Honda Integra 1994 User Manual

ACUrj|A

INTEGFIF|

Service

Manual

1994

INTRODUCTION

Manual

How to Use

This manual

marked with

tion is

index

thumb
tind the

ble of contents.

can

Each section

tirst

also be used

1. A table of
a

Parts

a

Bolt

a

Page references

2. Disassemblv/assembly

InsDection.

3.

4. Testing/troubleshooting.

Repair.

5.

6. Adiustments.

This

is divided

tab on this

page

includes:

disassemblv

toroues and

into 23 sections.

a black tab

of each section

The svmbols

quick

as a

contents. or

page

lines up with

that

the back cover.

and

without

printed
reference

sequence.

thread sizes.

descriptions

to

procedures

at the

an exploded

page

first

The

its corresponding

You can

looking through

top corner of

system.

view index

in text.

tools.

and

each sec-

of

quickly

full ta-

a

page

each

showing:

Specifications

Maintenance

Engine

trtl:{lt'

4Pi

H

I-""

Special

@
01 loss of

CAUTION:
damage

NOTE: Gives
CAUTfON:

salety
that
ic sgrvice
a vehicle
cannot

recommended
hazardous consequences
HONDA

toofa, whethor

or

sett

jaopaldized.

be

All information

information available

make changes at

to
tion

in any Jorm
recording, or
publisher.

Information

lnai""tes a strong

instructions al€

life it

possibility

Indicates

if instructions

helpful

Detaifed

principlos

this manual conlains

methods which

or make

cover all conceivablc

investigate

thoroughly

mav be reproduced,

by any

otherwise,

This

a

ale

information.

doscriptions

and servica

it

unsafe.

HONDA, might

bv

all such

recomonded

01 not

neither

that

contained

at

any time

means, electronic,

includes test.

possibility

not tollowed.

personal

ot

not followed.

ot standad

opelations

warnings

could cause

Pleaso understand

waYs in which

svery

of

ways. Anyone

personal

manual is based

in this
the time of

without

stored

without

figures and

are not

and cautions

PERSONAL

be done,

conceivable

by HONDA,

saf€ty

printing.

notice. No

in retrieval

prior

the

of sevor€

service,

using seryice

system, or

mechanical,

written

tables.

pelsonal

inlury

workshop

included

against

INJURY,

that those

whethea or

or of the

way,

,nust sttisfY

nor v€hicle safety

on the

We reserve

part

permission

iniury

or oquipmont

procedures,

Pleaso note

somo spocif-

damage

warnings

not

possibla

nor

could

plocedures

him-

will

product

latest

the right

publica-

of this

transmitted,

photocopying,

of the

Fuel and

Emissions

*Transaxle

*Steering

*

Brakes

(lncludins

!TEg)

Za

r-\

lDl
\.t/

o

Edition 7/93

First
All Rights
Specifications

Reserved

pages

1448

Apply to U.S.A.

As sections
special

and Canada

with r includ€

precautions

HONDA

Service

lequiled

are

MOTOR CO.,LTD,

Publication ottice

SRS components.

when servicing.

*Electrical

(lncludins

J--*

ISBE)

,,

SUPPLEMENTAL

The Integra

Rs model
necessary
contents
will require

'

To

avoid rondering

trontal

'

lmpTopor
ry

caussd by

for

to safely

page

special

collision,

3orvica

SRS

canada

includes

include,

unintsntional

RESTRAINT

have a front

service

or are

precautions

ths sRS

all sRs
proceduroa,

a driver's

passenger's

the

sorvico

SRS is included

located near,

and tools,

inoporativo,

work

including

activation

SYSTEM

airbag,

located

airbsg

in

SRS components.

and

which

must

inco.roct

ot tho

should thoreiore

be

airbags.

(SRS}

in the

located in

this servica

could lard

pcrformcd

r.movd

steering

r d Installation

wheel

the
Manual.
Servicing.

be done

porronll

to

by !n

dashboard

ruthorizcd

hub.

ltems

disassembling

by

Injury

of tha

ln addition,

above

marked

an authorhed

or darth In

Acu.!

SRS, could

all

mod€ls
the
with

daerrr,

glove

an

sstorisk

or roplacing

Acura

thc

cvant

Lld

box,

thea6

dealer.

pc[onc

to

excepi

InformaUon

(r)

ot. r.yr.

tna

on thr

ltems

Inlu-

'

All

sRs
stoering
bor. Do

NoTE:

*

disconnecting

-

removing

-

removing
After
tomer's

service,

oloctrical

Golumn,

not

The

5-digit

original

the No.
the radio.

wiring

front

uas oloctdcal

radio has

the battery.

32

reconnect

code

to restore

console,

(7.S

power

harnoa$!

dsrhboa.d,

te$
a

A) fuse

oquipmont

coded thett

to

the radio

radio

aro coverod

and

on thaaa

protection

Jrom

oDerauon.

the

and

undsr-hood

with

darhboard

turn it

yallow

citcuhs.

circuit. Be

on. When

In3ulatlon,

lowor

fuse/relay

plnol,

sure

the

word

to
box.

Rcbtcd

lnd in

get

the

,,CODE,,

customer's

componcnts

thc

d$hbolrd

code

is

displayed,

arc

bcrtad In

abovc

numb6r

enter the

tha

b€lore

tha

gaov!

cus_

General

Information

Chassis
ldentification

Warning/Caution

Lift

Towing

and

Lift

Floor Jack

Safety

and

Support

Stands

Paint Codes

Number

Label Locations

Points

Locations

1-2

1-4

1-5

1-9

1-10
1-1 1

1-12

I

Chassis

and

U.S.Model

Paint

Codes

Vehicle

Manutactulol,

Typ€

Line,

Body Type

of Vshicle

JH4:

Body

DB7: INTEGRA
DB8:
DC2:
DC4: INTEGRA

ldentification

HONDA

ACURA

and Engino

INTEGRA
INTEGRA

and

Number

Make

MOTOR

Psssenger

Trsnsmission

and

CO.,

car

Type

4-door/B1
4-door/81
3-door/B18C
3-door/B1

881
8Cl

8B

JH4DB754*

LTD.

1

j

Type

RSOOOOO

1

Engine

Engine Typ6

81881:

B l8Cl :

Se al Numbel

Number

1.8

Fuel-injected

1.8 | DOHC VTEC

Multi-port

f DOHC

Transmission

Sequentiat

engine

Fu€l-iniected

Numbsr

8l8Br-r300@l

-----T-----

Muhi-pori

Sequ€nrial

€ngin€

3: 2-door Hatchback

4: 2-doot

Automatic

5; 4-door

6: 4-door

Vehicle

4: RS

LS

5:

8;

GS-R

Check
Model

R:

Factory

Digit

Yaal

1994

Glado

Code

Hatchback

Sedan
Sedan

(Seriesl

S-speed

4-speed

s-speed

4-speed

Manual

Automatic

Manual

Transmission

Y80:
MPTA:

Serial

Manual

Numbel

Type

Automatic

Paint

Y80-

1

000@ I

Code

COLOR

S: Suzuka

Serial

Numb€l

Factory

in Japan

BG.33P

Vehicle

Federal

3DOOR

ld€ntification

Motor

Number

Vehicle

Safety

and

Standard

Certification

4DOOR

Paint

Paint

BG.33P

G-71P

NH-5O3P
NH-538
NH-575M
R-7

R-81
RP.24P

YR.5O3M

Code

2P

Code

Color

Paradise

Lausanne
Grsnada
Frost White

Thunder

Torino

Milano
Stealth
Rosewood

Blue-g.€en

Gr6en

Black

Grav Metallic

Red Pearl

Red

Gray Pearl

Brown

PeErl

Pead

Pea.l

M€tallic

1-2

Canada

Model

Vehicle

Manutacturer,

Type of

JH4:

Lino.

