL DEPLOYMENT.
NO SERVICEABLE PARTS
BLE,
PLACE
FOLLOW

ACID, WATER OR HEAVY METALS

STOBAGE TEMPERATURES MUST NOT

FOR PROPER HANDLING.

POISONOUS SODIUM AZIDE

SEEK FRESH AIR IN EVERY

AIRBAG

SERVICE MANUAL INSTRUCNONS

GASES OR EXPLOSIVE

REFER TO SERVICE MANUAL,

SWALLOWED, INDUCE VOMITING. FOR

ACID

IFROM

OF CHILDREN.

IS EXPLOSIVE AND, IF ACCIDEN.

CAN SERIOUSLY HURT OR KILL YOU.

UPRIGHT

WHEN

DANGER

WITH WATER FOR 15 MIN.

OR WATER CONTACTI

CASE. GET PROMPT

EOUIPMENI OR PRO&

INSIDE. OO NOT DISASSEM.

REMOVEO.

STEERING WHEEL

INSTRUC.

SUCH

HARM.

COM-

EXCEED

STORAGE AND

ANO POTASSIUM

ARE

CAREFULLY.

SUPPLEMENTAI- RESTRAINT
THIS VEHICLE
SEAT PASSENGER AIRBAGS*.
ALL

SRS ELECTRICAL WIRING
COLORED YELLOW.
TAMPERING
CAL TEST
THE SYSTEM INOPERATIVE
ING OF THE

WARNING
THE AIRBAG INFLATOR
TALLY OEPI-OYED. CAN
SERVICE MANUAL INSTRUCTIONS

'

Exc.et

CANADA CX

IS EOUIPPED WITH

WITH, OISCONNECTING

EOUIPMENT ON THE SRS

INFLATOR.

SYSTEM

OR CAUSE ACCIDENTAL

IS EXPLOSIVE ANO.

SERIOUSLY HURT YOU. FOLLOW

f: PASSENGER AIRBAG CAUnON

U.S. rnodol

WARNING
CHILDREN
AIRBAG.
THE

BACK SEAT IS THE

AND

UNDER, MAKE SURE ALL CHILDR€N

OR CHILO SEATS.

mod.l)

198

CAN BE KILLED

SAFEST PLACE FOR CHILDREN 12

OR

ISRSI

DNIVER AND FBONT

AND CONNECTORS ARE

OR USING ELECTRI.

WIRING CAN MAKE

CAREFULLY.

INJURED

8Y PASSENGER

USE SEAT BELTS

IF ACCIDEN-

FIR.

(cont'd)

1-23

Warning/Caution Label

Locations

(cont'd)

I

1-24

Under-hood Emissions

Control Label

(19!16,

1997

modell

Emission

Group ldentification

Example:

tsF COOUNI,

VACUUM HOSE ROUTING DIAGRAM

VEHICLE EMISSION

FAM|LY

ENGlrlE
EvApoMtrvt FAMrry vHNroTTByMAc

Hrr.n u
TUN!

N0 ollrEF aDJUSTT,TENTS NE!DEo.
IOLESPEED

THIS VTHICLE CONFORMS IO
OF CALIFO8NIA REGULAIIO1TS

MOOEL

112 nE-N2 H0N0A MOTO8

50ST

vHNl6vJcrcr

stcv'ct

LP CO\DNOIIS: ENGIN!

YEAN NEI1 MOTON VEHICIES.

CEBT]FICANON NtR 1

IN.USE

States}:

{50

THIS VEHICLE

CALIFORNIA
MODEL

49ST

YEAR NEW MOTOR VEHICLES.

(49

States/Fodoral):
THIS VEHICLE CONFORMS TO
APPLICABLE TO 1997 MODEL YEAR

(Californis):

CAL
THIS

VEHICLE CONFORMS TO
CALIFORNIA REGULATIONS
MODEL YEAR NEW PASSENGER
THAT

THIS VEHICLE IS

MERCE FOR

CONTROL

D.SB-ACEME{T

CATALYST

MA\uAr ro'

aDofl

AT

NOFMAI OPFMTING TTM'EqA-U8!.
ALt ACCESSoRTESTUq{Eo
TiANSMISSION

TMNSMISSION

U.S. EPA

APPLICAELE TO 1997

NEA 1FUTL

CONFORMS TO U.S. EPA AND STATE OF

REGULATIONS APPLICABLE TO 1997

SALE IN

USE 'o'EO SOLUTION

INFORMATION

ls90.F}q?

O0 CIVIC

rwcHo2s{2)sFl

'N.oRMA

ror{A,

IN NEUIML

ANO

ONLY

THE

ro\.

oFf,CooUNG

FAN

12" l I3TDC

e+l

SIAIE

C0., tTD.

U.S. EPA REGULATIONS

NEW MOTOR VEHI-

EPA AND

U.S.

APPLICABLE TO 1997

CARS PROVIDED

INTRODUCED

STATE OF CALIFORNIA.

oFf,

oBD CERTtftED

T!

r r

_9.,.'

ililulIl

STATE OF

INTO COM.

p:9

ff-Tl
I I|rf '

Engine

Evaporative

and

Engine Family:

Model Ysar

T: 1996
V; 1997

Manufacturer

HN: Honda

Di3placomont

Clsss

V: Light Duty Vehicle/Passenger

Fuol

Systsm and Numbsr of Valvo3

J: Electronic

(three

Sequential Multipon Injection

or more valves

per

Fuol Typ€

G: Gasoline

Standard

F; 49 or 50 States Tier 1
K: 49 or 50 States Tier 1
1: California Tier 1

2:

California TLEV
3: California LEV
4: California

ULEV

Catalyst

E, F,

H: Three Way

G,

Catalyst

OBD

K - T: OBD Equipped

Evaporative Family:

ModetYsar

T: 1996
V:1997

Manutaqturer

HN:

Honda

Storage System

1:Canister

Canirtor Wolking Caprcity
Canister Contigurstion

A: Plastic

Housing

B: Plastic Housing

Fu€l System

Y: Fuel Injection

Fuel Tank

M: Metal

Standard

A: Current Evap
E: Enhanced

Evap

Wild Card

lgrEmsl

(Closed

Eottom)

{Open

V HN

Car

cylinder)

V HN 1

T

Bottom)

Families

1.6VJGKGK

077 BYMAC

T

|

]

(cont'd)

1-25

Under-hood

Emissions Control Label

(1998

modell

(cont'd)

Emission Group ldentification

Example:

VEHICTE

OF CAL TORNLA RECULATIONSAPPLICABLE

STAT€
TO 1933 MOOELYEAR NEW TLFV PASSENGEfr

INTBOOUCEOINTO

CATALYST

two1r02s1?tEcR/sFt/0B0 | cEBTtF E0

VAIV€ LASH

NONDAMOTORCO LTD

50ST {50 States):
THIS VEHICLE
CALIFORNIA

MODEL YEAR NEW MOTOR VEHICLES.

EMISSION CONTROL

COMMERCE FOR SALE

CONFORMS

REGULATIONS

N TNE

TO

INFORIVIATION

EPA AND

U.S.

APPTICABLE TO I998

STATE OF

Engine

Evaporative

and

Engine Family: W

Model Y6ar

W: 1998

Manutacturer

HNX: Honda

Type

V: Light Duty Vehicle/Passenger Car

Displac€ment

Sequence Charaqters

Evaporative Family:

Mod€lYear

W: 1998

Manufacturar

HNX: Honda

Type

E: EVAP
Caniater Work Capacity
S€quonca Chrract6ls

lgrams)

WHNXE

Families

HNX V 01.6 JL2

AAD

0065

L

(49

49ST
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHI.

LLEJ.

CAL
THIS
CALIFORNIA
MODEL YEAR NEW PASSENGER

THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM-

MERCE FOR

States/Fed€ral):

(Calilornial:

VEHICLE

CONFORMS TO U.S. EPA AND STATE OF

REGULATIONS APPLICABLE

SALE IN THE STATE OF CALIFORNIA,

CARS

TO 1998

PROVIDED

1-26

Lift and

Support

Points

Lift and

@

romovod,
ot thc

NOTE:
.

Since each tire/whe€l assembly weighs approximately

assist with the weight distribution.

.

Use the same support

1. Place the lift blocks as shown.

2. Raisethe hoistafewinches

3. Raise the hoisttolull height,

Safety Stands

When heavy rear compon€nts such

placa

vohlcle,

ldditional

tha center of

woight in

gravlty

mty changa and can causs the vehiclo to tip forwsld

points

to support the vehicle on safety stands.

(centimeters)

and

luggage

the

androckthevehicletobesureitisfirmlysupported.

inspect lift

as suspension,

rrea before hoisting. Whon substantial woight b ramovod

pointstorsolid

30

lbs

{14

support.

fu€l

tank, spar6 tir€, hatch, and trunk lid

hoist.

on tho

placing

kg).

the

front

wheels in the luggage

ara to bo

from the r6a1

area can

REAR SUPPORT POINT

(cont'd)

1-27

Lift and Support

(cont'dl
Floor Jack

Points

parking

l.

the

Set
not

being

When lifting the rear of the

lever in reverse
position).

Raise the vehicle

stands.
Adjust and

will be approximately

them.

onto

brake and

lifted.

(Automatic

place

block

vehicle,

transmission/CW in

high

enough

the safety stands so

level. then

wheels that

the

put

to insert the safety

lower

are

gearshift

the

the vehicle

vehicle

the

Alway3 u3a
anv vchiclo that b 3upportod
Nover attompt
supporting tho

E

safoty stand3

to uso a bumper

vohicl€.

whcn working on 01 undol

by only a

iack.

for lifting or

iack

REAR:

LIFT

PLA

the

Center
bracket

jack

of the

Center the
b.acket

jack

of the

jacking

in the middle

platform.

lift

jack

the

in

middle

plattorm.

lifr

k-

ll

1-28

Towing

It the vehicle needs to be towed, call
ing service.

cle with

Em6rgency Towing

There

Never

just

rope

a

are three

popular

the vehicle behind another

tow

or chain,

lt is very dangerous,

methods of towing a

professional

a

vehicle:

tow-

vehi-

Front:

Flat-bed Equipment - The operator
the back of a truck.
vehicle.

Wh6d Lift Equipmont

a.ms that

off the

ground,

Sling-typ6
with hooks on the ends.
the
the vehicle off the

body can

is

attemDted.

lf the vehicle cannot be transported by

be towed with the front
damage, the vehicle
wheels

Manusl Transmission and CVT

.

.
Automatic

.

.

.

.

go

ground.

Equipm€nt - The tow truck uses

frame

oJ suspension,

be seriously damaged

on the

Release the

the transmission to

Shift

Transmission
Release the
Start the engine.
Shiftto lpl
Turn

off

This is the best way oftransponing the

-

The

tow truck

under the tires

The other two wheels

ground.

ground,

parking

parking

position,

the

engine.

(front

These hooks

and the cables

The vehicle's suspension and

wheels

must

do the

brake.

neutral

brake.

then

E

loads the vehicle on

or rear) and lifts them

it

this

off the

be towed

following:

(CVT

position.

uses two

go

method

flat-bed, it should

ground.

pivoting

remain

around

lift

with the front

to

on the

metal

parts

that end

of towing

lf due to

position).

E

cables

of
of

Roar:

TIE

OOWN

HOOKS

CAUTION:

.

lmproper towing
mi3sion,
cannot 3hift the lransmission

(automltic
portod
It

(80
Trying to

causa
to support tho

Follow

on a ffot-b€d.

is best to tow tho

km),

lnd

lift

sorious

propantion

tho above

trsnsmissionl.

vshicls no farthol th.n 5{t mibs

kosp tho sp€ed bdow 35 mph

your

or tow

damage. The bumpers are not d*ignod

vohicl6'3 weight.

will

damsgo the

procodur€

your

v€hicl9

vehicle by ths bumpeB will

€x6ctly. It

01 start th€ engine

mu3t

be

(55

trans-

you

trang

km/h).

TOWING

1-29

Specifications

Standards

Design
Body

Specifications

and

Specifications

Service Limits ..............

............................

..........

3-2
3-1 5
3-18

Standards

Cylinder

Compression

Cylinder

Camshaft

Vslve spring

guide

Valve

Rocker arm Arm-to-shaft clearance

Head/Valve

h6ad

and Service

Train - Section

rpm and wide open throttle

250

(kgf/cm',

kPa

Warpage
Height

play

End
Camshaft-to-holder
Total
Cam

Valve clearance
Valve

Stem-to-guide

widrh

Stem

Free length

l.D.
Installed height

psi) Nominal

runout

lobe height

(Cold)

O.D.

stem

clearance

installed height

Limits

-

arlilil,r(rrr

MEASUREMENT

oil clearance

D16Y7
D16Y5 IN

D16Y8

o

6

Minimum
Maximum

lN
EX

Primary
S€condary

IN

Primary
Mid
Socondary

Dl6Yt
D16Y5

D,I6Y8

variation

IN
EX
IN
EX
IN
EX

IN
EX
IN
EX

IN
EX
IN
EX

IN

EX

IN

IN
EX

STANOARD

'1,270

{13.0,

(9.5,

930
200

o*

0.05 - 0

0.050

0.03

35.299

37.241

38.127

32.193
38,784

36.774

38.211

37.065

38.008

0.18

0.23

5.48 - 5.19

5.45 - 5.46

0.02 - 0.05

0.05 - 0.08

0.85

1.25 - 1.55

53.17 - 53.61

53.17 - 53.64

57.9
56,512.221

57.9

58.0

58.7

5.51 - 5.53

5.51 - 5.53
17 .45 - 18.35

18.65

135)

Q.0,2al

gs.or

-

.15

-

0.089

(0.

001)max.

11.3897)

11.4678)

11.5129)
i1.267

11.5269)

11.4479)

11.50681

11.4592)

11.4964)

-

0.22

-

0.27

-

1.15

(2.28)
(2.28)

(2.28)
(2.31)

-

19.15

(0.002

{0.007
(0.009

(0.2157
(0.2146
(0.001
(0.002

(0.033
(0.049

0.0r7 - 0.050

184)

ta.arr

-

(0.002

4l

12.093
(2.093

(0.217
(0.217

(0.703

(0.734

(0.0007 -

{NEW}

-

r.66gt

0.006)

-

0.004)

-

0.009}

-

0.0111

-

0.2161)

-

0.2150)

-

0.002)

-

0.003)

-

0.045)

-

0.061)

-

2.112)

-

2.112)

-

0.218)

-

0.218)

-

-

0.754)

0.722)

0.0020)

0.018 - 0.054 10.0007 - 0.0021 )

SERVICE UMIT

0.05

{0.002)

0.5

{0.02)

(0.0061

0.15
(0.0021

0.04

iEi.rtnut

5.12

10.21341

0.08

{0.003)
(0.004)

0.11

(0.063)

1.6

2.0

{0.079}

53.49

Q.1221
(2.122)

53.89

(0.219)

5.s5

5.55

{0.219}

(0.003)

0.08
(0.003)

0.08

/

{L

3-2

tr

Engine Block - Seaion 7

Unit ot length: mm

(in)

MEASUREMET'lT STA]TDARD

Cylinder block Warpage of deck

Piston

Pislon ring Ring-to-grooveclearance Top

pin

Piston

Connecting

roo

Crankshatt Main

Bearings Main bearing-to-journal oil clearance

Eore

diameter
Bore taPer
R€boring limit

Skirt O.D. at 5
Cloa16nce

Groove width

Ring end

o.D.