Body

Body
D87:
DC2:
DC4: INTEGRA

Type and

3: 2-door

ldentification

Make

v€hicle

HONDA
ACURA

and
INTEGRA
INTEGRA

Engine

Hatchback

Numbel

and

MOTOR

Passenger

4-doot/Bl

3-dootBl
3-doori

Transmission

CO.,

car

TYPo

881

8C1

B18B1

TYPo

5-speed

JH4DB753.

LTD.

Manual

RS800001

Engine

Engin€

81881:
B18C1:

Serial

Number

Number

Type

1.8 I

Fuel-injected

1.8 I

Multi-Dort

DOHC Sequential

DOHC

Transmission

engine

VTEC

Fuel-iniected

Number

81881-1

Multi-port

Sequential

engrne

700001

4'. 2-door

Automatic

4-door Sedan

5:

4-door Sedan

6:

Vehicle

RS without

3:
4: RS

8: GS-R

Check

Model

R: 1994

Factory

S:

Digit

Yeat

Suzuka

Hatchback

Grade

with

Code

passenget SRS

Factory

s-speed

4-speed

{Sedes}

passenger

in Japan

4-speed

Manual
Automatic

SRS

aitbag

airbag

Transmission

Y80: Manual

MPTA:

Serial

Numbel

Type

Automatic

Paint

Y80-1000001

Code

COLOR

BG.33P

Serial

Numbel

Vehicle

ldentification

Canadian

3DOOR

Motor

Number

Vehicle

and

Safety

Standard

4DOOR

Certification

Paint

Paint

BG.33P
G-71P

NH-5O3P

NH-538
NH-575M

R-72P
R-81

RP-24P

YR-503M

Code

Code

Color

Paradise

Lausanne
Granada
Frost
Thunder
Torino

Milano
Stealth
Rosewood

Blue-green

Green

Elack

White

Gray

Red

Red

Gray

Pearl

Pearl

Metallic

Pearl

Pearl

Brown

Pearl

Metallic

1-3

I

I

I

ldentification

Vehicle
Number lvlNl

Number

ldontif ication

Locations

v.hiclo ldontif
Numb€r lVlNl

icalion

S

1-4

Transmbsion

lAuromatic)

Numbor

Transmissioh

lManuall

l\lumbor

Warning/Caution

Label

Locations

A: CABLE

BEFERTO-

B: CABLE

REFERTO- SERVICE

C: STEERII{G

REAL CAUTION

SERVICE

BEAL CAUTION

WHEEL

]{OT|CE
IMPROPEB
DAMAGE SRS
FOLLOW

D: DRIVER

WARNII{G

PflEVE T

TO

STEERII{G

COMPONENT.

SERVICE

INFLATOR

ACCIDE]TTAL

A

MANUAL

FOR DETAII'fD

B

MAI{UAL

OTICE

WIIEEL

FOR

REMOVAL OR

MANUAL

WAR[{|NG

D€PLOYMENT

INSTRUCTION

OETAILED

INSTRUCTION

INSTALLATION

INSTRUCTION

TAG

CAREFULLY.

AND

POSSIBLE

E: DRIVER

A DANGER
EXPLOSIVE/FLAMMABLE
CONTACT
AS COPPER,

FUL AND

POUNDS.

STORAGE

(1OOOCI.

POSAL

SRS SUPPLEMEf{T.

POTSON
CONTAINS
I{ITRATE.

FIRST AID
IF CONTENTS
FOR

MINUTES.

ARE

PROMPT MEDICAL
KEEP OUT

INHALED.

MODULE

WITH

LEAD

IRFITATING

T€MPERATURES

FOR

PROCEDURES

EYE CONTACT,

PROPER

POISONOUS

ARE SWALLOWED,

IF GASES

REACH OF

OF

DANG€R

ACID, WATER

MERCURY

OR

HANDLING.

REFER

SODIUM

FLUSH

IFROM

SEEK

FRESH

ATTENTION.

HEAVY

OR

MAY

GASES

MUST NOT

TO THE SERVICE

ACID

CHILDREN

OR

AZIDE

EYES

OR WATER

AIR. IN

METALS

PRODUCE

EXPLOSIVE

EXCEED

STORAGE

AND POTASSIUM

INDUCE

WITH U'ATER

EVERY CASE,

VOMITING.

CONTACT}

SUCH

HARM.

COM.

2OOOF

AND DIS-

MANUAL,

15

GET

INJURY:
ALWAYS

II{STALL

O THE INFLATOR

THE PNOTECTIVE

COI{I{ECTOR

DISCONNECTED.

SHORT

WHEN THE

COI{NECTOR

HARNESS

IS

F: DRIVER

WABNING

A,
THE
TALLY DEPIOYED,

.

.
.

.

AIRBAG

DO
ING
THEY CAN

NO SERVICEABLE
SEMALE.
PLACE

FOLLOW
CAREFULLY.

MODULE

INFLATOR

NOT USE

DEVICES.

AIRBAG

ELECTRICAL

CAUSE

SERVICE

WARNING

IS EXPLOSIVE

CAN

UPRIGXT

SERIOUSLY

TEST

ACCIOENTAL

PARTS

WHEN

MANUAL

AND' IF ACCIDEN-

I{URT OR

EOUIPMEI'IT

OEPLOYMENT.

INSIOE,

DO NOT

REMOVED'

II{STRUCTIONS

KILL YOU.

OR PROB-

DISAS.

(cont'd)

1-5

Warning/Caution

Label

(cont'd)

Locations

G:

DBIVEB

G:

DBIVEB

C.Ai

A_FRo_NT
SEATPASSENGER
TRAINT

: Lr_ll^gls_lglls

.

BEFoRE

1-6

TNFORMATTON

INFORMATTON

ALWAYS

IS

EOUIPPED

SEAT

SYSTEM

oRrvrNG,

{SUNV|SORt

{SUNvtSORt.

WEAR

pASSENGER

AIRBAG

{SBSI

ro

suppLEMENr

Reeo

L.qset

YOUN

WITH

AS

SCIT
A
nrnslc

A

msiDr

EELT

DRIVER
SUPPIEMENTAL

nNo

rHE

rxE

AIRBAG

sEAr

GLovE

ANO

e raoNi

BES.

BEt-r.

Box.

rThis

vo.3ion

paas€ngor's

ot tho

airbag.

lsb€l

i!

us6d

in

csrs

wtth

a,ront

soat

J: GLOVE

BOX

INFORMATIOf{

M: AIRBAG

AIRBAG

LABEL

SUPPLEMENTAL

.