Pin-to-piston
Pin-to-rod interlerence

Small end bore diameter
Large end bore diameter Nominal

play

End

journal

Rod

iournal

Taper
Out-ot'round

play

End
Totalrunout

Rod bearing-to-journ8l oil cl€arance

from

in

cylindor

{tor

gap

clearance

installed

diameter

diameter

surface

(0.2

mm

in)

bottom of skirt
ring)

on crankshaft

Top

Second

oil

Second
Top

Second
oil

No. 1 and 5journals
No.2.3

and 4journals

INEWI SERVICE UMIT

(0.003)

-

0.040

-

1.030

max.

(2.953

t2.9520

{0.0004
(0.0402

(0.0480
(0.1104

{0.0014

-

2.954)

-

-

0.0016)

-

0.0406)

-

0.0484)

-

0.1110)

-

0.0024)

2.95241

0.07

75.00 - 75.02

7 4.940 - 7 4.990

0.010
't.020

1.220 - 1.230

2.805 - 2.820

0.035 - 0.060

0.030 - 0.055 {0.0012 - 0,0022)

-

0.15 - 0.30

0.30 - 0.45

0.20 - 0.70

18.994 - 19.000

0.010 - 0.022

0.014 - 0.040

18.96- 18.98

48.0

0.15 - 0.30

54.976 - 55.000

44.976

0.0025

0.0025

0.10 - 0.35

0.03

0.018 - 0.036

0.024 - 0.042

0.020

(0.006
(0.012
(0.008

(0.0004
(0.0006

(1.89)

{0.001)

{0.746

(0.006

-

45.000 /.1.1701

(0.0001)
(0.0001)max.

(0.004

max.

10.0007
(0.0009

-

(0.0008

0.038

0.012)

-

0.018)

-

0.028)

-

(0.7478

-

0.0009)

-

0.0016)

-

0.747}

-

0.012)

-

(2.16,14

-1.17171

m6x.

-

0.014)

-

0.00'14)

-

0.0017)

-

0.0015)

0.7480)

2.1654)

(0.001)

0.10
(2.956)

75.07

(0.002)

0.05

(0.02)

0.5

(2.9516)

74.970

0.05

{0.002)

1.05

{0.041)
(0.049)

1.2s

(0.112)

2.85

(0.005)

0.13
(0.005)

0.13

(0.024)

0.60
(0.028)

0.70
(0.03r)

0.80

oro

ro.o'tur

ooos

to.ooort

0.005

{0.0002)

0.45

{0.018)
(0.002)

0.04

(0.002)

0.05

(0.002)

0.05

(0.002)

0.05

Engine Lubrication Soction 8

(uS

Engine oil

pump

Oil

Reliofvalve

Capacity f

lnner-to-outer
Pump housing-to'outer rotor radial clearance
Pump housing-to rotor axial clearance

Pressure setting with oil temperature 176'F

(kg7cm,,

kPa

qt,

rotor

psi)

MEASUREMENT STANDARD

ql)

lmp

radial clearance

D16Y7

Dl6Y5, D16Y8

(80'C)

at idle
at 3,000 rpm

(4.5.

4.3

3.8) tor engine overhaul

(3.8,

3.6

3.2)for oil change. including filter

(3.5,2.9)for

3.3
(3.9,

3.7

3.3)

(3.5,

3.3

2.9) for oil change, including filter

(3.2,

3.0

2.6)Ior oil change, without filter

0.02 - 0.14

0.10 - 0.18

0.03 - 0.08

70
340

(0.001
(0.004
(0.001

(0.7.'10)min.

(3.5,50)

(NEW)

oilchange. without filter

for engine overhaul

-

0.006)

-

0.007)

-

0.003)

min.

SERVICE LIM]T

0.20

{0.008)

0.20

{0.008)
(0.006)

0.'15

3-3

Standards

Cooling

-

and Service

Section 10

MEASUREMENT

Radiator Engine coolant capacity

Radiator cap Opening
Thermostat Start

fan Thermoswitch

Cooling

including engin6,
line and

Rosorvoir capacity:

0.41

Fully open
valve lift al

Thermoswitch

reservoir

(0.42

to opening

qt,0.35lmp qt,

US

pressure

'F

tully open

"ON"
"OFF"

('C)

'F

Limits

(US

qt,

,

heater, cooling

(kgf/cm'.

kPa

('C)

temperature

t6mperature

lmp

qt)

Mll

Nf

CVT

psi) 93 - 123

.F

(.C)

"F

(.C)

(4.4,

4.2
(3.3,

3.1

D16Y/

(4.3,

4.1
(3.2,

3.0

D16Y8

(4.5,

4.3
(3.3,

3.2
(4.5,

4.3
(3.3,

3.2

169 - 176

(90)

194

(0.311min.

8.0

'196

-

203

Subtract

STAiIDARO

3.7) tor overhaul

2.7) tor coolsnt change

3.6) tor overhaul

2.6)tor coolant
for oveIhaul

3.8)
for

2.8)

3.8)for

2.8) tor coolant chango

-

{0.95

-

(76

80)

-

(91

95)

5 - 15

change

change

coolant
overhaul

13.5 - 17.8}

1.25,

-

(3

8) from actual

INEWI

"ON"

Li

temperatur€

Fuel

pr6ssu16

Fuel
regulator

Fuoltank
Engine

Emission - Section

and

Clutch - Section

pedal

Clutch

clutch disc

Pressure

plat€

MEASUREMENT

(US

pressure

{kg7cm',

qal,

lmp

Pressure with fuel
disconnected kPa

CaDacity /
ldle speed rpm

ldle CO %

12

MEASUREMENT

Pedal height
Stroko
Pedalplay
Disengaggment height

Clutch surfac6
Rivet head depth

Thickness
Warpage

Diaphragm spring

runout

fingers alignment

11

regulator vacuum hose

psi)

gal)

016Y5
D 16\.'
D16Y8

to floo.

to floor
to carpet

260 - 310

15

(2.7

(11.9,9.9)

M/T

u.s.A.

670 r 50
670 I 50
670 I 50

0.1 m€x.

STA'{DAND INEW)

(6

165

1/2)

-

(5

140

130
12 - 21

l1t2

r/4)

83

t3
(1

44

0.05

1.3 - 1.9

8.5

0.03

0.6

min. Reterence

3/4)

{0.002}

{0.05

-

9.1

{0.33

(0.001)

max.

{0.02}

STANDARD {i{EWI

-

3.2, 38 - 46)

(neutral)

Canada u.s.A.

M

or CVr

700 I 50
750 r 50
750 i 50

1,4 - 5 1/2)

-

13t161

max. 0.15

-

0.07)

-

0.36)

max.

700 r

700 f 50

0.2

5.510.221

0.15

1.0

(E

or

E

Canada

50

750 + 50
750 r 50

SERVICE UMIT

(0.005)

(0.01)

(0.(X)61

(0.04)

position)

L.r

3-4

ti."

Manual Transmission Section 13

Unit of

length: mm

(inl

MEASUREMET'lT

(US

qt,

Transmission oil

Mainshaft End

Mainshaft
4th

Mainshaft
gear

3rd and

gears

5th

Capacity f

Diameter of ball bearing contact arsa A
(Transmission

Diameter of
Diameter of 3rd
Diameter of ball bearing contac't area D
lClutch
Runout

t.D.
End

Thickness

t.0.
End

play

housing

play

play

.

housing

4th,

lmp

gear

sth

gear

contact ar6a C

sidel

qt)

sids)

contact area B

Thickness

play

needle

b6aring contact area A

gear

contact area

(When

tightened by lhe specifl€d torque)

B

Countershaft Diameter of

Diameter of 1st
Diameter ol ball bearing contact area C
Runout

Countershaft lst
g€ar

l.D.
End
Thickness

Countershaft 2nd
gear

t.D.
End

play

(When

tightened by the spociti€d torque)

Thickness

Spacer collar
(Countershaft

g€ar)
Spacer collar

(Mainshaft
and sth

Reverse

Synchro ring Ring-to-gear clearance
Shitt fork Fork tinger thickness lstnnd

Reverse shift fork Fork

Shift arm A Inner diameter of shift arm C contact

Shift arm

Final
Differentielcarrier Pinion shaft boro diam€ter

Differential
gear

Set ring.to-bearing

goar)

idler

B

driven

4th

gear

gear

pinion

LD.

2nd

o.D.

Length

t.D.
o.D.

Length

t.o.

Gear-to-revsrs6

Fork-to-synchro sleeve clea16nce

pawl groove
Fork-to-rev€rse idler
L-groove width

Fork-to-5th/reverse shift

Shift arm A-to-shift arm C clearance
Inner diameter of shift arm B shaft contact

Shift arm B-to-shaft clearance
Shift arm B-to-shitt

Diam6ter
Backlash 0.07

Carrier-to-pinion shaft clearance
Driveshaft bore diameter
CarrieFto-driveshaft clearance

Backlash

gear

Pinion

gear-to-pinion

Pinion

race

orrter

gear

shaft clearance

pushed

{Ring

width

gear

cl€arance

oi€c6 oin

piece

ot shift Diece contact Doint

bore diameter

clearance

shaft cl6aranca

cl6a16nce

against

point

point

gear)

3rd/4th

STANDAND INEWI

(2.0,

1.9

1.7) for overhaul

(1.9,

1.8

1.6) fo. oilchangs

-

0.r1-0.18

21.987 - 22.000

26.980 - 26.993

33.984 - 3..000

25.917 - 25.990

0.02

(0.004

max.

{0.001)

(0.8656
(1.0622

fi.3380

11.0221

39.009 - 39.025 {1.5358

3rd

0.06 - 0.21 {0.002 - 0.008)

4th

0.06 - 0.19 {0.002 - 0.007)

-

3rd
4th

30.27

30.22

30.'t2 - 30.17
.009

37

-

37

.025

11.190
(1.186 -

.4510

t1

0.06 - 0.19 {0.002 - 0.007)

24.42 - 28.17

30.000 - 30.015

35.98,1-

24.980 - 24.993

(0.001)

0.02

41.009 - 41.025

0.03 - 0.10 {0.001 - 0.004}

30.41 - 30.44

44.009 - 44.025

0.04 - 0.12

31.91 - 3'1.96

33.000

38.989

32.03 - 32.06

27.002 - 27.012

4th

33.989 - 34.000

5rh

31.989 - 32.000

ath

22.83 - 22.86 t0.899 - 0.9(X))

5rh

23.53 - 23.56 {0.926 - 0.928)

15.016 - 15.043 t0.59'12 - 0.5922)

0.032 - 0.077 {0.0013 - 0.0030)

0.73 - 1.'r8

-

6.1

6.2

7.4 - 7.6

0.35 - 0.65

12.7 - 13.0

0.5 - 1.1

7.15 - 7.35

0.05 - 0.35

-

13.05

0.05 - 0.23

13.973 - 14.000

0.013 - 0.070 {0.0005 - 0.0028)

0.2 - 0.5

12.9 - 13.0

-

0.130 {0.0028 - 0.0051) 0.180

18.010 - 18.028

0.023 - 0.057 t0.0009 - 0.0022)

26.025 - 26.04s

0.045 - 0.086

0.05 - 0.15 {0.002 - 0.006}

-

18.042

-

0.055
(0

0 - 0.1

.119

t1

36.000
max.

(1.197 -

{0.002

(1.256 -

-33.0r0

-39.000
(1.261 -

(0.029

1O.211-

-

(0.291

(0.014-

(0.50

-

(0.020

(0.281
(0.002

'13.'t3

(0.514

(0.002 -

-

(0.008

(0.508-

(0.7091
(1.0246 -

(0.0018 -

'I8.066

{0.7103 - 0.7113)

(0.0021

0.095

-

0.004)

(1.1811 ­(1.4167 ­(0.9835 -

t1.6145

(1.7326

-

fi.2992

{1.5350
(1.0631-

(1.3381 ­(1.2594 -

-

O.2521

0.299)

-

0.5'l)

0.043)

-

-

{0.550r - 0.5512}

0.020)

0.007)

-

0.8661)

-

1.0627)

-

1.33861

-

1.02321

Adjust

21.930

26.930

33.930

25.920

0.05

'1.5364)

-

39.07

0.33

-

1.1921

1.188)

-

1 .15711

-

1

.1211

1.1817)

1.4173)

0.9840)

-

1.6152)

1.198)

-

1.7333)

0.@5)

1.258'

-

1.2996)

-

1.535,r)

1.262)

1.0635)

1.3386)

1.2598)

0.046) 0.4

0.026)

0.289)

0.014)

-

0.517)

0.009) 0.35

0.512)

-

0.7@81

0.31

30.15

30.05

37.07

0.31

28.35

29.950

35.930

24.930

0.05

41.07

0.22

30.36

44.07

0.24

31.85

33.04
3{'.93

32.01

27.05

33.93

31.93

22.81

23.51

15.08

0.r4

(0.016)

to

roonr

(0.07)

1.8
(0.02)

0.5

0.16

0.62
't2.78

o.ogu

1.0254)

0.0034)

-

0.0037) 0.15

0.11 {0.006)

Adjust with shim

SERVICE Ui T

(0.8634)
(1.0602)

t1.3358)
(1.0205)

(0.002)

(1.538)

{0.013}
(0.012)

(1.187)
(1.183)

(1.459)

(0.012)

(1.1161

{1.1791)
(1.4146)

(0.98151

{0.002)

{1.617)

{0.009}

(1.195)

(1.735)

(0.009)

(1.254)

fi.3011
(1.533)

(1.260t

{1.065)
(1.336)

(1.257)
(0.898)
(0.926)

{0.594)

(0.006)

{0.014}

(0.006)
(0.02441

(0.5031)

(0.007r)

to.ooot

(0.006)

3-5

Standards and

Automatic Transmission - Section

Service

-

ctl;ttt

MEASUREMENT

Transmission
flu id

Hydraulic
pressure

(kgtcm', psi)

Capacity

pressure

Line
lst

clutch

.2nd

clutch

3.d and

f

pressure

pressure

4th

lmp

{US

2,OOo rpm in E or

at

at 2,000

at 2,000

pressure

clutch

qt,

tion

(Ch€ck

Stall speed rpm
Clutch

with vehicle on level

initialclearance

Clutch

return spring free

Clutch

{A4RA,
(M4RA

Clutch disc thickness

plate

Clutch

Clutch end
(A4RA,

B4RA Transmission)

Clutch end

Transmission)

{M4RA

Transmission)

B4RA

Transmission)

thickness

plate

thickness

plate

thickness

Limits

tt t.l

14

q0

position

E
Pll

E

position

position

posi'

lQl

lst, 2nd

4th

3rd,

lst

2nd,3rd,

lst

2nd,3rd,

lst

2nd,3rd,4th

4th
4th

Mark 1

Mark 2
Mark 3
Mark 4
Mark 5

6

Mark
Mark 7
Mark 8
Mark 9

Mark 1

Mark 2

Mark 3

Mark 4

Mark 5

Mark 6

Mark 7

Mark 8

Mark

9
Mark 10
Mark 1l

12

Mark
Mark 13
Mark 14
Mark 15
Mark'16
Mark 17

18

Mark

rpm in

rpm in

2,000 rpm in

at

ground) 2,700

longth

(6.2,

5.9

2.7

{2,9,

-

830

800 - 850
with linear solenoid connector

disconnected

150

0-

with linear solsnoid

battery voltage

810 - 860

with linear solenoid

disconnected
0-150(0-1.5,0-21)

with linear solenoid

battery

0.6s

0.40 - 0.60

32.0

30.5
31 .1

30.5

1.88 - 2.00

1.55 - 1.65

1.95 - 2.05

2.05

2.15 - 2.20

2.25

2.35,2.40

2.{5

2.55 - 2.60

2.65 - 2.70

2.75

2.85 - 2.90

2.3 - 2.4

2.4-2.510.094-0.098)

-

2.5

-

2.6

2.7 - 2.8

2.8 - 2.9

2.9 - 3.0

3.0 - 3.1

3.1 - 3.2

3.2 - 3.3

-

2.0
,2.2

2.r

2.2 - 2.3

3.3 - 3.4

3.4 - 3.5

€.5 - 3.6

-

3.6

3.7 - 3.8

STANDARO

5.2)tor overheul

2.4}lor fluid change
(8.5

880

(8.2

(0-

(8.3

voltage

-

(0.026

0.85
(0.016

(1.26)
{1.20)

11.22)
(1.20)

(0.074
(0.061

10.077

-

(0.081

2.10
(0.085

-

2.30

{0.089
(0.093

-

(0.096

2.50
(0.100

(0.104

-

(0.r08

2.80
(0.112

(0.091

(0.098

2.6
(0.102

2.7
(0.106

(0.110
(0.114
(0.118
(0.122
(0.126
(0.079

2.1
(0.083
(0.087

{0.130
{0.134

(0.138
(0.142

3.7
(0.146

{NEWI

-

9.0,

-

8.7, 120

1.5,0-21)

-

8.8. 1'18 - 125)

-

0.033)

-

0.024)

-

0.079)

-

0.065)

-

0.081)

-

0.083)

-

0.087)

-

0.091)

-

0.094)

-

0.098}

-

0.102)

-

0.106)

-

0.110)

-

0.114)

-

0.094)

-

0.102)

-

0.r06)

-

0,110)

-

0.114)

-

0.118)

-

0.122)

-

0.126)

-

0.130)

-

0.083)

-

0.087)

-

0.091)

-

0.134}

-

0.138)

-

0.1421

-

0,146)

-

0.150)

120 - 130) 780

'124)

-

connected to

connector

connecled to

760
with linsar solenoid
conn€ctor

150
with
connected to
voltage

760
with linear solenoid
connector disconnocted

150
with linear sol€noid
connectecl
voltage

2,550 - 2,450

30,0
2a.s

29.1

28.5

Until
Discoloration

Discoloration

Discoloration

Discoloration

Discoloration

SERVTC€ UM]T

(8.0,

110)

(7.7,

110)
disconnected

21)

{1.5,

lin€ar solenoid

(7.8,

(1.5,21)

baftory

11 1)

to battery

{1.18)
t1.12)

(1.1s)
fi.12)

grooves

worn out

I

I

l

I

L{

L(

3-6

\-

Automatic Transmission Section

MEASUREMEifl

Transmission

Diameter of needle bearing contsct arsa

on mainshaft stator shaft

mainshaft 2nd

On
On mainshaft
On mainshaft

countershaft

On
On countershaft 3rd
On countershaft
On countershaft
On count€rshaft

reverse idler

On

lnside diameter of

On mainshaft 1st

mainshaft 2nd

On
On mainshaft 4th
on countershatt
On countershaft 3rd
On countershaft
On countorshaft

reverse idler

On
On

On stator shaft
Reverse idler
End

Mainshatt 1st

Mainshaft 2nd

Mainshaft 4th

Countelshaft 1st

Countershaft 3rd

Countershaft

Reverse idler

Countershaft
Selector hub O.D.
Mainshaft
Mainshatt 4th
Mainshatt 1st

Countershaft

Countershaft 3rd
Countershaft reverss

Countershalt

thickness

Countershaft
Countershaft 1st

stator

play

shaft

4th

gear

gear

4th

gear

1st

(left

side)
gear
gear

4th

r6verse

gear

lst

gear

shaft

noodle bearing contact area

gear

gear

gear

gear

1st

96ar
gear

4th

reverse

gear

(ATF

pump

(stator

gear

4th
gear

reverse

gear
gear

gear

distance collar length

reverse
1st

side)

shaft holder l.D.

gear

gear

gear

gear

gear

gear

gear

collar l€ngth
collar flange thickness

collar length

gear

collar length

gear
gear

gear

collar length

gear

collar flange thickness

bearing

collar

collar

collar

gear

collar

gear

collar
collar

14

collar

sid€)

flange

length

'96,
'98

'97

models

model

STANDAND NEWI SERVICE

-

22.980
3s.97s - 3s.991

31.975

30.975

36.004 - 36.017

35.980 - 35.996

27.980 - 27.993

31.975

31.975 - 31.99']

35.000 - 35.016

41.000 - 41.0't6

38.000 - 38.016

38.000 - 38.016

41.000

33.000 - 33.0r6

38.000 - 38.016

29.000
27

0.08 - 0.19

0.05 - 0.13

0.075 - 0.185

0.'1 - 0.5

0.05 - 0.17

0.10 - 0.18

0.05 - 0.18

0.10 - 0.25
5r.87 - 51.90

45.00 - 45.03

4.435 - 4.525

27.00 - 27.15

38.87 - 38.90

38.92 - 38.95

38.97 - 39.00

39.02 - 39.05

39.07 - 39.'t 0

39.12 - 39.15

39.'17 - 39.20

39.22 - 39.25

39.27 - 39.30

21.15 - 21.20

20.65 - 20.70

2.4 - 2.6

2.4- 2.6

22.993

-31.991

-

30.99'l

-31.991

13.990 - 14.000

-

41.016

18.007 - 18.020

-29.01311.1411 -

.O00 - 27 .021

14.416 - 14.434
{0.003

(0.002

(0.003

(0.004

(0.002
(0.004
(0.002
(0.004

(2.042
fl.771

(0.1746
{1.063

1.530 - 1.5311

1.532 - !.533)

1.534

1.536 - 1.537)

1.538

1.540 - 1.541)

1.542

1.544 - 1.545)

1.546 - 1.547)
(0.833
{0.813

14.5 - 14.6

14.5 - 14.6

(0.571

{0.094

(0.571

{0.094

-

(0.9047
(1.4163
(1.2589
(1
(1.4175
(1.4165
(1.1016
(1.2589
(1.2589­(0.5508

(1.3780
(1.6142
(1.4961
(1.4961
(1.6142
(1.2992
(1.4961
(0.7089

(1.0630
(0.5676

-

-

-

0.9052)

-

r.4169)

-

1.2595)

.2195 - 1.2201l-

-

1.4180)

-

1.4172)

-

1.1021)

-

1.2595)

1.2595)

-

0.5512)

-

1.3786)

-

1.6148)

-

r.4967)

-

1.4967)

-

1.61481

-

r.2998)

-

1.43671

-

0.7094)

1.14221

-

1.0638)

-

0.5683)

-

0.007)

-

0.005)

-

0.0071

0.020)

-

0.007)

-

0.007)

-

0.007)

-

0.010)

-

2.0€)

-

1.773)

-

0.178'l)

-

1.069}

-

1,535)

-

1.539)

-

1.543)

-

0.835)

-

0.825)

-

0.575)

0.102)

-

0.575)

0.102)

unit of l€ngth: mm

LIM]T

Wear or damage

Wear or damage
Wear or damage

W€ar

or damage

wuu, o, du-"n"
Wear or damage

Wear

or damage

Wear

damage

or

(in)

(cont'd)

3-7

Standards and ServiceLimits

{cont'd}

MEASUREi'ENT STANDARD INEWI

Taansmission Mainshaft 2nd

Thrust wash6r thickngss

Mainehsfl ball boaring loft
Mainshaft 1st
Counte6haft 3rd

One-way clutch contact area

Countershaft lst

Parking
Mainshaft leed
end)
Mainshaft foed

Countershaft feed
€ndl

Mainshatt sealing ring thickness

(29

mm
Mainshaft
Mainshaft
Couni6rhaft bu6hing l.D.
Mainshaft

Rogulstor
valve body

Shifting device and
parking

br6ke con-

trol
Servo body Shift fork shaft bore l.D.

pump

ATF

Differsntla

catnot

Diffsrential
pinion gear

Set ring-to-bsaring out6r race

I

Sealing ring contact

Reverse
Parking
Parking

Shift tork

pump gear

ATF

pump gear-to-body

ATF

pump

ATF

pump

ATF
Pinion shaft contact aroa l.D.

Carier-to-pinion cle616nc6
Driveshaft
Carrier-to-driveshatt cloaranco

Eacklash
l.D.

gear-to-pinion

Pinion

g€ar

thrust washgrthicknegs 3.97

gear

g€ar

gear

(1.1
bushing l.D.

bushing
sealing ring

shift fork finger thickhoss

brako

ggar

shaft

driven
driven

contscl 8re LD.

gea.

O.D.
pipe

A,

pipe

B. O.D.

pipe

in)and 35 mm

l.D.

argo LD. 35.000

pawl

valvo

bore i.D.

side clearance

gesr
g€ar

shrftclearance

clearance 0

Section 14Automatic Transmission

side

'97

'96,

washer

splined

l.D.

(at

15 mm

O.D.

(at

30 mm

{1.2

15 mm

O.D.

{at

(1.4

in))

goovo

widlh

clearance Drive

l.D.
shaft

O.D.

models

'98

model

(0.59

in) trom

in)trom end}

(0.59

in}trom

Drivan

-

4.00

4.02 - 4.05

4.07 - 4.10

4.12 - 4.15

4.17 - 4.20

4.22 - 4.25

4.27 - 4.30

4.32 - 4.35

4.37 - 4.1010.172

1.12 - 1.15

-

2.95

3.05

2.€ - 2.50

4.15 - 4.50

4.95 - 5.00

83.339 - 83.365

66.685 - 66.698

8.97 - 8.98 t0.353 - 0.354)

5.97 - 5.98

7.97 - 7.98

-

1.87

r.97 {0.074 - 0.078)

6.018 - 6.030

-

(0.r56

0.157)

-

(0.158

0.159)

-

(0.160

0.161)

-

(0.162

0.163)

-

(0.164
(0.166
(0.168

{0.170

10.171-0.1751

(0.116­(0.096­(0.175
(0.195

(0.2350 ­(0.3138 -

t651

0.

-

0.'t67)

-

0.1691

-

0.171}

-0.1131

0.120)

0.098)

-

0.177)

-

0.197) ;""i":,":","

-

{3.2810
(2.6254 -

3.282r)

2.6259)

0.2354)

0.3142)

(0.2359 -

0.2374)

9.000 - 9.015 {0.3543 - 0.3549)

8.000 - 8.015 {0.3150 - 0.3156t

2.025 - 2.075

-

5.90

14.000 - 14.010

37.000 - 37.039

0.03 - 0.05 {0.00t - 0.002)

0.r050

0.0350 - 0.0625

14.016 - 14.034 {0.5518 - 0.5525}
r3.980

18,010 - 18.028 {0.7091 - 0.7098)

0.023 - 0.057

26.02s - 26.045

0.045 - 0.086 {0.00r8 - 0.0034}

-

0.05

18.042

0.055 - 0.095

-

0.15

(0.0797 -

-

35.025 t1.3780 - 1.3782)
(0.232

6.00

-

0.1325 {0.0041 - 0.0052}

-

13.990

(0.0009

0.15 t0.002 - 0.006)

-

18.066

(0.0022 -

-

0.006} Adjusr

{0

0.04171

-

0.236) s.40

{0.5512 - 0.5516)

-

(1.4567

(0,00'14
(0.5504 -

{1.0246 - 1.0254)

(0.7103

-

0.0025)

0.5508)

-

0.0022)

-

0.7113)

1.4582)

0.0037) o"r

SERVICE UMIT

Wear or damage

1

I

I

Wear or damage

Wear or damage
W€sr or damag€

(0.3s2)

8.95
(0.234)

5.95
(0.313)

7.95

1.80

{0.071)

(0.2380)

6.045
(0.356)

9.03
(0.316)

8.03
(0.082)

2.08

(1.3799)

35.050

{0.213}

or other defect

lWear

37.045

{1.4585}

(0.003)

0.07

Wear

or damage

Wear or damage

(0.004)

0.1

0.12

{0.005)

to.ooot

L

Automatic Transmission

MEASUREMENT

-

Seqtion

ltt

STANDARD

(NEWI

Unit ot length: mm

{in)

Springs

Regulator
Regulator valve spring
Stator
Modulator valve spring
Torque convoner
Cooler
Reliel valve spring
2nd orifico

1-2 shift valve spring
2-3 shift
3-4 shift

1st accumulator
4th accumulator
4th

accumulator
2nd accumulalor spring
3rd accumulator
2nd accumulator
3rd accumulator
2nd accumulator spring
Lock-up shilt
Lock-up timing v6lv6 spring
Lock-up cont.ol
3-4 orifico
Servo control valve 6pring

valve spring

CPC
CPB valve spring

cw Sostion

Transmiasion
fluid

Hydraulic
pressure

MPa
(kg7cm,,

Stall sp€6d

Clutch

psi)

rpm

position

E
E, E, B

{Ch6ck

positions

valve spring A

reaction spring

relief valve spring

control valve spring

valve

spring

valve spring

valve spring

controlvalve spring

B

check valve spring

spring

spring B

A

spring

A

A

spring

spring I

B

spring

C

valve spring

14

(US

qt.

Capacity

Forward clutch

Reverse brake

Drive
Drivgn
Lubrication

with vehicle on levsl

Clutch initisl clearance

Clutch return spring

Clutch disc thickn€ss

Clutch

f

pr€ssure

pressur€

pulley pre$ure

pulley pressure

pressure

plate

thickn€ss

(0.071)

1.8
(0.071)

1.8
(0.177)

4.5
(0.055)

1.4
(0.039)

1.0
(0.039)

1.0

1.1

{0.043)
(0.028)

0.7

0.9

{0.035)
(0.03s)

0.9
(0.035)

0.9
(0.083)

2.1
(0.09r)

2.3
(0.102)

2.6
(0.094)

2.4
(0.110)

2.8
(0.063)

1.6
(0.087)

2.2

2.210.0811

0.9

{0.035)
(0.035)

0.9
(0.028)

0.7
(0.028)

0.7
(0.039)

1.0
(0.024)

0.6
(0.035)

0.9
(0.0351

0.9

MEASUBEMENT

qr)

lmp.

at 1,500 rpm in

1,500 rpm in

at

at 1,500 rpm

at 1,500

at 3.000

ground)

lree length Forward clutch

rpm in

rpm in

position

Lql

position

El

position

in

E

position

Lll

position

E

Forward clutch
Start clutch
Reverse brake

Start clutch
Reverse brake
Forward clutch
Stan clutch
Rovers€ brake
Forward clutch
Start clutch
Roverse brake

(0.584)

14.7
(0.381)

9.6
(1.407)

35.4
(0.374)

9.4
(0.334)

8.4

8.4

{0.334)

8.6

{0.342)
(0.262)

6.6

7.6

{0.302)

7.6

{0.302)
(0.302)

7.6

16.0

{0.636}

r0.2

{0.402}
(0.676)

r7.0

(1.152)

29.0
(0.695)

17.s
(0.3s8)

9.0

3r.0

11.220)

14.5

{0.576}

7.610.3021
(0.3'19)

8.1
(0.262)

6.6
(0.262)

6.6
(0.322)

8.1
(0.223)

5.6
(0.322)

8.1

6.1t0.2421

STANDABD INEWI

(6.8,

5.6) for overhaul

6.4

3.9

3.4) for fluid change

{4.1,

1.4 - 1.75 114.3
1 .4 - 1 .7 5

0.2

1.5 - 2.3

Above 0.2

2,500
3,000

0.6 - 0.8

0.5- 0.7

0.45 - 0.75

30.5

40.9

29.4

1.88 - 2.00

1.88

1.94 - 2.06

1.95 - 2.05

2.25 - 2.35

1.90 - 2.00

-0.7

12.0

(15.3

(0.024
{0.020

(1.201)
{1.6't0)

t1.1571

-

2,00

114.3

-1.1,28 -

-

(2,

30)