THE SRS

IS INSTALLED.
ON

DRIVER'S

.

DIAGNOSTIC
COMPONENTS

DEALER

.

SEE
INFORMATION.

K: FRONT SEAT

A WARNING
ACCIDENTAL

THE CERTTFICATION

YOUR OWNER'S

MUST

DOOR JAMB.

AIRBAG

AIBBAG

BE INSPECTED

TI{E DATE

CHECKS

MUST

PASSENGER

INFORMANO

RESTiAINT

OF INSTALLATION

PLATE,

AND

DONE BY

BE

MANUAL

INFLATOR

DEPLOYMENT

SYSTEM

TEN YEARS

LOCATED ON

REPLACEMENT

AN AUTHORIZED

FOR AODITIONAL

WARNING

CAN

(SRS)

AFTER

IS SHOWN

OF SNS

TAG

SERIOUSLY

IT

THE

SRS

N: SRS

SUPPLEMENTAL
THIS

ALL SRS
COLORED
TAMPERING

CAL
THE SYSTEM

ING OF
A.

THE AIRBAG
TALLY

FOLLOW

WARNING IENGINE

VEHICLE

ELECTRICAL

YELLOW.

TEST EOUIPMENT

THE INFLATOR.

WANING

DEPLOYED,

SERVICE

IS EOUIPPED

WITH,

INOPERATIVE

INFLATOR

HOODI

RESTRAINT

WIRING

DISCONNECTING

ON

IS EXPLOSIVE

CAf{

MANUAL

SERIOUSLY

SYSTEM

WITH

TI{E SRS

OB

INSTRUCTIONS

DRIVER

AND CONNECTORS

CAUSE

(SBSI

SIDE

OR USING

WIRING

ACCIOENTAL

AND,

HURT

YOU'

AIRBAG.

ELECTRI-

CAN

IF ACCIDEN-

CAREFULLY.

ARE

MAKE

FIR'

HURT OR
INSTALL
FLATOR

L: FRONT

A DANGER
EXPLOSIVE/FLAMMABLE
CONTACT
AS COPPER.

FUL AND
POUNDS.
STORGE

tlOO"CI.
POSAL

SBS

SUPPLEMENT.

KILL

THE RED SERVICE

HARNESS

SEAT

WITH

TEMPERATURES
FOB PROPER

PROCEDURES

YOU.

DISCONNECTED

IS

PASSENGER

ACID,

LEAD

IRRITATING

WATER

MERCURY

OR

HANDLIING,

REF€B

CONNECTOR

MODULE DANGER

OR HEAVY

PRODUCE

EXPLOSIVE

STORAG€

GASES

MUST

TO THE SERVICE

MAY
OR

NOT EXCEED

WHEN

METALS

THE

SUCH

HARM'

COM.

2OOOF

AND

MANUAL,

IN-

DIS-

N: SRS

SUPPLEMENTAL
THIS VEI{ICLE

SEAT
ALL

COLORED
TAMPENING

CAL
THE SYSTEM

ING OF
A

THE AIRBAG
TALI-Y DEPLOYED,

FOLLOW

WARNING IENGINE

RESTRAINT

IS EOUIPPED

PASSENGER

SRS

TEST

WABNING

ELECTRICAL

YELLOW.

WITI{,

EOUIPMENT

INOPERATIVE

THE INFLATOB.

INFLATOR

SERVTCE

HOODIi

SYSTEM {SRSI

WITH DRIVER

AIRBAGS.

WIRING

DISCONNECTING

ON THE

IS EXPLOSIVE

CAN

MANUAL

SEBIOUSLY

AND CONNECTORS

OR

SRS

CAUSE

OR

INSTRUCTIONS

WIRING

HURT

ANO

USI

ACCIDENTAL

AI{O,

G ELECTRI'

CAN

IF

YOU'

CAREFULLY.

FRONT

ARE

MAKE

FIB'

ACCIDEN-

POTSON

CONTAI'\'S

NITRATE.

FIRST
IF CONTENTS
FOR
MINUTES.

IF GASES
HALED,
MEDICAL
KEEP OUT OF

A' WARNING
THE AIRBAG
TALLY DEPLOYEO,

.

.

AID

EYE CONTACT,

DO NOT USE
ING
THEY CAN CAUSE

NO

POISONOUS

ARE

(FROM

SEEK

ATTENTION.

DEVICES.
SERVICEAALE

FRESH

REACI.I

INFLATOR

SWALLOWED,

ACID

CAN

ELECTRICAL

SODIUM

FLUSH

OR WATER

AIR. IN

OF CHILDREN.

IS

SERIOUSLY

ACCIOENTAL

PABTS

EYES

EXPLOSIVE

AZIOE

INDUCE

WITH WATER

EVERY CASE.

TEST EOUIPMENT

INSIDE.

AND POTASSIUM

VOMITING.

FOR 15

CONTACT)

GET

AND. IF

HURT

DEPLOYMENT.

OR

OO

NOT OISAS-

ARE IN.

PROMPT

ACCIDEN­KILL YOU.

OR PROB.

'This

passonger's

vorsion

tho

ol

airbag.

labol is u36d

in cs.t

with

a front

soat

SEMBLE.

.

PLACE

.

FOLLOW
CAREFULLY.

AIRBAG UPFIGHT

SERVICE

MANUAL

WHEN

REMOVED.

INSTRUCTIONS

{cont'd)

fi{lHfiFe*%

1-7

_

Warning/Caution

Label

(cont'd)

Locations

SERVICE

BATTERY

CAUTION

INFORMATION

C)

SPARK PtUG
II{FORMATION

AIR
MENDEO
FILTER

CLEAI{€R,

OIL and

SERVICE

RECOM-

RADIATOR
CAUTIOI{

CAP

1-8

TIRE INFORMATION

{300()R)

TIRE INFORMATIOII

t4DOOR)

Lift and

Support

Lift

Points

Wh€n

il]iii6iliieigltt

gravity

cantor

NOTE:
with the

1. Place

2. Raise

3.

of

Since each

weight

the lift blocks
the

Raise the

heavy 16ar

in the tuggage

may

distribution.

hoist a lew
hoist to

chango

tire/wheel

as

inches

full height

compon€nts

area

and can

assembly

shown

bsfore

cause

weighs

(centimeters)

and

inspect lift

such

aa susponsion,

hoisting.

the cal to

approximately

and

points

luel tank, spale

When substantial

tip folward

14 kg

rock the car

for solid

on

(30

to be

support.

tile

woight

the hoist'

lbs),

sure it

is lemoved

placing

is firmly supported.

and hatch ale to

ths

the

from

front wheels

b€ removod,

l€ar ol

in trunk

th€ car, ths

can assist

plac6

FRONT SUPPORT

POINT LIFT

BLOCKS

BEAR SUPPORT

POINT

1-9

Li

ft

FI

and

oor

Jack

Support Points

1.

2. When

3.

4.

Set the
not being

when tritrng

lever

sition).
Raise

Adjust

1-1

er

in

the car high

1 so the

the car

parking

lifted.

lifting

reverse

and

the

the

place

car will

onto

brake

rear

rear

(Automatic

enough

the

them.

and

of the

of

safety

be

approximately

block

to insen

stands

the wheels

car,

transmission

put

the safety

as shown

the

level,

gearshift

in

then

that

@

stands.

on

are

po-

page

low-

a

Always
der

Naver

porting

any vehicle

attompt

uss satety

that is

to use a bumpor

tho

car,

stands when

supponed by

iack

working

only a

fo. lifting

oo 01 un-

jack.

or

sup-

Front

Center
bracket
ot the

jack

Rear

the

jsck

in

the middle

lift

platform.

JACK LIFT PLATFORM

JACK LIFT

1-10

PLATFORM

Center
bracket in

of the

the

jack

jack

the middle

platform.

Iift

Safety

Stands

RUBBER

ATTACHMENTS

t$

\F

FROI{T

SUPFORT

POII{T

SAFETY STANDS

REAR

SUPPORT POINT

1-11

Towing

It the

car needs to
service. Never
a rope

or chain. lt

be towed,

tow

the car behind

is very

professional

call a

another

dange.ous.

towing

car with

just

Front:

rl

Emergency
There

are three

Flat-bed
back
car.

Whsol

ing
them
the

Sling-type
with hooks
of the frame
of the car
can be
tempted.

It the
towed
damage.
on the

Manual

a
a

Automatic

a
a
a
a

Equipmont-The

of

a truck. This

Lift

arms that

otf the ground.

ground.

Equipmont-The

off the

seriously

car cannot

with

the car must

ground,

Transmission
Release
Shift the

Release
Start
Shift to

Turn

the

Transmission

the

the engine.

@

off

Towing

popular

Equipment-The

go

under

on the

or suspension

ground.

damaged if

be transponed

the tfont

do the tollowing:

parking

transmission

parking

oosition,

the

engine.

methods

is the

the

The

ends.

These hooks

The

wheels

be towed

brake,

brake.

then to

to

of towing

operator

best way

tires

other

tow

and

this method

loads

of transporting

tow

truck

uses two

(front

or rear)

two wheels

truck uses

go

the cables lift

car's suspension

of towing

by

flat-bed,

with

position.

S

ground.

the front

oft the

Neutral.

a car:

the car

and lifts

remain

metal

around

that

and

it should

lf

wheels

on the

the

oivot-

on

cables

parts

end
bodv
is

at-

be

due to

Real:

TOWING

HOOKS

NOTICE:
transmission.
cannot
matic
flat-bed.

a

NOTICE:

will cause

to support

lmproper

shift the

transmission), your

lt is

best to

km).

and keep

Trying

serious

the

towing

Follow

the above

transmission

tow the

car's

car no tarther

the

speed below

to litt

or tow

damage.

weight.

preparation

procedure

or

stan the

car must

The bumpers

be transDorted

than

3b mph

your

car

will damage

exactly. lf

engine

SO miles

(bE

by the bumpers
are not

the

you

(auto-

on a

lgo

km/h).

designed

tool

lists are

Tools

Special

lndividual

located

at the

front

of

each

section

Specifications

Standards

Design

Body

Specifications

Specifications

and

Service

Limits

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

.'-.'.'."-'-'

'.....'.'.

3-2

3-1

3-20

7

Standards

and

Service

Limits

Cylinder

Compression

Cylinder h.ad

Camshaft

Head/Valve

Train

250 rpm
kPa

W6rpage

Height

End

Camshaft-to-holder
Total runout
Cam lobe height

Valve clearance
Valve

Stem-to-guide

(kgflcm?,

play

and wide

psi)

stem O.D.

(B188t

MEASUREMENT
open th.ottl€

oil clearance

(Cold)*

clearance

enginel

Nominal
Minimum
Maximum

-

Secti

Declron

variation

tN

EX
lN

EX

tN
EX
lN
EX

6

STANDARD

1,370

930

200

r31.95-

0.05 - 0.15

0.030 - 0.069

0.03

33.7 16

33.528

0.08

0.'r 6

6.580

6.550

0.02

0.05

(14.0,

(9.5,

140)

t2.0,2a)

132.05

(0.001)

.327 1l

11
(1.3200)

-

0.12

-

0.20

-

-

-

0.0s

-

0.08

{0.003 - 0.005)
(0.006

6.590

6.s60
(0.001

(0.002

{NEWI

199)

(5.195

(0.002

10.0012 - 0.0027)

max.

(0.2591 ­(0.2579

-

-

-

-

-

5.199)

0.0061

0.008)

0.2594)

-

0.2583)

0.002)

0.003)

'

SERVICE LIMIT

0.05

0.5

0.1s

0.04

6.s5

6.52

0.0810.003)

0.11

(0.002)

(0.02)

{0.006)
(0.002)

(0.258)
(0.257)

(0.004)

Valve

Valv6

*:

Measured
NH: NIHON
CH: CHUO HATSUJO

spring

guide

between

HATSUJO manufactur€d

the camshaft and rocker

manufacturod

width
Stem instslled

Free

Lu.

Installed

length

height

height

{Reference}

valve

valve

arm.

spring

sDrino

tN
EX
tN

EX

lN

EX NH

CH

lN

EX
lN

r.25 - 1.55

1.25 - 1.55

40.765

12.763

42.36

47.09

47.08

6.61 - 6.63

6.61 - 6.6s

13.75
r5.75

-

-

(1.668)

{1.854}
(1.854)

-

-

(0.049
{0.049 - 0.061)

41.235

43.235

(0.260
(0.260-

14.25

16.25

-

0.061)

(1.6049

t1,6a37

-

0.261)

0.261)

{0.541 - 0.561}

10.620

-

-

-

0.640)

1.6234)

1.7022)

2.0

t0.08)
(0.08)

2.0

41.485

43.485

41.s6

46.27

46.21

6.65

6.6510.2621

(1.6333)
(1.7120)

{1.636)
tl.A22l
l1.a22l

(0.262)

3-2

Engine

Block

(81881

k

{Bl6E1

englnel

-

sectlon

s cti

7

Unit of

length:

mm

{in}

Cylinder

Piston

Piston

block

ring

Warpage ot

Bore diameter

Bore taPer
Reboring

Skirt O.D.

Clearance
Groove

Ring to-groove

Ring end

deck sLrrface

limit

15 mm

at

in cylinder

width

(For

clearance

gap

MEASUNEMENT

(0.6

ring)

in)Irom

bottom

Top

Second

oil

--

top

Second

'....=-

lop

Second
oit

of skirt

R

T

;

T

R

T

STANDARD

(NEWI

0.0710.003)max.

-

81.00

80.98

0.01

1.030

1.230 - 1.210

2.805

0.045 - 0.070

0.040

0.045

0.20

0.20

0.40 - 0.5s

0.20

0.20 - 0.45

81.02

-

80.99

-

0.04

-

r.010

-

2.820

-

0.065

-

0.070

-

0.35

0.30

-

0.s0

{3.189

(3.188

(0.0004

(0.0406
(0.0484
(0.1104

{0.0018

(0.0016
(0.0018

(0.008
(0.008

(0.0
(0.008
(0.008

r6 - 0.022)

-

-

-

-

0.014)

-

0.012)

-

0.020)

-

0.0181

3.190)

3.189)

0.0016)

0.0409)

-

0.0488)

0.1110)

-

0.0028}

-

0.0026)

-

0.0028)

SERVICE

0.10

81.07(3.192)

0.05

0.25

(0.004)
(0.002)

(0.010)

LIMIT

80.9713.188)

0.05

(0.002)

1.0610.042)

1.26

(0.050)

2.8410.112\

0.13

0.13

0.13

{0.00s)

(0.00s)
(0.005)

0.60 {0.024)

0.60

0.70

0.70

0.70

10.024)
(0.028)

(0.028)
(0.028)

rrston rln

Connecting

rod

Crankshaft

Bearing

o.D.