(0.018

{0.074
(0.074

{0.076
(0.077

{0.089
(0.075

(3.4s7)

87.8
(1.732)

44.0
(1.193)

30.3
(1.378)

35.0
(1.331)

33.8

33.8

{1.331)

37.1

{1.461)

34.8

{1.370)
('1.626)

4'1.3
57 .0

t2.2441

57 .0

12.2441

89.1

{3.508)

51.6

{2.031)

.0

a1

13.4251

(1.535)

39.0
(3.5161

89.3

20.7

{0.815)
(1.382)

35.1
(2.677)

68.0

73.7

12.9021

(3.r77)

80.7
(1.4961

38.0
(

37.5

52.1

{2.051)

12.2

{0.480)

47.211.858)

(1.433)

36.4

-

17.A.203 - 2531

-

17

203 - 2331

.8,

1011

23.5. 218 - 334)

-

0.031)

-

0.028)

-

0.030)

-

0.079)

-

0.079)

-

0.081}

-

0.081)

-0.093}

-

0.079)

1.4751

SERVICE LIMIT

2.350 - 2,650
2,800 - 3,100

28.5

t1.122)
(1.531)

38.9
27 .4

11.O79J
grooves

Until

grooves

Until
Oiscoloration
Discoloration
Discoloration

16.5

11.0

1.9

10.9
8,2

13.4

22.0

26.8

26.8

13.8

14.2

2.9

15.6

6.1

2.4

13.9

32.0

45.8

14.1

21.6

20.4

5.5

18.3

19.5

worn out
worn out

(cont'd)

3-9

Standards

CvT

{cont'dl

Clutch

and Service

-

Forward

Reverse brake end

pump

ATF

Transmission

ATF
ATF
ATF

ATF
ATF

Diameter of needle bearing contact are

Thrust clearance

Limits

Section

pump
pump
pump

pump gear
pump gear-to-body

lnout shaft - flvwheel side
Input shaft - forward clutch side
Drive
Drive
Drive

Carrier and ring
Driven
Input shaft and ATF
Secondary

14

MEASUREMENT

piate

end

clutch

gear

drive
driven
body bushing

side clearance

shaft - start clutch side

Dullev
pulley

shaft - flywheel side
shaft - forward clutch side

oullev

pulley

goar

thickness Mark 1 or

plate

thickness

shaft O.D.

gear

shaft O.D.

LD. Driv€

clearance

gear

shaft and start clutch

pump

and flywheel ball bearing

shaft

drivon sprocket

vlark 2 or'16
Mark 3 or
Mark 4 or 18
Mark 5 or 19
Mark6
Mark7 or 2l
Mark
N4ark 9 or 23

Mark
Mark 11 or 25

Msrk
Mark 13 or 27

U::I I

vlark 3

vlark 4

Vlark

vlark 6

t4ark 7

vlark 8

g€ar

gear

Driven

gear

Drive

gear

Oriven

hub

or
8 or
10

or 24

'12

or 26

5

shaft

STANDARD

-

15

3.4

3.5 - 3.6

17

3.6 - 3.7

3.7 - 3.8

3.8 - 3.9

20

3.9

4.0-4.t

22

4.1 - 4.2

4.2 - 4.3

4.3 - 4.4

4.4 - 4.5

4.5 - 4.6

4.6 - 4.7

3.55

3.75 - 3.85

3.95

4.15

4.35 - 4.45

4.55 - 4.65

4.75 - 4.85

4.95 - 5.05

9.98 - 9.99

9.98 - 9.99 {0.3929

shaft

0.015 - 0.035 {0.0006

0.035 - 0.0505 {0.0014-0.0020)

0.035 - 0.0505

43.981 - 43.991

24.007 - 24.020

24.007 - 24.020

0.050

0.000 - 0.130

0.370 - 0.650

0.00

(0.134

3.5
(0.138
(0.r42
(0.146
(0.150

-

4.0

{0.154
(0.157

(0.161
{0.165

(0.169
(0.173
(0.177
(0.r81

-

(0.140

3.65
(0.1€

-

(0.r56

4.05

-

(0.r63

4.2s

{0.171
(0.r79

(0.187
{0.19s
(0.3929

10.000 10.015

10.000 - 10.015

19.987 - 20.000

19.987 - 20.000

-

0.r 10

-

(0.00

0.1s

IiIEW}

-

0.138)

-

0.142)

-

0.r46)

-

0.150)

-

0.1s4)

-

0.157)

-

0.161)

-

0.165)

-

0.169}

-

0.1731

-

0.'177)

-

0.r81)

-

0.185)

-

0.'|44)

-

0.152)

-

0.1591

-

0. t67)

-

0.175)

-

0.1831

-

0.1911

-

0.199)

-

0.3933)

-

0.3933}

-

(0.3937
t0.3937

(0.0014-0.0020)

(0.7869
(0.7869

{1.7315
(0.945

(0.945

(0.0020
(0.000-

{0.015-

-

-

-

0.0014}

-

-

-

-

-

-

0.004:))

0.005)

0.026}

0,006)

0.3943)

0.3943)

0.7874)

0.7874)

1.7319)

0.946)

0.946)

SERVICE

Disco

loration

Disco

oralron

Disco

otalton

loration

Disco
Woar or damaged

Wsar or d€mag€d
Wear or damaged
W6ar or damagad

(0.0021

0.050

Wear or damaged
Wear or damaged
Wear

or
Wear or damagod
Wear or damagod

LMTT

damaged

\-- {

L{

3-10

L(

cw

_.an3mission

conld)

device

Shifting

parking

and

brake control

Saction

14

MEASUREMENT

Thrust shim.25 x 31

Cottelslhickness

pump

ATF
thickness

Secondary

thickngss

Input shaft l6ed

Input shaft bushing l.D.

Driven shaft teed

Driven

Secondary
Stan clutch e-nd
Input shaft sealing ring
Drive

Parking brako
Parking brake
Parking

drive sprocket

gear

pulloy

Drivs

Forward clutch feed

pull€y

Drive

Forward clutch
Start clutch

pulley

Driven

Start clutch feed

pullsy

Start clutch

pulley

Drive

Stan clutch

driven

pulley

gear

mm thickness

shaft

pip€

O.D.

pipe

leed

pipe

foed

feed

pipe

pipe

f66d

teed

pipe

shaft bushing LO.

pip6

feed

pipe

feed

pipe

feed

gear

plate

shaft l.D. at sealing

cone

pawl

thrust shim,

thrust shim, 25 x 35

pipe

bushing

pip€

bushing

O.D.

(right

pip€

(flywhe€l
(right
(fl)'wheel

sealing

l.D.

groove

22 x 28 mfi

side cover side)

housing side)

side cover

housing sido)

groove

ring

width

ring

mm

sidel

width

STANDARO INEWI

1.02 - 1.05

1.09 - 1.12
'1.16

1.23 - 1.26

1.30 - 1.33

1.37 - 1.40

1.44

1.51

1.58- 1.61

1.65

1.72 - 1.75

1.79

1.05s - 1.085

1.125

1.195

1.265

1.335 - 1.365

1.405 - 1.435

1.475 - 1.505

1.545 - 1.575

1.615

1.685 - 1.715

1.755 - 1.785

2.87

2.97 - 3.00

3.07

3.17 - 3.20

1.12

1.37 - 1.40

1.62
r.87 - 1.90

2.'t2 - 2.15

2.37 - 2.40

2.80 - 2.85

2.90 - 2.95

3.00 - 3.05

3.10 - 3.15

3.20 - 3.25

3.30

3.40 - 3.45

3.50 - 3.5s

3.60 - 3.65

3.70 - 3.75

3.80

6.97 - 6.98

11.47 - 11.48

7.000

11.500 - 11.518

6.97 - 6.98

11.47 - 11.48

8.97

7.000 - 7.015

11.500

9.000 - 9.015

2.50 - 2.65

88.900 - 88.935

2.00 - 2.10

24.007 - 24.020

(0.040
(0,043

-

(0.046-0.047)

1.19
(0,048
(0.051­(0.054

-

1.47

{0.057

-

(0.0s9

1.54
{0,062

-

(0.065

1.68
(0.068

-'!.82

(0.070

-

1.155

-

1.225

-

1.295

-

1.645

-

(0.113

2.90
(0.117

-

(0.121

3.10
(0.125

-

(0.044

1.15
(0.054

-

1.65

{0.064
(0.074

(0.083
(0.093

{0.110
(0.114

(0.118
(0.122
(0.126

-

(0.r30

3.35

10.134

10.138

(0.142

10.146

-

(0.150

3.85

(0.274-0.275)

-

7,015

(0.274

-

(0.353

8.98

't

-

1.518
{0.098

{0.079

(0.0415
(0.0443
(0.0470
(0.0498
(0.0s26
(0.0553
(0.0580
(0.0608
(0.0636
(0.0663

{0.0691

(0.4516
(0.2756

(0.4516

{0.2756
{0.3s4

-

0.041)

-

0.044)

-

0.050)

0.052)

-

0.055)

-

0.058)

-

0.061)

-

0.063)

-

0,066)

-

0.069)

-

0.072)

-

0.0427)

-

0.0454)

-

0.0482)

-

0.0510)

-

0.0537)

-

0.0565)

-

0.0593)

-

0.0620)

-

0.0648)

-

0.0675)

-

0.0703)

-

0.114)

-

0.118)

-

0.122)

-

0.126)

-

0.04st

-

0.055)

-

0.065)

-

0.075)

-

0.085)

-

0.094)

-

0.112)

-

0.116)

-

0.120)

-

0.124)

-

0.128)

-

0.1321

-

0.136t

-

0.140)

-

0.1441

-

0.148)

-

0.1521

-

0.4520)

-

0.2762)

-

(0.4528

-

0.275)

-

0.4520)

-

0.354)

-

0.2762)

-

(0.4528

-

0.355)

-

0.104)

-

(3.500

-

0.083)

-

(0.945

0.4535)

0.45351

3.5011

0.946)

length: mm

Unit of

SERVICE UMTT

or oamageo

or damaged
or damaged

Wear

Wear or damaged

Wear

or damagsd

+

I

I

Wear or damaged

or damaged

or oafiaqeo

(0.274)

6.95
(0.45'I)

11.45

7 .030

10.2171

(0.454)

11.533

6.9510.27{}

11.45

{0.451)

8.95

{0.352}

(0.277)

7.030

(0.454)

1'1.533

(0.3561

9.03
(0.105)

2.655

Wear

2.105

Wear or damagsd
W6ar

Wear or other daf€ct
Wear

damaged

or
(0.083)

other defect

or
or other defect

(cont'd)

(in)

3-11

I

Standards

CW

{cont'd}

D iffe rontia

carier

Differential
gear

I

pinion

and Service

-

Sectaon 14

Pinion shaft
CarrieFto-pinion
Drive
Carrier-to-driveshaft

Backlash
t.D.
Pinion

Set ring'to-bearing

Springs

Steering

outer race

PH 169ulator
PH
PL 169ulator
PH-PL

Clutch r€ducing valve
Lubrication
Shift valve spring
Shift
Start clutch control valve
Pitot regulator
Start clutch
Rgverse control valv6
Shift inhibitor valve

-

Section 17

MEASUREMEiTT

contact area l.D.

shaft contact area l.D.

cl6arance

clearance

gear-to-pinion

clearance

MEASUREMENT

control valvo

valve spring

spring

valve spring

control valve spring

valve

spring

control valve spring

valve

valve accumulator

spring

spring

Limits

shaft clearance

spring

spring

spring

spring

Wir. Dia.

1.2

t0.0471
(0.067)

1.7

0.9

{0.035)
(0.039)

1.0
(0.075)

1.9

1.6

t0.063)

1.4

{0.055}

1.0

{0.039)
(0.016)

0.4
(0.024)

0.6

1.2

{0.047)
(0.047)

1.2

1.3

{0.051)

STANDARD

0.057

0.086

(0.002

(0-

0.006)

(0.7091 -

(0.0009

(1.0246

(0.0018 -

(0.7103

(0.0022

18.010 - 18.028

-

0.023

26.025 - 26.045

-

0.045

0.0s - 0.15
r8.042 - 18.066

0.05s - 0.095

-0.15

0

o.D. FJ.. Longth

(0.354)

9.0
(0.528)

13.4

7.2

t0.283')

(0.391)

10.0

16.8

{0.661}
(0.528)

13.4
(0.323)

8.2

7.4

{0.29r)

4.1

{0.161)

5.7

10.2211
(0.327)

8.3
(0.370)

9.4

(0.s20)

13.2

{NEW} SERVICE LIMTT

0.7098)

-

-

0.006)

-

0.0022)

-

1.0254)

0.0034)

-

0.71r3)

0.0037)

25.7

39.4

14.6

31.4

41.4

51.6

34.1

19.3

12.1

9.5

29.8

31.4

48.3

{1.236)
i'1.7

{2.031}
(1.343)

{0.760}
(0.476)

(0.374)
('t.173)
(1.236)

{1.902)

0.1

0.12

nru

Adjust

{1.051}
(1.5511

(0.5751

481

(0.004)

(0.005)

to.oout

No. of

Li

Coilt

10.0

4.7

8.6

8.0

11.6

13.0

6.8

5.0

12.3

11.0

10.6

Steering wheel

G6arbox

Pump

Power stee ng
fluid

Power

steering

belt*

M/S: Manual
*:

When

using a new

Readjust

the deflection or

Play at

steering wheel circumference
Starting load
N

lbf)

{kgt.

lvlanualsteering
Power

Angle

of rack

trom

locked

Preload

at

pressure

Pump

temp./speed: 40'C

{oil
Do not run for
kPa

{kgflcmr,

Recommended
Fluid

capacity f

Deflection
between

Tonsion

(kgt.

N

lbf)

steering, P/S: Power

belt, adjust deflection

tonsion to

MEASUREMENT

at steering wheel

steering

guide

screw loosened

position

pinion

gear

with valve

morethan

psi)

power

(US

with 98 N

pulleys

measured with

steering

('10

or tension to new values.

used belt

circumference

shaft N.m

(105'F)

steering tluid

qt,

kgf,

belt tension

(kgf.cm,

closed

min.,4dle.

5 seconds).

qt)

lmp

22 lbt)

816A2
Other Engin€ Types
816A2 Engine Type
Othor Engine

values.

Engine

running

lbtin)

Reservoir

gauge

Engine Typ€

Types

Run the

0-10{0-0,4)

(1.5,

15

29

{3.0,

M/S

2015"
20 Max

M/S

0.5 - 1.7

0.6- 1.2

6,400 - 7,400

HONDA

(0.90,0.75)

0.85

0.4

{0.42,

10.5 - 14.0

7.5 - 10.0

only

390 - 540
340 - 490

only

-

740

880

640 - 780

engine for 5 minut6s

STANDARD

3.3)

6.5)

-

17,

4.3 - 14.8)

{5
(6-

Power Steering Fluid-V

0.35)
{0.4'l

(0,30

(40
(35

(75
{65

-

12,5.20

(65

-

-

-

-

10.42)

-

75,

920 - 1.070)

at disassembly

-

0.55) with

-

0.39) with new

55, 88 - 120) with
50, 77 - 110) with
90, 170 - 200) with
80,

'176}

-

143

then turn it

usod belt

wirh new

off.

(NEwl

\-l

or S

belt

used belt
used belt

new belt

belt

3-12

Suspension

alagnment

Wheel

bearing

Sestion 18

MEASUREMENT

Camber
Caster

Totaltoe
Front wheel turning angle Inward wheel

Rim runout

play

End

Outward

Aluminum wheel Axial
Steelwheel

wheel

Front

Rear
Front
Front

Rear

Radial
Axial
Radial

Front
Rear

STANDARD I EWI

'1"

0.00' l

1.40'r 1.
In 1.0 t 2.0
In 2.0
39"50'
33'10'(Reference)

0 - 0.7
0 - 0.7
0 - 1.0

-

0
0 - 0.05

0 - 0.05

:i3

1.0

{1/161

-

{0

-

(0

-

(0

-

(0

-

(0

-

(0

(1/16

0.03)

0.03)

0.04)

0.04)

0.002)

0.0021

t 1/16)
1/15)

Unit ot

SERV|CE UitlT

(0.08)

2.0

1.5

{0.05}
(0.08t

2.0
(0.06)

1.5

lgngth: mm

(in)

Brakes Section

Parking brake
lever

Foot brake
pedal

Master cylinder Piston-to-pushrod
Disc brake Disc thickness

Rear brake
drum

*1.

5410 Stamped on the caliper body.

*2.

2056

Stamped on the caliper

19

Play in stroke at 196 N

(with

hoight

Pedal

play

Free

runout Front

Oisc

parallelism

Disc
Pad thickness

t.D.

Lining thickness

body.

Air Conditioning - Section

Conditioning

Compressor Lubricant type: SP-10

Compressor
belt*

*:

When using a new belt. adjust

Roadjust

deflection or tension

Lubricant type: SP-'10
Lubricant capacity
m?

Lubricant capacity mf
Field coil resistance at 68"F
Pulley-to-pressure

Deffection with 98 N
between

Belt tension N
Measured with belt tension

lmp oz) Evaporator

oz,

lll

pulleys

deflection or tension to new values. Run the engin€

to used belt values.

MEASUREMENT

(20

kgf.

44 lbfl

lover

force

floor mat refioved) M/T

A,/T, CW

cl€arance 0

Front
Rear

Front and rear
Front

22

MEASUREMENT

-

P13 - AoIAH

38897

oz, lmp 02)

{20'C}

gauge

or 3889

Condenser
Line or hose

Feceiv€r

o

plate

(kgf,

(P/N

(ll
clearance

(1O

kgf,22lbtl

lbf)

STANDANO

To be locked when
6 - 9 notchos

(6.16)

156.5
(6

161

5/16)

1-5(1/16-3/16)

-

-

(0

0.4

0.02)

20.9 - 21.8

9.5 - r0.5r1

8.5

200 0 .a7l

4.0

-

P13 - A01l
20
45
10
10

130 - 1s0

3.05-3.35

0.5

7.5 - 9.5

5.0 - 6.5 {0.20 - 0.26)

340 - 490
690

(0.82

-

9.5*'

(0.16)

0.71

l2/3

2f3, 1 .61

11
(1/3,

0.4)

(1/€,0.4)

(4
(0.020

r 0.15

{0.30

(35

-

(70

830

tor 5 minutes then turn it off.

INEWI

pulled

-

0.86)

STANDARD {l{EW)

retrigerant HFC-134a

{For

r/3 - 4.6, 5.0 - 5.3)

r 0.006

-

0.37) with used belt
wilh new

-

-

77

50,

-

85, 150 - 190) with new b€lt

)

'110)

with

19.0

0.1s,(0.004)

0.10

0.015

1.6

1.6

201

2.0

bolt

usod

SERV|CE Ui,llT

{0.75}
(0.004)

(0.00061

{0.06)
(0.06)

(7.911

(0.08)

(R-134a})

belt

3-13

Standards and Service

Electrical

-

Section

23

Limits

MEASUREMENT STANDARD

lgnition coil Rated voltage V

lgnition wire

plug

Spark

Primary

winding resistance at 68'F

S€condary winding resistance at 68'F

Resistance at 68"F
Firing

order

(20"C)

k0

Tvpe
Gap

lgnition

timing

Alternator belt* Oetlection with 98

Alternator
(MITSUBISHI}

motor

Starter
(MITSUBA

1.0 kw

1.2 kW)

*:

When using a new belt, adjust deflection or tension

Readjust deflection or tension to used belt

Ar idle
"

(Red)

BTDC

N

betlveen
Belt tension N

Measured with

Output
Coil resistance
Slip ring O.D.

Brush length
Brush spring

Type
Commutator mica depth
Commutator runout
Commutator O,D.

Brush
Brush spring tension
N

pulleys

13.5 v at hot A

l.ngth

(ksl,

lbf)

11okgl,22lbf'l

lbf)

lkgf,

belt tension

(rotor)

tonsion

(new)

values.

at 68'F

gauge

120"C)

(oz)

g

to new values. flun the engine lor 5

(20'C)

(20"C)

k0

0

HITACH I
TEC

kO

HITACHI

INEWI

12

0,45 - 0.55

0.63 - 0.77

22.4 - 33.6

12.4- 19.2

1-3-4-2
See section 23

1,0- 1,1

(0.043

_i

oo.)

12+2

-

10.5

8.0

6.0 8.5
340

540 - 740

-

(0.26

490

{0.31 - 0.41)

-

(35

-

(55

STANDARD

3.4 - 3.8

22.7 t'.agl |
1qnro76l | 50{0.20)

-

(10.6

450

300
Gear reduclion

0.4 - 0.5

0 - 0.02

28.0

15.8 16.2

15.7

(1.60

(0.016

(0

-

28.1

-

17 .7

-

1.80, 3.5
minutes

-

0.0008)

(1.102
(0.62

with usod

0.33)with new belt
77 - 110)

50,
75, 121 - 165) with new belt

belt

with used belt

(NEWI

22.210.87)

-

15.9)

-

0.020)

-

-

0.64)

-

4.0)
then

1.106)

turn it off.

t--'

0.15

0.05

27.5

11.0

SERVICE UM]T

(0.006)
(0.002)
(1.083)
(0.43)

{

3-14

L{

Design Specifications

Unit ot lengthi

mm

{in)

I

a

DIMENSIONS Overall

OverallWidth
Overall

Wheelbase
Track
Ground
Seating Capacity

WEIGHT

WEIGHT

E NGINE

STARIER

(USA)

(CANADA)

Gross

2-door

2-door Hatchback CX.

4-door Sedan OX, LX

Gross

2-door Coupe

2-door Hatchback

4-door Sedan

Cylinder Arrangement
Bore and Stroke
Displacement
Compression Ratio

Valve Train
Lubrication

Pump Displacement at 6,800 engine

Oil
Water Pump Displacement
at 6,000 engine rpm
FuelRequired

Type/Make
NormalOutput
NominalVoltage

Ratino

Hour
Direction of

lTEM

Length 2 door Coupe/+door

Height 2-door Coupe/2-door

Vehicle Weight

Vehicle Weight Rating

2-door Hatchback

Hatchback
tl-door

Sedan

FronvRear

Clearance

Coupe DX, HX

System

notation

Rsting

HX A,/T
EX
HX CVT
HX

DX with ABS

LX A,/T with ABS,

DX
DX

si(1996)

si(1997)

cX

cx
cx
LX, EX M/T
EX

D16Y7, Dl6Y5
016Y8

{GVWR)

M/I

(1996)
(1997)

CVT

(1996,

DX

M/T, LX Ay'T

{GVWR)

(1996)
(1997)

(1996),
(1997),
(1998),

A/T

Sedan

1997)

{1996,
(1998)

1997)

(1998)sMT

EX

(1996)

cX-G

(1997)

CX-G
DX

{1998)

rpm

METBIC

4,445 mm

mm

4,170
4,180 mm

1,705 mm

mm

1.375
1,390 mm

2,620 mm

1

,47511 ,175

4AT

wat6r-cooled, +stroke SOHC*',

VTEC'3, SOHC

75.0 x 90.0 mm
'1,590

Belt driven, SOHC

Forced and wet sump,

33.4 f {35.3 US

1251

UNLEADED

reduction/MITSU

Gear

mm

'150

mm

1,500 kg
1,510 kg
1,560 kg

1.570 kg
1,495 kg

kg

1,505

kg

1,510
1,510 kg

't,540

kg

4-cylinder, transverse

Inline

(m/)

cm3

(132

US

Octane Numbsr or

1.0 kw, 1.2 kw

Clockwise as

ENGUSH NOIES

'175.0

in
in

164.2

164.6 in
in

67.1
in

54.'1

54.7 in

103.1 in

58.1/58.1

5.9 in

3,290lbs

rbs

3,330

tbs

3,440
3,220 tbs
3,330lbs
3,285 tbs

tbs

3,290

3,300 lbs
3,330lbs
3,460lbs

SOHC

1
1

9.4

9.6
4 valve

trochoid

110 lmp

wilh 86 Pump

gasoline

2.95 x 3.54 in

97.0 cu-in

per

cvlind€r

pump

qt)/minut€

higher

WEC-E*1

qt,29.4lmp qt)/minute

qt,

gasoline

gA

12V

30 seconds

vigwed from

gear

end

in

engine

*,:
*3:
*+:

Dl6Y7
Dl6Y8
D'|6Y5

(cont'd)

3-15

Design Specifications

(cont'dl

STARTER

CLUTCH

(cont'd)

Weight MITSUBA 1.0,

Clutch Type

Clutch Facing Area

TRANSMISSION Transmission Type

Primary Reduction

TRANSMISSION Manual transmission

Gear Ratio 1st

FinalReduction Gearratio

Automatic

Goar

Final Reductaon Gear

transmission

Ralio lst

cw

Gear Ratio Low - O.D.
Secondary Reduction Gear Ratio

AIR
CONDITIONING

Final Rgduction
Cooling Capacity

Compressor Type/Make

Condenser

Evaporator Type

Blower Type

Tgmp€rature

Compressor Clutch

Refrigerant Type

Gear

No.
Cspacity
Max.
Lubricant Capacity

Control

|TEM METRIC

1.2 kW 3.4 kg 7.5

Mlf
CW

Synchronized 5-speed forward, 1 reverse

CW

D16Y5 D16r' D16Y8

2nd
Jro
4th
5th
Beverse

tYPe

G€ar

2nd
3rd
4th
Reverse

ratio

Gear type

Revelse

Ratio

Cylinder

of

Speed

Type Corrugated

Motor Input
Speed Control
Max. Capacity

Type

Power Consumption

Ouantity

plate

Single

Non-stage

3.250

1.742

1.172

0.909

0.102

3.153

3.722

3,530 Kcal/h

u5,/ mt/tev I i.zz

Torque converter

plates

Multi

160 crn'

4-speed automatic, 1 reverse

speed

3.7 22''

Single helicalgear

D,I6Y' D16Y8

2.600
'L468

0.926

0.638

1.954

1.35"1 4.357
Single helicalgear

2.466 - 0.449

Scroll/SANDEN

'130

mf

Corrugated fin

4-speed

460 m3/h

Dry. single

40 W max./12 V at 68'F

HFC-134a

6so

hs

ENGLISH NOTES

dry, diaphraom

wet sanp,

Direct 1 : 1

Engine typ€

3.250

1.182

1.172

0.909

0.102

3.153

hydraulic

25

|

forward, 1 reverse

11.034*'

Engine type

2.722

0.975

0.638

1.954

2.466

4.357

14,000 BTU/h

10,000 rpm

|
|

Sirocco

200w112v

variable

|

plate, poly-V-bell

(R-134a)

cu-rn/rev

4 1/3ll oz.

4.6lmp oz

fin

Ian

16.200 cu-Vh

(20'C)

22.9

tbf

spring

sq-in

3.250

1.909

1.250

0.909

0.702

3.153

4.250

drive

-laoz

*1:

2'door Hatch

oacx

*2:

2-door
and 4-door
Sedan

sP-10

L!

Coup6,

LJ

3-16

L{

length

Unit of

mm lin)

ITEM METRIC ENGLISH NOTES

STEEBING
SYSTEM

SUSPENSION

WHEEL
ALIGNMENT

BRAKE

SYSTEM

Type
Overall Ratio

Turns, Lock-to-Lock

Wheel Dia.

Steering

Type Front and Rear

Absorber Front and Rear

Shock
Camber Front

Caster
TotalToe Front

P/S
M/S

Rear
Front

Bear

Rear

Rear

Parking Brake Type

TIRE

Front and Rear 2-door Coupe

Size

Spare Tire

2-door Hatchback
4-door

Sedan

t

(uS

qt,

WASHER

RESERVOIR

ELECTRICAL Batt€ry

P/S: Power steering, M/S: Manual steering
*l:

2-door

*4:
*5:JAPAN

USA

(HAM),

Coupe

oroduced

*2:

2-door Hatchback

(HCM)

Canada

|

Capacity

Staner

In Underdash Fuse/Relay Box
In Under-hood Fuse/Relay Box

In Under-hood
Headlights
Front Turn
ReEr Turn Signal Lights
Brek€/Taillights
Inner Taillights*'
High Mount Brak€ Light
Back up Lights
License Plate Lights
Ceiling Light

Trunk Lights
Gauge Lights
Indicator
lllumination and Pilot Lights
Heater

Signal/Parking

Lights

Control

produced

qt)

lmp

ABS Fuse/Relay

Lights

Panel Lights

*3:

4-door Sedan

Box

HighAow

Powsr assisted, rack and

Sack and

P/S:17.7,lt4/Sr20.3

P/S:3.6, M/S: 4.1

380 rnm

Independent double wishbone, coil sprins

Telescopic, hydraulic nitrogen

In 1.0 mm
In 2.0 mm

Power-assisted sel{-adiusting

Powe.assisted self-adjusting solid disc

37.5 cm,

44.1cm, x2 6.94 sq-in x 2

67.2 cm, x 2 10.4sq-inx2

50.2 cm,

l,lechanical actuating,

P175D0R13 82S: DX
P185/65R'14 85S: EX,
P175t0R13 82S: CX, DX
P175t0Rr3 82S: DX
Pl85/65R14 85S: LX/EX

T105/80D13 Cars

T105t0D14 2'door Coupe EX
T115/70D14 DX

T125r0O14 Cars with ABS 2 door Coupe,

2-doot coupe 2.5 l.2.6,2.21
4'door Sedan 4.5
2-door hatchback 2.5

2-door Coupe EX

(Canada)
(Canada)

2-door
with ABS

4 door Sodan LX, EX
4'door Sedan EX
2-door Coupe Si
with ABS

12 V

7.5 A, 10 A, 15 A, 20 A

7.5 A, 10 A, 15 A, 20 A,30 A, 40 A, 80 A

12 V_ 18 W*" 21

12 V- 8 W

12

V-5 W

i

0.00'
1'40'

ventilated disc

\2

x2 7.8

rear

HX

(USA),

(USA),

(canada)

EX
without ABS Except

Cars

(USA),

4'door Sedan LX

Coupe

4.0}

{4.8,

(2.6,
(4.8,

4.5

12 V - 38AH/5HR

-

kW, 1.2 kW

1.0

12V-154

7.5 4,20 A, 40 A
12V-60AsW

12V 21tsW

't2

v - 21W

-21/5

12V
12V 5W

12V-21W
12V 5W

(With

(Witholt

12v-1.4W,3W
12V-1.12W, 1.4 W
12V-0.84W, 1.4 W

12V-1.4W

pinion

pinion

gas

l/16

In

5.8 sq-in

sq-in x 2

wheel

Nvo

(USA),

Si

(USA),

CX G

(Canada)

LX

(uSA),
(USA),

without ABS

(Canada)

DX

(USA),

(Canada),

(Canada)

2.2)

4.0)

W
Wrl.

moonroof)

moonroof)

15 in

filled

in

in

1/16

x 2

brakes

(Canada)

{Canada)

Si
S;

lUSA),

Cars

Cars

+3

Unit: mm
5,110 Stamped on ths

2056
caliper body

Orum
Drum l.D.:180

USA model
Canada
DX

(in)

Stamped

l.D.:200

model

on the
(7.9)

(7.'!)