Pin-to-piston
Pin-to-rod

Smallend

Large end
End

Main

Rod

play

journal

iournal

Taper

Out-of
End

round

play

Runout

Main bearing-to-iournal

Rod bearing

clearance

interference

bore diameter
bore diameter

installed

on crankshatt

diameter

No. 1, 2, 4 and
No. 3

iournal

diameter

No.
No. 3

1, 2, 4 and

journal

to-iournal

oil clearance

oil clearance

Nominal

journals

5

journals

5

-

20.994

0.0r0

0.013

21.000

-

0.022

-

0.032

20.968 - 20.981

48.0

0.1s

54.976

54.970

44.S76

0.00510.0002)

0.005

0.10

0.03

0.024

(1.89)

-

0.30

(0.0002)

-

0.35

(0.001)

(0.006

-

55.000

-

54.994

-

45.000

(0.004

0.042

0.030 0.048 {0.0012

0.020

0.038

(0.8265

(0.0004
(0.0005

(0.825s

-

0.012)

(2.1644
(2.1642

{1.7707

max.
max.

-

0.014)

max.

{0.0009

(0.0008

-

-

-

-

-

-

0.8268)

0.0009)

0.0013)

-

0.8260)

-

2.1654)

-

2.1651)

-

1.7717}

0.0017)

0.0019}

0.0015)

0.010

0.010

0.45

0.04

(0.0004)
(0.0004)

(0.018)
{0.002)

0.05010.0020)

0.060

0.050

(0.0024)
(0.0020)

Ri RIKEN manutacture

T:TEIKOKU

PISTON

Piston

RING

ring

manufacture

piston

ring

3-3

Standards

and

Service Limits

Cylander Head/Valve

Compr€6sion

Cylind6r hoad

C.mshsft

250 rpm
kPa

lkgl/cmr,

Warpage

H6ight

End
Camshaft-to-holdsr
Total runout
Cam lobo height

play

Train

and wide

psi)

(B18Cl

enginel

MEASUBEMENT

op€n throttle Nomin6l

Minimum

Maximum

oil clearance

lN

Primery
Mid

Socondary

EX Primary

Section

variation

6

STA]TDARD

1,860

930

200

'r41.95

0.05 - 0.1s

0.050

0.015

33.411{1.3154)

36.377

34.547

33.1110.3036)

(19.0,

(9.s,

270)

140)

t2.o,2a)

-

1C2.05

(0.002

-

0.089

(0.0006)

tl.13221

(1.3601)

(5.s89 -

-

0.006)

(0.0020

max.

INEWI

5.593)

-

0.0035)

SERV|C€

0.05

0.5

0.15

0.03

{0.002)

(0.02)

{0.006)
(0.001)

UM|T

Valvo seat

Valv€

Bpring Fre6length

Valvo clorrance
Valve stem
Stom-to-guid6

Width
Sr6m installed

O.D.

(Roferenca)

lcoldl*

clerrsnco

h€ight

lN

EX

Mid

Secondary

Outer
Inner

lN
EX

lN
EX
lN
EX

tN

EX

lN

EX
NH

CH

NH

CH

35.72011.4063)

34.381

0.15 - 0.19

0.17

5.475 - 5.48s

5.450 - 5.460

0.025

0.050 - 0.080

1.25

'1.25

37.465

37.16s - 37.635

41.05

36.'16

36.19

41.96

41.94

{1.3536)

{0.006 - 0.007}

-

0.21

-

't.5s

-

-

1.s5

-

(r.6161

{1.4241
t1.425)

(1.652)
{1.651)

(0.007 -

0.055

(0.049 ­{0.049

37.935

(0.2156
(0.2146 -

{0.00'10
(0.0020

-

('1.4750
t1.4632

0.008)

-

0.21591

0.21s0'

-

0.0022}

-

0.0031)

0.06't)

0.061)

-

1.4935)

-

1.4817)

5.11510.21441

s.420

0.08

0.11{0.(x)4)

2.0

2.0

38.185

37.885

40.26

35.30

35.30

40.95

40.95

{0.2134)

10.003)

(0.08)

(0.08)

(1.5033)
(1.491s)

(1.585)
(1.390)
(1.390)
(1.612)
(1.612)

Valve

Rock€r erm

':

M€asured

NH:

CH: CHUO HATSUJO

guido

betwoon

NIHON HATSUJO manufacture

the camshatt and

manufscturo v6lve

l.D.
Instslled

Arm-to-shaft

hoight

clearance

v6lve

rcc(er srm.

spring

spring

tN
EX
lN

EX

lN

EX

5.51 - 5.53

5.5r - 5.53

12.55

12.55

0.025 - 0.0s2

0.025 - 0.0s2

-

-

(0.217

{0.2r7

r3.0s

13.05

(0.494
(0.494

{0.0010
(0.0010

-

0.218)

-

0.218)

-

0.514)

-

0.s14t

-

0.0020)

-

0.0020)

5.55

5.5s

0.08

0.08

(0.219)

{0.219}

(0.003)
(0.003)

3-4

E

ngrne

BI k

]'ocK

(818C1

(ltluur

englnel

-

Section

7

Unit

of length:

mm

(in)

Cyiinder block

Piston

Piston ring

MEASUREMENT

warpage of

Bore diameter
Bore taPer
Reboring

Skin O.D.
Clearance
Groove

Ring-to-pistongrooveclearance
Ring

width

end

deck surlace

limit

15 mm

ar

in cylinder

(For

gap

ring)

(0.6

in) {rom bottom ot

skirt

ToP

Socond

oil

Top
Second

I oP

Socond

oil

STANDARD

0.05

81.00 - 81.02 {3.189

80.98 - 80.99

0.0r

1.030

1.230

2.805

0.045

0.010

0.20 - 0.35

0.40

0.20

(0.002)

-

0.04

-

1.0,r0

-

1.240

-

2.820

-

0.070

-

0.065

-

0,55

-

0.s0

max.

13.188

{0.0004

{0.0406
(0.0484

(0.1104
{0.0018

(0.0016

{0.008
(0.016

{0.008

(NEWI

-

-

-

0.0016}

-

-

-

-

-

-

0.014)

-

0.022)

-

0.020}

3.190)

3.189)

0.0409)

0.0488)

0.11101

0.0028}

0.0026)

SERVIC€

0.08

81.0713.192)

0.05

0.25

80.97

0.05

1.060

1.260

2.840

0.13

0.13

0.60

0.70

0.7010.0281

(0.003)
(0.002)

(0.010)

(3.188)

(0.002)

(0.0417)

(0.0496)
(0.1118)

(0.005)
(0.005)

(0.024)
(0.028)

LIMIT

rrston rtn

Connecting

rod Pin

crankshatt

Eearing

o.D.