Except OX

3-17

Body

2-door

Coup€:

Specifications

Unit: mm

L

(in)

3-18

L

\,

2-door Hatchback:

lr'tgl91e'l

3-19

Body Specifications

4-door

S6dan:

(cont'd)

Unit: mm

Lr'

(in)

L

3-20

(

Maintenance

Lubrication Points
Maintenance Schedule

Normal Conditions
Severe

Maintenance Schedule

Normal Conditions
Severe

Maintenance Schedule

Normal Conditions
Severe

Conditions

Conditions

Conditions

for 1996 Model

for

for 1998

............4-2

........4-4

.........

1997 Model

........

.........

Model

........4-12

.........4-14

4-6

4-8
4-10

Lubrication

Points

I

For th6 details of lubrication
proc€durss

No. LUBRICANON POINIS LUBRICANT

'I

(such

Engine

as Asssmbly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.

points

and types of

lubricants

to b€ applied,

API Service Grade: Use

grade
The oil container m8y also displsy the API
shown below.

SAE Viscosity: Se6 chart below.

rsfsr

oil.

Make

lllustrated Index

to the

SJ

it

sure

says

'Energy

"For

2 Transmission Manual Genuine Honda MTF*1

Automatic

Genuine
Automatic Transmission Fluid

Honda Premium Formula

(ATF)*,

CW Genuine Honda CVT Fluid'3

3 BrEka Ling
1 clutch Lin€ Genuine Honda

c Pow€r

6
7 Release tork
I

o

10
11
12
13

l'[
15

16
17

18

19
20
21
22

23
21

ste€ring

Shift lever

Steering

Tailgate hinges and latches

Steering

lever

Shift

P6dal linkage
Braks mast6r cylind6r

Trunk hinges
Couoe)
Door hinges
Door opening dstents
Hood hings

Fuel fillor lid
Clutch m8st6r cylinder
Throttle cabl€ ond and thronl6linksge
Rear brakg
Steering wheel

Caliper
Throttle cable end

25 Pow6r st66ring system
26 Air

conditioning comprsssor Comoressor oil:

API SEFVICE LABCL

gesrbox

pivots

{manual

(manual

boots

joints

ball

(sutomatic

lstch

and

and lower

upper

and hood latch

linkages

shoe

(back

piston

seal, dust seal,

pin, piston

caliper

(dsshboard

transmission)

transmission)

(2-door

transmission)

pushrod

(,|-door

pushrod

side)

(for

Sedan and

lower

cars with P/Sl

Hatchbackl

2-door

Danel)

API

CERTIFICAIIOII

Genuine

Stesring

Gresse with molvbdenum disulfide
Super

Multi-purpose

Honda White

Multi-purpose

Silicons

Genuine Honda Power Steering Fluid-V

SANDEN: SP-10 P/N 38At - P13
(For

SEAL

Hond8 DOT3

grease

High Temp

grease

Lithim Grease

Brake
Brske Fluid'a

DOT3

P/N

08733 - 8070E

Urea Grease

grease

grease

R6frigsrant: HFC-1348

Recornmendod Engine

(R-f

Fluid*.

{P/N

-A01AH
34a))

Oil

various work

and

Conserving"

Cenification

Gasoline Engines,"

08798 - 9002)

or S'5

or3@9-

mark

P13-A01

\-

L

q

NOTE: Th€ following information as marked
Il:

Alwsys
dogs not contain

*2:

Always

shift

*3:

Us6 Genuin6 Honda

r,l:

Always

ot the system.

:5:

Alwsys

transmission fluid can cause incr€ass w€ar

use Genuine Honda Maoual Transmission Fluid

use Genuine Honda Premium Formula Automatic Transmission Fluid

quality.

uss Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid

use Gonuine Honda

the

propor

fluid

CVT

additiv€s,

only. Using other

Pow6r

4-2

ffi

*1, *2, 13, *4

fluid

csn aftect transmission operation

Stooring Fluid-V or S. Using 8ny

8nd

poor

15

and

on above chart details for 1997 model.

(MTF).

Using motor

steoring in cold weathsr.

r ,--;--i------

Engine oil viscosity
ambrent tempe€ture ranges

oil can cause stiffer shifting

(ATF).

Using a non-Honda ATF

and

can cause corrosion and

other type of

pow6r

for

may reduce

stssring fluid

t

because

can affect

transmission lif6.

decresse the

sutomstic

or

it

(

life

@

(4{oo.

\

s.d.n)

@

NOTE:

Lubricate all hinges, latches

In

corrosive areas.

We recommend Honda White

once a

year.

locks

and

more

frequent lubrication is necessary.

Lithium Grease.

4-3

I

1996 Model

Maintenance

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4-15

Engine

Engine
Cylinder
Engine
Engine
lntake
Gooling

Removal/lnstallation

Head/Valve
Block
Lubrication

Manifold/Exhaust

Train

..........

......".'.'.... 5-1

........'..'.'."..

.....'.'..'7-1

........... 8-1

System

........ 9-1

.........

6-1

10-1

Engine RemovaUlnstallation

Removal
f nstalfation

.......5-2

...5-12

Engine

RemovaUlnstallation

Removal

@

.

Mako surs
and hoist brackets aro attached to ihe corroct

tions on th€ engine.

.

Mako surc the

you

whilo

CAUTION:
.

Uso tandar covors to ayoid damaging

face.

.

Unplug the wiri||g connoctors carefully whilo holding

the conn6ctor

.

Mrrk
Abo, be sur6 that thoy do

hos€s or interf?ro with othor

1, Secure the

2.. Disconnect the battery negative terminal first, then

3.

wiring and hosss to lvoid misconnoction.

all

positive

the

Disconnect

fuse/relay box and battery

and 3atety stands ar6

iacks

brehiclo

working und.r it.

are

poiion

hood

terminal.

the

will not roll olf rtands

ayoid

to

not

contact other

parts,

as oDen as

battery cables from the under-hood

possible.

positive

placed properly

damago.

terminal.

and fall

painted

wiring or

posi-

sur-

4. Remove

battery and battery base.

the

I x 1.25 mm
21 N.m

l2.1kgl.m,

{

17 lbf-ftl

TERMINAL

BATTERY

CABLES

Disconnect the
Disconnect the

WIRE HARNESS

MAIN
CONNECTOR

connectors from the ECM/PCM.
main wire harness connsctor.

ECM/PCM

I

(

5-2

{

\}

7. Remove the intake air duct and air cleaner housing.

D16Y7 enqine:

D16Y5, Dl5Y8 engines:

a. Disconnect the IAT sensor connector,

then

remove the intake air duct and air cleaner hous-

a. Remove the resonator and intake air duct.

6x1.0mm

AIR

INTAKE
DUCT

L

RESONATOR

Disconnect the intake air temperature

o.

sor

connector, then

remove

the air cleaner hous-

(lAT)

sen-

6x1.0mm

9.8

8. Disconnect the engine wire harness

ing.

6x1.0mm

AIR

CLEANER

9.8 N.m

kgf.m, t.2lbtft)

11.0

I ng.

N.m

{1.0

the left

kgt.m,7.2lbt.ft)

INTAKE
OUCT

IAT SENSOR
CONNECTOR

connector

side of the engine compartment.

AIR

(cont'd)

5-3

Engine Removal/lnstallation

Removal

9.

Relieve fuel

!@
system. Kogp

work

arga. Drain fuel

10. Remove
canister hose

D16Y7

the

engin€:

(cont'dl

pressure

uo not

smot(e whde working

open flams

only into

evaporative

and fuel

(see

section 11),

or spark

emission

feed hose

on th€ tuol

away from

an approved coDtainer.

(EVAp)

tho

control

11. Remove
hose

and vacuum hose.

D16Y7 engine:

the brake

VACUUM

booster vacuum

HOSE

hose, fuel return

FUEL FEED HOSE

Dl6Y5.

D16Y8

engines:

BANJO

EOLT

(3.4

33 N.m
2s

tbf.ftl

kg{.m,

Dl6Y5, D16Y8

engines:

5-4

I

12.

Remove the
then slip the cable
age.

throttle cable by

end out of the accelerator link

loosening

the locknut,

13. Remove
pull

then

grommet

the
out the ECM/PCM connectors.

and wire harness

clamps,

NOTE:
a

Take

care not to bend the cable when removing
it. Always
one.

.

Adjust

the throttle cable when installing

tion 1 1).

D16Y7 engine:

LOCKNUT

NUT

replace any kinked

cable

with

(see

a new

sec-

6x1.0mm

14.

Remove the mounting

power

the

NOTE:

steering

Do not disconnect

bolt and lock

(P/S)

pump

the P/S hoses.

bolt, then

belt and

remove

pump.

Dl6Y5, D16Y8 engines:

LOCKNUT

[ocK aoLT

x 1.25

8

mm

(2.4

24 N.m

kgf.m, 17 lbt.ftl

MOUNTING

8 x 1.25 mm

(2.4

24 N.m

BOLT

kgf.m, 17 lbf.ftl

(cont'd)

5-5

Engine Removal/lnstallation

Removal

15. Loosen
bolt,

pressor

(cont'dl

the idler

then remove the air conditioning

belt.

pulley

center nut

IOLER PULLEY

NUT

10

x 1.25 mm

4,r

N'm

and adjusting

ksf.m.33

14.5

(A/C)

CENTER

lbl.ftl

com-

17. Remove
assembly

NOTE:
.

Do not

.

Do not operate

cylinder has

.

Take

care not to bend the line.

6x f.0mm

(t.1

,t N.m

6 tbr.ft)

the clutch slave cylinder

(M/T).

disconnect the

been

,m,

kg

pipe/hose

the clutch

removed.

8x1.25fifi

21N.m

l2.1kgr.m,

assembly.

pedal

17 lbnftl

and

once

line/hose

the slave

16.

Remove
clamp.

HOSE CLAMP

the transmission

GROUND

CABLE

ground

6x1.0mm

cable and hose

18. Remove the shift

PLASTIC

cable

WASHER

CABLE

SHIFT

(CVT).

LOCKNUT

29 N.m

kgt m, 22 lbtft)

{3.0

\

,

5-6

19. Disconnect
switch con

nector, and

clamp.

Remove the radiator

20.

E@@
cap to avoid

21.

Raise the

hoist to full

power

the

cap.

use care

scalding by

height.

steering

remove the

when removing

pressure

wire harness

the radiator

hot coolant or steam.

(PS

P)

23. Drain the engine
plug

the drain

24. Drain the

a new washer

using

in the radiator.

transmission

25. Drain the engine

washer

new

26. Remove the

(see
shift rod and extension

SHIFT ROO

x 1.25 mm

8

(2-2

22 N.m

27. Remove the

NOTE:

kgf.m, 16 lbf,ft)

A,/C compressor.

Do not disconnect the

(see

page

coolant

10-6), Loosen

fluid. Reinstall the drain

(see

section

13. 14).
oil. Reinstall the drain
page

8-5).

rod

A,/C hoses.

plug

bolt using

(M,/T).

a

Remove the front tires/wheels

22.

6x1.0mm

N.m

9.8
rbl.ft)

7.2

and splash

(1.0

kd m,

shield.

SHIELD

8 x 1.25 mm
2,r N.m

{2.{

A/C COMPRESSOR

kgf.m, 17 lbf.ft}

(cont'd)

5-7

Engine Removal/lnstallation

Removal

28. Remove the shift
NOTE:

.

Take

it. Always replace
one,

.

l

Adjust the
tion 14).

x 1.25 mm

I

22 N.m

(cont'd)

(A,/T).

cable

care not to bend

shift cable when installing

kgd.m. 16lbtft)

12.2

the cable when removing

any kinked cable with

a new

(see

sec-

29. Remove

D16Y5, D16Y7

8 x 1.25 mm

(2.2

22 N.m
Replace.

SELF-LOCKING

8 x 1.25 mm

16 N.m

11.6
12 tbf'ft|
Replace.

exhaust

kgt m, 16 lbl.ftl

pipe

engines:

kgt.m,

A.

PIPE

SELF.LOCKING NUT
10 x

A

33 N.m

25 tbt.ftt

Replace.

1.25 m.n
(3.4

L

kgtm,

{

6x1.0mm

14

N.m

{1.4

kgf.m.

10 lbf.ft)

Dl6Y8

engine:

8 x'1.25 mm
22

N.m

GASKET

Feplace.

SELF.LOCKING
8 x'1.25 mm

16 N.m
Replace.

(1.6

12,2

kg'i.m,

kgf.m, 16lbtftl

NUT

'12lbf'ftI

EXHAUST
PIPE

A

SELF,LOCKING

10 x 1.25 mm

5{ N.m

{5.5

Replace.

NUT

kgt.m,

,10

lbf.tt}

\

5-8

30.

Remove the damper lorks

(see

section

'18).

Lower the hoist.

Jt,

Disconnect
(see

section 18).
Remove the driveshafts.

CAUTION:
o

Do
com€ apart.

.

Use care when
Pull il straight to avoid damaging the difterential
oil seal or

NOTE; Coat all orecision-finished

clean engine oil. Tie

enos.

the suspension

pull

not

on the driveshaft, the CV

intermediats

prying

plastic

lower

out the assembly.

shaft dust seal.

bags over the driveshaft

ioini

joints

may

arm ball

surfaces with

Remove

34.
heater hoses.

the upper and

lower

radiator hoses and

RADIATOR

HOSE

Remove the ATF cooler hoses, then
cooler hoses and

Dipes

(Ay'T).

plug

HOSES

the

ATF35.

(cont'd)

5-9

gine

En

Remov

aUlnstaf lation

Removal

36. Attach the chain hoist

(cont'd)

to the

engine,

HOISTING

lnstall

witha8xl.25mmbolr.

BRACKET

on the

cylinder head

5-10

37. Remove the left and

riqht front mount

and bracket.

Remove the uooer bracket.

39.

UPPER

Replace.

38. Remove the rear mount bracket.

FROI{T

MOUNT/BRACKET

40. Remove the transmission mount bracket,
remove the

TRANSMISSIOt{
MOUNT

transmission

mount.

TRANSMISSION
MOUNT

BRACKET

then

T

41. Check that the engine/transmission is completely

free of vacuum hoses, fuel and coolant hoses and
electricalwirino.

42.

raise the

Slowly
Check once again that

nected f rom

engine approximately

hoses

all

the engine/transmission

and

150 mm

wires

(6

in).

are discon-

Raise the engine allthe way, and remove it from the

43.

car,

5-11

t'

Engine

RemovaUlnstallation

Installation

Bracket Bolts Torque

D16Y5. O16Y8

REAR STIFFENER

8 x 1.25 mm
24 N.m

12.4

EXCEPT D16Y5,

STIFFENER
Tighten

in the numbered sequence as shown

bolts on the stiffener

the

(O-O).

Specifications:

enginGs

kgf.m,

17 lbtft)

D16Y8 engines

(M/Tl:

10
44 N.m
33 tbtft)

{M/T):

e)8x1.25mm

24 N.m

17 rbt.ftl

x 1,25 mm

{4.5

(2.4

10 x 1.25
44

33 rbtft)

kgl.m,

kg[.m.