Pin-to-piston

to-rod int€rference

Small

Large end
End

Msin

Rod

Taper

Out'ol
End
Runout

Main bsaring-to-journal

Rod bearing-to-journal

end bore

play

journal

iournal

round

play

clearance

diameter

bore diameter

installed on crankshaft

diameter

No. 1,2,4 and 5
No. 3

diameter

No.
No 3

journal

oil clearance

1, 2, 4 and 5

journal

clearanc€

oil

Nominal

iournals

journals

-

20.994

0.010

0.017 - 0.035

20.964 - 20.997
€.0

0.15 - 0.30

54.976

54.974

44.976

0.005 {0.0002}

0.004 {0.0002)

0.10 - 0.35 {0.00{

0.020

0.024 - 0.042

0.030

0.032

21.000

-

0.022

(1.89)

(0.006

-

55.000

-

54.998

-

45.000

(0.0008)

-

0.048

-

0.050

(0.8265
{0.0004
(0.0007

(0.8254

-

(2.1644
(2.'|643

{1.7707

max.
max.

-

max.

(0.0009
(0.0012
(0.0013

-

0.8268)

-

0.0009)

-

0.0014)

-

0.8267)

0.012)

-

2.16541

-

2.1553)

-'I.7717)

0.014)

-

0.0017)

-

0.0019)

-

0.0020)

-t-oou
lo.ooort

0.050

0.060

0.060

(0.0020)
{0.0024)

(0.0024)

3-5

Standards

and

Service

Limits

Engine

Engine

pump

Oil

Relief

oil

valve

Lubrication

-

Capacity

(US

f

Inner-to-outer
Pump
Pump

rressure

kPa

qt,

lmp

horising-to-outer
housing-to,rotor

setting

lkgtcm,,

Section

eclton

MEASUREMENT

qt)

rotor

at engine

psi)

g

u

clearance

rotor

axial

_

clearance

clearance

oil

temp.

At idte

At

3,000 rpm

etaet

818C1

176.F

{gO.Ct

engine

engine

STANDARD

4.6

{4.9,
(4.0,

3.8

3.513.7,

4.8

{5.1,
(4.2,

4.0

3.7 i3.9 3 3l fdr ^il .hi

0.04

0.10

0.02 - 0.07
(0.7,

70
3{0

{3.5,50)

-

0.16

-

0.19

10)

4.0}tor

3.3) for

3.11 for

4.2) for

3.5) lor
(0.002 -

(0.004 _
(0.001

min.

min.

engine
oil

change,

oil

change,
engine
oit

change,

0.006)

0.007)

,

0.003)

INEW}

overhaul

overhaul

inctudin

without

includin

g

tiher

g

talter

filter

0.20

0.21

0.1s

(0.008)
(0.008)

(0.006)

SERVICE

LIMTT

Cooling

Radialor

Radiator

Thermostst

Cooling

cap

fan

ng the

-

Section

Coolant

I

I

Reservoir

0.61

Opening

start to
Fully

Valve

lhermoswitch

Thermoswitch

coolant

in

t0

capacity

Including

cooling line

(0.63

open

open

lift

the reservoir

engine,

and reservoir

capacity:

qt,0.53

US

pressure

oF

.F

(.C)

at fully

open

"ON"
"OFF"

and

MEASUBEMENT

I

{US

heater,

kPa

(.C)

temperature

that remaining

qt,

lmp
I

I

tmp

temporature

qt)

(kgf/cm?,

q0

psi)

.F

in the

81881

818C1

{oC)

"F

(.C)

engine

engine

engine.

M/T:

A,rf:
M/T:

,3

169
194

8.0
196

Subtract

6.4

4.4

6.7

4.7

6.7

4.7

-

113

-

176

(90,

(0.31)

-

203

{7.1, 5.9) for

{5.0, 4.1) for
{7.1,
{5.0,

toss - trs, r3=

5 - 14

(6.8,

(4.6.3.9)

5.6)tor

5.9}

4.1)

{76 80}

-

(91

for

for

95)

-

(3

f6r

STANDARD

overhaul

s66lsn1gh66q.*

overhaul
coolant
overhaul

coolant

chanoe*

chanoe*

INEWI

-

Jt&

8) from

actuat

-ON',

temperature

3-6

Fuel and

.u.l

pump Disolacoment

F

aa3uro

tualt6nk

En9in6

Emissions

rggulator

(fl

m,
Pressure

(kgflcm', psi) Bl8Bl engine

kPa

Caprcity, {US

ldle sDeed

Fast idle

ldl6

CO

Section

in

lmp oz)

oz,

with

with headlight

rpm

%

11

MEASUREMENT

l2 V, 10 seconds

regulator

vacuum hose disconnected

gal,

gal)

lmp

and cooling

81881 engine

818C1 engins

Bl8Cl engin€

rpm

fan ofi

sTAt{ItAno

-81 min.

.5,7

222 17

(12.3,

(13.2,

11.01

(M/T:
{A/T:

i 2(x'

max.

12.8)

(3.35

lM/T:
(A/T:

364

275 - 32a 12.8
329 - 378

50

7501 50
750I 50

1,600
l,eoo I 200

0.1

(Newl

min.

-3.9,39.6

-

3.85,

neut..ll

or

E

E

nsurr6l)

or

E

-

46.9)

47.6- 5.47)

position}

po6itioo)

E

Unit

12011.1'

|

(:.1,

too

I

ot length:

SERVICE

1'21

g.st

UMIT

mm

{in)

Clutch

padsl

clutch

clutch disc

Pr6sur6

plat€

Section

P6d6l
Siroke
Pedal
Disengagement

Clutch
Riv€t

Thickness
Warpage

Oiaphragm

12

height
play

runout

sudace

h€ad depth

spring

MEASUREMENT

height

alignment

linger

to

to

lloor

floor

STAM'Ad'

(6.46)

164
130 - 140
12 - 21
83

0.05 10.002)

1.3

8.4- 9.1

0.03
0-6

(0.47

(3.27)

(0.05)

(0.001)

(0.02)

(5.12

min.

max,

min.

(0.3

mrx.

ma*

-

-

-

5.51)

0.83)

0.36)

IiEWI

0.'15
(0.011

0.2
(0.24)

6.0

0.15
(0.03)

0.8

SERVICE

(0.006t

(0.006)

UMIT

{n+

3-7

ll

Standards

Manual

Transmission oil

Mainshaft

Mainshafi

3rd and

gears

4lh

Mainshaft

gear

5th

Transmission

and Service Limits

Section 13

MEASUREMENT

qt,

Capacity f

play

End

Diameter

Diameter
Diameter

Runo!t

ot ball bearing

(clutch

of 3rd
of ball besring

(transmission

t.D.

play

End

Thickness

t.D.

play

End

{US

housing side)

lmp

gear

contact

housing

q0

Thickness

Countershaft Diameter of needle bearing

Diameter
Diameter of 1st

of ball boaring contact area

gear

contact area

Bunout

Countershaft

gear

lst

Countershaft

gear

2nd

Spacer collar
(Countershaft

gear)

2nd

Spacer collar

l'rainshaft

{
4th and

gears)

sth

t.D.

play

End

LD.

play

End
Thickness 81881

t.D.
o.D.

Length

t.D.
o.D.

Length

contact area

area

contact area

side)

conlact area

818C1

3rd
4th

engino
6ngine

B

B

STANDARD {NEWI

2.2

2.3

-

0.11

0.18

27 .977 - 27

37.984 - 38.000

27.987 - 28.000
(0.0008)

0.02

43.009 - 43.025

0.06 - 0.21

34.92 - 31.97

31.12 - 31.17

43.009 - 43.025

0.06 - 0.21

31.42 - 31.47

-

33.000

24.980

36.984 - 37.000

0.02

42.009 - 42.025

0.04 - 0.12

47.009 - {7.025

0.05 - 0.12

34.62 - 34.67

28.92 - 28.97

36.48 - 36.49

41.989 - 42.00011.6531 - 1.6535)

29.02 - 29.04

29.07 - 29.09

31.002 - 31.012

37.989 - 38.000

56.45 - 56.55

26.03 - 26.08

33.015

-

24.993

10.0008)

-

{0,004

l.1.101

s90

{1.495
{r.1018

max.

11.6933

(0.0024

(1.3748

11.2370

(1.6933

(0.0024

t1.237

(1.299
{0.9835

(1.4561

max.

11.6539

(0.0016 -

11.8507

-

(0.0020

(1.3630
(1.1386

(1.4352
(1.r42s

(1.1444

(1.2205
(1.4956

12.2224

(1.0248

0.007)

-

1.9}lor

{2.3,
(2.4,

2.0) lor assembly

-

1 .1021

-

1.495}

-

1.1024}

,

1.6939)

0.0083)

-

1.3768)

-

1.23SOl

-

1.6939)

0.0083)

-1.2391

-

1.300)

-

0.9840)

-

1.4567)

-

1.6545)

0.0047)

-

1.85r4)

0.0047)

-

1.3650)

-

1.1405)

-

1.4366)

-

1.1433)

-

1.1453)
'1.2209)

-

-

1.4951)

-

2.22641

-

1.0268)

SERVICE UMIT

oilchange

Adjust

(1.10)

27.93

37.93

{1.493)

21 .94 /.1.10!'

(0.002)

0.05

43.08 t 1 .696)
(0.012)

0.3
(1.370)

34.8
(1.2321

31.3

43.08

{1.696)

(0.012)

0.3
(1.232)

31.3

32.95

\1.297)
(0.982)

24.94

36.93

{1.454)

0.05

t0.002)

(1.657)

42.08

Adjust

47.0811.854)

Adjust

(1.358)

3{.5

(1.134)

28.8
(1.437)

36.5

(1.651)

41.94

('1.223)

31.06

(1.494)

37.94

3-8

Manual

Reverse

idler

gear'1
Synchro

Oouble cone

ring

synchro

itt fork

Sh
qeverse

shift

arm

Shift

piece

Shift

Selector

'1:81881
'2

818C1 engine

Transmission

LD.
Gear-to-reverse

ring

*2

engine

Ring-to-gear clearance
Clearance

Shift
Fork-to

Shift

Fork-to-reverse
"1"

Fork-to-5th/reverse

Groove
Change

Groove
Shift
LD.
Shift
Diameter of
Shift

Diameter of change

Arm-to-change

Groove

Arm-to-interlock

Section

MEASUREMENI

gear

shaft

pushed

{rin9
Outer synchro
lnner synchro
Outer synchro

tork finger thickness

synchro sleeve

fork

groove

width of change

piece-to-shift

width of shift

piece'to-shift
piece-to-shaft
piece-to-shift

widlh of

ring-to-gear

ring-to-gear

ring-to-synchro

pawl groove

width

gear

idler

shift

arm clearance

clearance

shift Iork cont6ct

fork shaft

piece

piece

interlock contact
clearance

13

clearance

(ring pushed

against

clearance

width

clearance

piece

piece

clearance

arm
arm contact area

contact

clearance

against

gear)

cone

at sth
at reverse

pin

clearance

at 5th

at

contact

area

clearance

area

area

gear

gear

reverse

area

99ar)

side

gear

side

gear

20.016

0.036 - 0.084

0.85

0.95

0.5

0.5-

7.4,7.6

0.35 - 0.65

13.0

0.5

7.40 - 7.70

7.05 - 7.25

side

0.4 - 0.9 {0.016

0.05 - 0.45

side

11.8

0.05 - 0.35

7.9 - 8.0

0.10

14.000 - 14.068

0.011-0.092
1'1.90

0.20 - 0.50

11.90

0.05

10.05 - 10.15

0.05 - 0.2s

STANDARD INEW)

-

-

-

1.10

r

1.68

1.0

1.0

-

13.3

1.1

-

(0.7880

20.043
(0.0014

(0.033

(0.037

-

(0.02

0.04)

-0.04)

{0.02

-

(0.291

(0.014

(0.512

-

10.020
(0.291

0.299)

0.043)

(0.278

-

0.03s)

(0.0020

-

(0.4646-

12.0
(0.002

-0.315)

(0.311

-

(0.004

0.30

-

-

-

0.35

12.00
(0.008

't2.00

{0.002
(0.002

{0.551

(0.0004
(0.469

(0.469

{0.3957

-

-

0.0033)

-

0.043)

-

0.066)

-

0.026)

-

0.524)

-0.303)

-

0.28s)

-

0.018)

0.4724)

-

0.014)

-

0.012)

-

0.554)

-

0.0036,

-

0.472)

-

0.020i

-

0.472)

-

0.014)

-

0.3996}

-

0.010)

0.7891)

length: mm

Unit of

SERVICE LIMIT

(0.7909)

20.09
(0.006)

0.16
(0.0't6)

0.4
(0.024)

0.6
(0.01)

0.3
(0.01)

0.3

(0.039)

1.0

13907)

0.8010.031)

(0.024)

0.60
(0.0059)

0.150

oso

to.oart

(0.020)

0.50
(0.020)

0.50

(in)

-

Automatic

Transmission
lluid

Hydraulic
pressure

kPa

I

lkgflcm',

Stall speed

Transmission

Capacity

Line

psi)

rpm

(E

2nd clutch

(DJ
3rd clutch

(lqr
4th clutch

{E
2nd clutch

(Elposition)
1st clutch

([O
'lst'hold

(Elposition)
Throttle

(Check

with car

pressure

position)

or

E

pressure

position)

pressure

posirion)

pressure

position)

pressure

position)

or

E

clutch

pressure

on level

-

Section

oEutrlrrl

MEASUREMENT

(US

I

2,000 rpm

at

at

at 2,000

pressure

at

pressure

B

ground)

14

rr

qt)

qt,

lmp

rpm

at 2,000

2,000 rpm

rPm

2,000 rPm

at

2,000 rpm

at 2,000

Throttle fully closed
Throtlle Iully opened

rpm

STANDARD {NEWI

5.2)for overhaul

5.9

16.2,
(2.9,

2.7
830 - 880

460
throttle

I

I

830 - 880
throttle

2.4)
(8.5

-

67)

14.7,
Iully closed

(8.5

more than

for lluid change

830 - 880 {8.s

830 - 880

830

0
830

(8.5

-

880

{8.5

-

1s

{0-0.15,0-

-

(8.5

880

2,200 - 2,600

-

120 - 130)

9.0,

-

9.0, 120
3/16 opened

-

120 130)

9.0.