N.m

mm

{4.5

kgf.m,

ALTERNATOF
BRACKET

10 x 1.25 mm

(5.5

54 N.m
a0 lbf.ftl

10 x 1 .25 mm

/t4

N.m

{4.5

33 rbtft)

I

kgf.m,

kgf.m,

\ {

10 x 1.25

O

44 N.m
33 rbf.ft)

E 46

c-tz

mm

{4.5

kgf.m.

8 x 1.25
24

N.m

17 rbf.ft)

8 x
24
17

10

x 1.25

,14

N.m

33 rbtftl

mm

kgf.m,

{2.4

D16Y5.
engine3
FRONT

STIFFENER

1.25

mm

N.m

{2.4

tbf.ftl

mm

{4.5

O16Y8

lM/Tl:

kgf.m,

kgt

m,

10x

1.25

44

N.m

33 rbf.ft,

mm

(4.5

kg,t

m.

10

x 1.25 mm
44 N.m
33 tbtft)

A/C COMPRESSOR
BRACKET

kgf.m,

{i1.5

{

Engine Installation:

Except Cw:

Installthe
Reinstall
Failure
noise

1. Install

engine in the reverse order of removal.

the mount bolts/nuts in the following sequence.

to follow these

procedures

may

cause excessive

and vibration, and reduce bushing life.

the transmission

tighten the bolts on the

NOTE: Do not tighten the
mission

side.

mount

frame

and bracket, then

side.

bolts/nuts on the trans-

TRANSMISSION

MOUNT

12 x l25 mm
64 N.m

{6.5

17 tbt.ftl

kgf.m,

CW:

N.m

38

t

kgf.m, 28 lbf.ftl

13.9

2. lnstall the upper bracket, then
the numbered sequence shown

tighten the

-

(O

@).

nuts in

TNANSMISSION
MOUNT BRACKET

(412x1.25mm

{7.5

kgt m,

?4 N.m
54 tbf.ftl

(il

12
74 N.m
54

x 1.25 mm

17.5

rbf.ftl

UPPER
BRACKET

kg{.m,

(cont'd)

5-13

Engine RemovaUlnstallation

Installation

Install

the rear mount bracket,

(cont'd)

in the numbered sequence

cvT:

x 1.25 mm

12

O

N.m

59
€ tbf.fr)

Replace.

Except CVT:

16.0

kgJ m,

then tighten the bolts

shown

O

@).

x 1.25 mm

12

N.m

59

(}

rbt frl

-

(O

Replace.

x 1.25

12

N.m

59

lbt ft)

a:l

Replace.

't2

x 1.25

O

59 N.m
$ tbt.ft)
Replace.

(6.0

mm

16.0

mm

16.0

kgJ m,

kgt'm,

kg{.m.

4. Tighten
bracket in the

12 x t.25 mm

O

74 N.m

the bolt/nuts on the transmission mount

-

kgt.m,

(Ot

@).

numbered

kg{.m, 5il lbtft)

{7.5

sequence shown

12

x 1.25 mm

(6.5

64 N.m
47

tbtftl

O14xt.5mm

tB N.m

18.5

61

tbf.ftl

Replace.

kgf.m,

Tighten

5.

the bolts on the right front mounvbracket

the numbered sequence

CW:

to x

t.zs

O

54 N.m

15.5

/r0

lbf.ftl

mm

kgt.m,

shown

(O

-

in

O).

5-14

I

-

Except

CVT:

7.

Perform

following:

the

N.m
tbt

f0

mm

14.5

kgf.m,

10 x L25
a4
33

Tighten the bolts/nut on the

numbered sequence shown

12 x 1.25 mm

O

83

N.m

(8.5

kgl.m, 61

left front mount in the

-

(O

O)

Clean the areas

where

the driveshaft(s)

intermediate shaft contact the transmission
ferential) thoroughly
cleaner. and drv

Check that
shaft and

the set rings on the ends of the drive-

intermediate shaft

CAUTION: Use

a

Adjust the shift cable

a

Adjust

a

Adjust the cruise control cable

a

Refill the engine with engine oil

a

Refill

throttle cable

the

transmission with fluid

the

with

with

compressed air.

new

set

rings.

(see

(see

solvent or carburetor

into

click

section

Dlace.

'14,.

section 11).

(see

section

(see

page

(see

section

14).

Refill the radiator with engine coolant

10-6).
Bleed
valve open
Clean the battery

from the cooling system with the heater

air

(see

page

10-6).

posts

and cable terminals with

sandpaper. assemble them, then apply
prevenr

Inspect for fuel

After assembling
tion switch

fuel

and the fuel
tion two or

age at any

corroston.

Ieakage

tuel line, turn on

the

(do

not

operate

pump

runs for approximately

pressurizes.

line

three times, then check

point

in the fuel line.

(see

section

the starter) so

Repeat this opera-

11).
{ll)

two seconds

for

and the

(dif-

23).

8-5).

13,

(see

page

grease

the igni-

that the

fuel leak-

to

44 N'm

rbf.ftl

33

14.5

kgt.m,

12 x 1.25 mm

@

59 N.m

43 lbf'frl

Replace.

16.0

kgt.m,

(cont'd)

5-15

Engine Removal/lnstallation

Installation

Mount and Eracket Bolts/Nuts Torque Value Specifications:

'1.25

A: 10 x

64 N.m

Br 10 x 1.25 mm

44 N.m
12

C:

83 N.m

D: 12 x 1.25 mm

59

Replace.

mm

(6.5
(4.5

x 1.25 mm

(8.5
(6.0

N.m

(cont'd)

kgf.m, 47 lbnft)
kgnm,

33 lbift)
kgf.m,61 lbl.ft)
kgt m, 43

lbl.ft)

RIGHT FRONT
MOUNT

\

SIDE ENGINE
MOUNT

5-16

Special

Tools

I

Rel. No. Tool Number

-

o

@
@
@
@
@

o

orO-1

andO-2

@

o

e='T------_ts

OTHAH
07JAA - 001010A
07JAB - 0010204
OTLAJ . PR3O2OB
07NAB
07NAJ
07406 - 0020201
OTMAJ - PY4O1
OTMAJ PY4O120
07406 - 0070300
07742 - 0010100

PJTOl

-

0010404

-

P07010A

OB

1A

Description

50

mm

mm

W/Panel

Valve Guide Reamer, 5.5
Socket, 17 mm

Holder Handle

Air

Stopper

Attachment,

Holder

Pressure Gauge Adapter
A/'I Pressure Hose
A"/T Pressure Hose, 2.210 mm
A/T Pressure Adapter
A/f Low Pressure Gauge
Valve

Guide

Driver,5.5 mm

oty Page Retsrsnce

6,43

6-8, 10

6-4
6-4
6-4
6-4
6-4
6-41, 42

\

g

@

o

@

\-J

@

6-2

.;*'

@

@

\

a

VTEC

Control System

Troubleshootin

----

tFl2Egl Il"-:1"".

Refer

V ItC Solenord Valve

page

to

The
DTC P1259 is stored.

Check the VTEC Control System:

1. Do the
(ECM)/powertrain

ule
section 11).

2.

Start the engine.

3. Warm up the engine to normal
operaling temperature
ing fan

4.

Do the Road Test.*

1 1 38 through 1 1'55 before troubleshooting.

MIL has been reported on.

engine control

(PCM)

Reset ProcedLrre

comes on).

ls DTC P1259 indicated?

g

tool indicates Diasnostic Trouble

control mod

Flowchart

crrcuit.

module

(see

(cool-

(DTC)

Code

*

Road Test:

Accelerate in lst

(D16Y5

engine) or 6,000 rpm
Hold that engine speed for
lf

DTC P1259

the

repeat this test two more times.

Intermittent failure.
at this time.
Check tor
loose wires
switch. VTEC solenoid valve
ECM/PCM.

poor

at

Pl259: A

gear

to an engine speed over 3,000 rpm

is not repeated during the first road

system is OK

conneqlions or

VTEC

oressure

(D16Y8

least

at

and

problem

two seconds.

in the VTEC Pressure

engine).

Switch circuit

test,

VTEC PRESSURE SWITCH
CONNECTOR

or

Test the VTEC Presslre
'1.

Turn

2. Disconnect the VTEC Pressure
swrtch

3. Check for continuity

VTEC
tor terminal No. 1 and No. 2.

T6st the VTEC Pressur€ Switch
Wi16:

1. Turn

2. Measure
VTEC
tor No. 1 and body

ignition

the

connector.

pressure

ls

there continuity? fleplace the VTEC

ignition

the

the

pressure

ls

there approx. 12 V?

(To

page

Switch:

switch OFF.

between

switch connec-

switch ON

voltag€

between

switch connec'

ground.

YES

6-4)

(ll).

pressrre

Inspect

for an open oa short to

ground

in the wir€ betweon tho

pressure

VTEC
PCM

tCls).
It the wire is OK. sub3titute a
known-good ECM/PCM

rech6ck.

switch and

switch.

ECM/

rnd

TERMINAL
TERMINALS

/Ta

fll

\3-l

WIFE

SIOE OF FEMALE

TERMINALS

SIDE OF MALE

vTM

{sr-ulelrt

I

I

{9)

Y

I

-L

(cont'd)

6-3

VTEC Control

System

Troubleshooting

(From

page

Tost the

Wire:
Measure voltage across
pressure

Test the

1. Turn the

2.

3. Connect a tachometer

4. Start the
5-

6.

VTEC Pt.ssure Switch

switch connector.

approx. 12 V?

ls there

VTEC Solonoid Valve:

Remove the VTEC
switch
tool as shown, then
the VTEC

tion 11).
Warm up engine to

operating
fan comes on).

Check oii

lowing engine speeds:

engine:

Dl6Y8 engine:

5000 rpm.

ls
{0.5

ignition

and install the special

pressure

engine.

temperature

pressure

1000

and

1000, 3000 and

pressure

below 49 kPa

kgflcm',7

psi)?

Flowchart

6-3)

the VTEC

OFF.

switch

pressure

reinstall

switch.

(see

normal

(cooling

at

the

D16Y5

3000 rpm,

sec-

fol-

(cont'dl

Ropair open
VTEC
A23 ot tho ECM/FCM.
ll the wire ia OK,
known-good
rochock.

NOTE: Keep
possible

load

because

(less

than one

Insoect ihe

in the wire batwe'€n

Dr€66ure

switch and

ECM/PCM .nd

A10 or

3ubstilut€ a

LOW PRESSURE

A/T
W/PAiIEL

07406-0070300

.-,,-t

measuring time as short as

engine is running

minute).

VTEC solenoid

with no

valv6.

L-

PRESSURE GAUGE
ADAPTER

07NAJ - P07010A

VTEC PRESSURE
CONNECTOR

WIRE SIDE OF
TERMINAL

A/I PRESSURE
07i106 - 0020201

A/T PRESSURE HOSE,
2-210 mm
07MAJ - PY4O11A
A/T
OTMAJ - PY|{}l20

SWITCH

FEMALE

PRESSURE ADAPTER

HOSE

and

Test the

VTEC

1. Turn the ignition switch

2. Disconnect the
valve connector.

3. Attach the baftery
minal to the GFNIYEL termi'
nal.

4. Start the engine and check
oil
engine
3000
rpm.

ls the
engine:250

psi),

36
(4.0

kgf/cm',57

Solenoid

pressure

pressure

at the following

speed: D16Y5 engine

rpm, D16YB engine 5000

above:

kPa

D16Y8 enginer390

(To

page

6-4

Valvel

VTEC solenoid

(2.5

psi)?

OFF.

positive

D16Y5

kgvcm?,

kPa

6 5)

ter

the

0020201

-

PYO12O

HOSE

HOSE,

PRESSURE

A/T

-

07406

A/T PRESSURE
2,210 nn
07MAJ - PYlOltA .nd
A/T PRESSURE ADAPTER
OTMAJ

In3ooct tha VTEC solonoid

valve.

IOW PRESSURE GAUGE WPANEL

-O070300

07406

PRESSURE
GAUGE
07NAJ - P07010A

ADAPTER

page

lFrom

T6t lhe VTEC Pr6.sure Switch:

1. Turn

2. Reconnect
swrtch connector,

3. Staft the engine.

4. With
minal

solenoid valve, measure volt-

age between
A.23

ls
5,000 rpm?

Test

1. Turn

2. Disconnect

terminal from
noid valve,

3.

Check
the VTEC
neclorterminal No. 1
grouno.

Tosi
Wi.e:
Check for continuity
VTEC
terminal

ignition

the

the battery

connected to the VTEC

thsre approx.

VTEC

th.

the ignition switch OFF.

for

ls there 14

tho VTEC Solenoid Valv€

solenoid valve connector

No. I and A8.

6-4)

switch OFF.

the VTEC

Solenoid Valve:

the battery

continuity between

sol€noid

pressure

positive

C15 and A'10 or

'12

V above

positive

VTEC

the

valve

and body

-

O?

30

between the

ter-

sole-

con-

R€plac€ the VTEC

ReDlace

the

VTEC

pressure

solonoid valve.

switch.

ECM CONNECTORS

(32P1

A

WIRE SIDE OF FEMALE
TERMINALS

VTEC SOLENOID VALVE
CONNECTON

TERMINAL
TERMINAL

VTEC SOLENOID
VALVE
CONNECTOR

c

tT------ I

l[-]f-r

I

OF MALE

SIDE

ECM CONNECTOR

(32P1

A

ws

{GRN/YELI

(3rP)

I

I

-L

ls

there continuhy?

Tost

tho VTEC Solenoid Valvo
Whe:
Check for continuity
VTEC solenoid valve
min6l

No. 1 and body

ls there

Sub3tituto
PCM
indic.tion

th. originel ECM/PCM.

a known-good ECM/

and roch6ck. lf symptom/

goo3

between the

connector ter-

ground.

continuity?

away, .oplace

R€pair

open

the ECM/PCM

noid

valvo connoclor.

RoDair

3hort

rho

€cM/PcM

noid valv6

connoctor,

in

the wiro botweon

VTEC

and

{48}

in

the wire betwoon

(A8l

and VIEC sot€-

aote-

WIRE

SIOE OF

TERMINALS

VTEC SOLENOID VALVE
CONNECTOR

FEMALE

r=

I t--l

SIDE

WIRE

TERMINAL

OF

I

I

r5'

Y

I

FEMALE

6-5

VTEC Solenoid Valve

Inspection

'1.

Disconnect
noid valve.

2. Measure resistance
grouno.

Resistance: 14

the

'lP

connector

-

O

30

from the VTEC sole-

between the

terminal and body

4. If the filter is not clogged,
valve with

.

lf the VTEC solenoid
engine

your

finger and check

pressure.

oil

6x1.0mm

12 N.m

valve is normal,

(1.2

kgtm,8.7 lbtftl

push

the

its movement.

VTEC solenoid

the

check

lf

resistance

the
VTEC solenoid valve assembly from the cylinder
head.

and check the VTEC solenoid valve filter for

cloggrng.
.

lf

there

and the engine oil.

VTEC SOLENOID VALVE ASSEMBLY

is within specifications, remove the

is

clogging, replace the engine oil filter

VTEC

SOLENOID

VALVE

FILTER

Replace.

6x1.0mm
12 N.m

o-o

ksf.m,8.7

{1.2

lbf.tr}

{

VTEC Rocker

Arms

Manual

1.

Set the No. 1

2.

Remove
NOTE: Refer

der
lvlove

cylinder manually.

Check that the intake
independently

Inspection

the cylinder head

head

cover.

the intake

(D16Y5

piston

at TDC.

cover.

page

to

6-46 when installing

secondary rocker arm on the No. 1

secondary rocker

primary

of the

intake rocker

engine)

the cylin-

arm moves

arm.

Manual

'1.

Set the No. I
Remove

2.

NOTE: Refer to

der

3.

Push the intake mid rocker

der manually.

Check that the intake mid rocker
dently of the
arms.

Inspection

piston

at TDC.

the cylinder head cover.

page

head

cover.

primary

6-46

(D16Y8

when installing

arm on the No, I cylin-

and secondary intake rocker

engine)

the cylin-

arm moves indepen-

MID ROCKER
ARM

SECONDARY

ROCKER ARM
.

Push and

Check the intake
cylinder

.

.

at TDC.

lf the intake
remove

arms as an assembly
the secondary and
smoothly.

lf

any

mary

secondary

primary

the

rocker

arm needs replacing.

and secondary rocker

ROCKER

PBIMARY

PBIMARY

pull.

secondary rocker

rocker

and secondary intake rocker

and check that the

primary

ROCKER

arm of each

arm does not move,

rocker arms move

replace the

arms as an assembly.

ARM

ARM

pistons

pri-

in

SECONOARY
ROCKER

Check the

TDC.

.

lf the intake mid
remove the mid,
rocker arms as an assembly

tons in the mid

smoothly.

.

lf
primary,

assemoly.

intake

mid rocker arm of

rocker arm does not move,

primary

primary

and

any rocker arm needs replacing, replace

mid,

and secondary rocker

ARM

each cylinder at

and secondary intake

and check that the

rocker

pis-

arms move

the

as an

arms

6-7

VTEC Rocker

Arms

Inspection Using SpecialTools

CAUTION:

.

Eelore

that the

indicates over

a

tnspect the valve clearance bgfore

tlon.

.

Cover the
belt.

.

Check

TDC.

1.

using the Valve Inspection

pressure gaugs

air

iloo

kPa

timing belt with a shop towalto

the intake

Remove the cylinder

NOTE: Refer to

der head cover.

Plug the relief

pdmary

page

hole

with the special

kgt/cm', 57

{4

rocker arm of each cylinder

head

6-46

cover.

when installing the cylin-

Tool. make sure

on the

air compressor

psil.

rocker arm inspec-

tool.

(D16Y5

protect

the

at

engine)

3. Remove the
and connect the

1.0

10 x
SEALING

N'm

20

mm

{2

BOLT

kgf'm,

0

sealing bolt

Valve Inspection

14lbf'ft}

trom the inspection

Tool.

STOPPER

AIR

-

OTLAJ

PR3O2OB

hole

Y'

_

PR3O2OB

OTLAJ

x 1.0 mm

l0

ADAPTER

Loosen the

and apply specified air

tool

rocker

a.m timing

Specified Air
250 kPa

TNSPECTTON HOLE

regulator valve on the valve

Prossure:

kgt/cm,, 36

{2.5

piston.

psil

VALVE
TOOL

(Commercially

available)

.

pressure

INSPECTION

Pullthe dial and
turn to adjust,

inspection

to the intake

6-8

5. With the specified
plate;

timing
and engage
Visually
piston.

the synchronizing

the intake secondary rocker

check the engagement

pressure

air

piston

push

will

arm.

up the

pop

out

applied,

of the synchronizing

6. Stop applying air
plate;

the synchronizing
original
Visually check the
nizing

position.

pistons.

pressure

piston

disengagement of the

push

and

will snap

up the

timing

back to

synchro-

its

NOTE:
.

The

synchronizing

betlveen

.

With the
the timing

pushed

piston

the secondary and

plate

timing

piston,

position.

out

engaged in the

the

can be seen in

primary

piston

TIMI]TG PLATE

rocker

is locked in

gap

the

arms,

groove

the

TIMII{G
PLATE
SPRII{G

on

NOTE:
.

.

PASSAGE

otL

PRIMARY
ARM

TIMING

When

the timing

the timing

the synchronizing

Replace
either does not work

ROCKER

piston,

the intake rocker arms

TIMII{G

--il.

SPRIIIIG

TIMING

PISTO

plate

letting

piston

pushed

is

the return spring move

its

to

original

as an assembly if

correctlt.

PLATE

RETURIT SPRI G

SY CHRONIZING
PISTON

up, it releases

position.

SECO'{OAFY
ROCKER

ARII

A|R PNESSURE

PRIMARY

ROCKEB

ARM

TIMING

$

TIMING

SECONDARY
ROCKER ARM

SYNCHRONIZI''IG
PISTON

SPRING

1.

Remove

After inspection,

(MlL)

lamp

the special tools.

check that the malfunction

not

does

come on.

indicator

6-9

I

VTEC Rocker Arms

Inspection

CAUTION:
.

Before using the Valve Inspection Tool, make
that the air
indicales

a

Inspect
tion,

.

Cover the timing

the belt.

.

Check the intake
at TDC.

Remove

1.

NOTE: Refer to
neao cover.

Plug

the relief hole with the

Using Special Tools

pressure gauge

il00

over

the valve clearance belore rocker arm inspec.

the cylinder head cover.

kPa

belt with a shop towel to

primary

page

6-46

on the air compressor

(4

kgt/cm,, 57

rocker arm of each cylinder

when installing

special tool.

psi).

(D16Y8

sure

protect

the cylinder

engine)

3. Remove
and connect the

10 x 1.0 mm
SEALING BOI-T
20 N.ln

the sealing bolt

Valve Inspection Tool.

14

kgt.m,

12.0

lbf.ft)

from

inspection hole

the

RELIEF

HOLE

Y'

-

OTLAJ

PR3O2OB

TOOL
(Commercially

available)
.

Pullthe dial
turn to adlust,

and

\

6-10

\

q

4. Loosen the regulator valve
tool and

arm synchronizing
SDecified Air

250 kPa

apply the specified air

piston

AVB.

Prsssure:

{2.5

kgf/cm,.

36

psi)

on the valve inspection

pressure

to

the

rocker

Remove the

7.

Use a 10 mm
motion assembly
Replace
smoothly.

special tools.

diameter rod to depress

through its full movement.

lost

any

motion assembly

each lost

that does move

PRIMARY ROCKER
ARM

TIMING
PISTON

SYNCHRONIZING
PISTON A PISTON

Make sure
rocker arms

and that the mid rocker

pushed

that the intake

mechanically

are

manually.

MID ROCKER
ARM

SYNCHRONIZING

primary

connected by the

arm does not move when

SECONDARY
ROCKER ARM

B

and secondary

piston

ASSEMBLY

lf any intake mid rocker

primary

the

rocker arms

and secondary rocker arms. replace

as a set.

arm moves independently

the

of

After inspection,
on.

check that the MIL

does not come

6-11

Valve

Clearance

Adjustment

NOTE:

.

Valves should be

head temperature

.

Alter adjusting,
(see

page

6-16).

'1.

Remove the cylinder

Referto

NOTE;
neao cover.

Remove

the No. 1

Set

shaft

align with the cylinder

upper cover

the

piston

pulley

should be at top, and

"UP"

adjusted only

is less than

retorque the crankshaft

head cover.

page

G46when installing

(see

TDC.

at

head surface.

MARK

when the cylinder

(38"C).

100"F

page

5-19).

"UP"

mark on the cam-

TDC marks should

TOC

pulley

bolt

the cylinder

MARKS

Loosen the locknut, and turn

5.
until the feeler
slight amount of drag.

D16Y7

engine:

CAUTIONT Do not overtighten
rockgr arms

INTAKE and
LOCKNUTS

(1.8

18 N.m

gauge

are made ol aluminum.

ExHAUST VALVE

kgt m, 13 lbf.ftl

the adjustment screw

back and forth with a

slides

the locknuts; the

\

{

4. Adiust valves on No. 1 cylinder.
Intake: 0.18 - 0.22 mm

Exhaust: 0.23 - 0.27 mm

10.007

(0.009

-

0.009 in)

-

0.011 inl

D16Y5, Dl6Yg engines:

INTAKE and EXHAUST VALVE
LOCKNUTS
20 N.m

Adiusting 3crew locations:

kgf.m, 14 lbnft)

12.0

No.4 No,3

{

INTAKE

o.2

t6 at^

o-tz

\

"/

6. Tighten the locknut, and check the clearance
Repeat the adjustment if necessary.

FEELER
GAUGE

again.

8. Rotate the crankshaft 180"
bring No.4
once again visible. Adjust valves

piston

to TDC.

Both TDC

counterclockwise to

grooves

on No. 4 cylinder.

are

Rotate the

7.
shaft

the exhaust side. Adjust valves

.UP'MARK

pulley

crankshaft

turns 90").

180"

counterclockwise

"UP"

The

mark should be on

No.

on

(cam-

3 cylinder.

9.

Rotate

the crankshaft 180" counterclockwise

piston

No. 2

intake

the

to TDC. The

side. Adjust valves on No.

"UP"

mark

should be on

2 cylinder.

-UP"

to bring

MARK

6-13

Valve Seals

Replacement

NOTE: Cylinder
procedure.

procedure

The
car valve spring
YA8845 2A7l8" attachment).

!@

using

Turn the crankshaft so that

1.
pistons

2. Remove the cylinder
assemoty.

NOTE:
.

Alway wear approved

the in-car

are at top dead center

Refer to
removal.

When removing or

assembly, do
bolts. The bolts

rocker arms on the shaft.

and
Refer to
head cover.

(Cylinder

removal is

head

shown

below applies

compressor

valve spring compressol.

head cover and

page

6 30 for

installing the

not remove the camshaft

will keep the

page

when installing the cylinder

6-46

head removal

not required in this

when using the

(Snap-on

the No.

(TDC).

rocker arm assembly

YA8845

protection

eye

'l

and

the rocker arm

holders, springs

with

when

the No.

rocker arm

holder

not required)

lntake Valve Sealsi

6, Select

in-

7.

4

IN-CAR

the 7/8

ment, and fasten the

lever arm with the speed

the

lnsert an air adaptor
air into the cylinder
compressing

ers.

Position the

lever is

sor attachment

spring being

on the lever as shown.

slot

SPRING

in

diameter

springs

lever arm under lhe

perpendicular

rests on

compressed.

COMPRESSOR

short compressor

attachment to the

pin

into the spark

to keep the

and removing the

the shaft and the compres-

to

top of the retainer

Use the front

No. 4 hole of

supplied.

plug

hole. Pump

valve closed

valve keep-

cross shaft so the

attach-

while

for the

position

Remove

3.
Uslng

the two uprights
camshalt

shaft as shown.

Insert the cross shaft through

5.
two uPflghts.

the fuel injectors and

the 8 mm bolts supplied

to the cylinder

holders.

The

the wire harness.

with the tool,

head at the end

uprights

fit over the cam-

the top hole of

mount

the

NOTE:
prevent

Put shop towels

valve keepers

the

OIL PASSAGES

over the oal

from falling into the cylin-

passages

to

L

6-14

PASSAGES

OIL

q

J

9. Using

10.

11.

12.

Exhaust

t5.

14.

a downward

press

the

sPring.
Remove the valve seals

Install the

Install the springs,

reverse order of

Select the 7/8

ment, and

the lever arm

Position the

lever is
sor attachment
spring being
slot on the

NOTE: Put shop towels

prevent

der

valve spring and

the

valve stem. Slowly

valve seals

Valve Seals:

in.

fasten the attachment

with

lever arm under the cross

perpendicular

compressed. Use

lever as shown.

valve keepers

the

head.

motion on the lever arm. com-

remove the keepers

release

(see

(see

page

the retainers and the

removal.

diameter

the

rests on top of

short compressor

speed

to the shaft and the

over the oil
from falling into the cylin-

pressure

page

6-38).

6-43,.

to the No.2

pin

supplied.

the retainer

the front

keepers in

shaft so the

compres-

passages

from

on the

attach­hole

of

for

the

position

to

15, Using a

press

the

spnng.
Remove the valve seals

16.

17.

lnstallthe

18.

Install the springs, the
reverse order of

19.

Repeat steps 6 to 18 on the other

downward

valve spring and

the

valve stem. Slowly

valve seals

motion

(see

removal.

page

6-43).

lever

keepers from

the

pressure

6-38).

cylinders,

on the

remove

release

(see

page

retainers and the

com-

arm,

on the

keepers in

IN.CAB SPRING

7/8 in SHORT

COMPRESSOR

A

6-15

Crankshaft Pulley

and

Replacement

Pulley

Bolt

When installing
procedure

Clean, remove

below.
O: Clean
x:

Remove any

a: Lub.icate

Crankshaft
14 x 1.25
20 N.m

below,

CRANKSHAFT

pull€y

mm

(2.0

kgf'm.

oil

and

tightening

any

oil, and lubricate

bolt siz€ and

lil lbf'ft] + 90"

torque value:

pulley,

the

TIMING
GUIDE PLATE

follow the

points

BELT

shown

1. Tighten

Torque:
Use a felt tip

wasner.

EMBOSSING MARKS

pulley

the

20 N'm

bolt to the

(2.0

kgf.m, 14 lbf.ftl

pen

to mark the

specified torque.

pulley

bolt head and

NOTE:

}IOI.DER HANDII
o'JAB - tD1020A

Do not use

impact

an

HOLDER

-

07 AB

wrench when

ATTACHMENT.
00100A

SOCKET,

o'JAA

lComm.rcillly rv.ihbl.)

installing.

mm

50

17 mm

-

@1010A ot

3. Tighten

the

pulley

bolt an additional 90'.

MARKING

\

t^ at^

o-to

L-

Timing

Belt

lllustrated

NOTE:
.

Refer to

.

Mark the direction

a

Do not use the upper

.

Clean

.

Replace

.

Refer

page

the upper cover and lower cover before installing.

the

camshaft

page

to

Index

for

6-20

6-16 before installing

how to

rotation

of

cover and

seals

position

on the belt before removing.

lower

and crankshaft seals if there is

crankshaft

the

cover for storing removed items.

the timing belt.

pulley

and

leakage.

oil

CYLINDER HEAD
COVER

page

Refer to
when installing.

6 46

HEAD COVER GASKET

Replace when leaking,
damaged
Apply liquid
the tour corners of the
recesses.

before installing

or deterioraled.

gasket

the belt.

at

@y

@

TIMING BELT
DRIVE

PULLEY

Replacement,

page

6-16

10

r 1.25 mm

4,1 N.m

kgf.m, 33 lbtft)

{4.5

TIMING BELT
Inspectaon,
Adjustment,
Removal,
lnstaliation,

page

page

page

O.RING

Replace.

6-18

page

6-19

6-18

6,20

6x1.0mm
12Nm11.2kgl'm,

8.7 lbf.ftl

8 x 1.25 mm

(3.8

37 N.m
Apply
threads.

CRANKSHAFT

ICKF)
Replacement,

kg{.m.27 lbf.ftl

engine

SENSOR

oil

page

UPPER COVER

to the bolt

FLUCTUATION

SPEED

6'22

6x1.0mm

9.8 N.m

7.2 tbtftt

6x1.0mm

9.8 N.m

1.2 tbl.trl
RUBAER
Replace
or deterioratod.

LOWER COVER

RUBBER

PLUG

CRANKSHAFT

Replacement,

PULLEY
1a

x 1.25 mm

20 N.m

lia

lbf.ft) +
Replacement, page
Do
wranch when

ll.0

kgf.m,

11.0
SEALS

when damaged

PULIEY

page

BOLT

kgl.m,

{2.0

90'

not use an impact

installing.

kgf.m,

6-16

6-16

6-17