-

9.0, 120

-

9.0,

21)

-

9.0,

-

130)

-

130) 780

120 - 130}

120 - 130)

SERVICE

780

{8.0,

410

{4.2.60)

throttle fully closed

I

780

{8.0,
throttle
3/16 opened

(8.0,

780

(8.0,

(8.0,

780

780

18.0,

Below
above

LIMIT

110)

110)

more than

110)

110)

110)

110)

2,200,
2,600

(cont'd)

3-9

Standards and Service Limits

Automatic Transmis3ion

(cont'dl

MEASUFEME'YT

Clutch Clutch initialcl6aranco lst, 2nd

Clutch rdtu.n spring troe length lst,

Clutch disc thicknosg

plale

Clulch
Clutch ond

('l8t)

Clutch ond
(2nd,3rd,

Clutch ond
(lst-hold)

thickn$3

platothictnoss

plato

thickn$s MARK 1

ath)

pl.t6

thicknoss MARK 1

-

Sostion 14

3rd, 4th

lst-hold

3rd,

2nd

lst-hold

MARK 1
MARK 2
MARK 3
MARK 4
MARK 5
MARK

6
MABK 7
MABK

8

MARK

9
MARK 10
MAFK 1,I
MARK 12
MARK 13
MAEK 14

MARK 2
MARK

3
MARK 4
MARK 5
MARK 6
MARK 7
MARK 8
MARK

9
MARK 10

MARK 2
MARK

3
MARK 4
NO MARK
MARK 6
MARK 7

4th

STANDARD {NEWI SEBVICE UM]T

-

{r.22}
{1.31)

('t.36)

-

2.0

-

2.05

-

3.00

-

2.30

(0.026
(0.016

(0.020

{0.071

(0.077
(0.08'1

{0.085
(0.089

{0.093
(0.096

(0.100
(0.104
(0.108
(0.1

12 - 0.1 11)

(0.116
{0.120

(0.124
(0.128
(0.132

(0.081

{0.085
(0.089

{0.093
{0.096
{0.100

(0.104

{0.108
{0.112

10.116

{0.081
(0.085

{0.089
(0.093

(0.096

10.100
(0.101-

-

-

0.031)

-

0.079)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

0.0331

0.024)

0.08r)

0.083)

0.087)

0.091)

0.091)

0.098)

0.102)

0.106)

0.110)

0.118)

0.122}

0.126)

0.130)

0.1341

0.083)

0.087)

0.091)

0.094)

0.098}

0.102}

0.106)

0.r 10)

0.1r4)
r8)

0.1

0.083)

0.087)

0.091}

0.0941

0.098)

0.102)

0.106)

29.0

31.2

32.6
Until
Discoloration

Discoloration

Discoloration
Oiscoloration

Discoloration
Discoloration

Oiscolor6tion

0.65 - 0.85

0.40 - 0.60

0.5- 0.8

31.0

33.2

34.6
'1.8

1.95

2.05 - 2.10

2.1s - 2.20

2.25 - 2.30

2.3s - 2.40

2.45 - 2.50

2.55 - 2.60

2.65 - 2.70

2.75 - 2.80

2.85 - 2.90

2.95 - 3.00

3.05 - 3.'r0

3.15 - 3.20

3.25 - 3.30

3.35 - 3.40

2.05 - 2.10

2.15 - 2.20

2.25 - 2.30

2.35 - 2.40

2.45 - 2.50

2.55 - 2.60

2.65 - 2.70

2.75 - 2.80

2.85 - 2.90

2.95

2.05 - 2.10

2.15 - 2.20

2.25

2.35 - 2.40

2.45 - 2.50

2.55 - 2.60

2.65 - 2.70

(1.14)

11.231
(1.28)

groov€6

I

I

I

I

t

I

I

worn

out

-

AutomaticTransmission

iransmission

Diameter

mainshatt and stator shaft

On

mainshaft 2nd

On

mainshaft

On
On mainshaft
On countershaft
On countershatt
On countershaft
On countershaft
On countershaft
on sub'shaft
On sub-shaft
On

Inside diameter of

On mainshaft
On mainshaft
On mainshalt
On countershaft
On
On countershaft

On countershaft
On sub-shatt
On reverse
On stator
On

Reverse idler

play

End

Mainshaft
Mainshaft 2nd
Mainshatt
Countershaft
Countershaft
Countershaft
Sub-shaft

Reverse idler

Countershaft
Selector
Mainshaft
Mainshatt'lst
lvlainshaft

Countershaft

Countershaft

Countershaft

thickness

Countershaft
Countershaft
Sub-shaft
Sub-shaft

-

Section

atcuarrurr

MEASUREMENT

of needle bearing

gear

gear

4th

gesr

lst

(left
3rd

4th

reverse
lst

(left

side)

gear

4th

gear

idler

reverse

countershaft 3rd

stator shaft

hub O.D.

needle bearing conlact

gear

lst

gear

2nd

gear

4th

lst

4th
reverse

gear

4th

gear

idler

(right

shaft

{stator

gear

shaft

gear

1st

gear

gear

4th

gear

1st

gear

3rd

gear

4th

gear

4th

gear
reverse

gear

4th

4th
4th

collar

gear

collar length

g€ar

Ist

collarflange thickness

distance collar

reverse
reverse

gear

1st
'1st

gear

gear

collar length

gear

collar flange thickness

14

r.t

contact area

collar

collar

side)

gear

gear

gear

gear

gear

gear

gear

gear
gear

collar
collar flange

collar

collar

collar

shaft

gear

side)

side)

holder l.D.

gear

length

length

collar
collar

length

length
flange

thickness

area

SIANDARD {NEW}

22.980 - 22.993

35.975 - 35.991

31.975 - 31.99r

-

30.975

-

36.004

35.980 - 35.996

27.980 - 27.993

31.975-31.991

-31.991

31.975

-

25.991

27.980 - 27.993

13.990 11.000

-

35.000

41.000 - 41.016

-

38.000

-

38.000

-

41.000

33.000 - 33.016

-

38.000

-

32.000

18.007, 18.020

29.000 - 29.013

27.000 - 21.021

-

14.416

0.08 - 0.24

0.05 - 0.13

0.045 - 0.140

0.1 - 0.5

0.04 - 0.15

0.05 - 0.13

0.05 - 0.17

0.05 - 0.

0.10 - 0.25

51.87 - 51.90

-

49.00

27.00 - 27.15

2.5 - 2.6

38.97 - 39.00

39.02 - 39.05

39.07 - 39.10

39.12 - 39.r5

39.17 - 39.20

-

39.22

39.27 - 39.30

38.87 - 38.90

38.92 - 38.95

-

14.610.57r 0.575)

14.5

2.4 - 2.6
'14.5

-

14.6

2.4 - 2.6

24.0, 24.1

-

3.15

3.00

(0.9047

0.4163
(1.2589

30.991

t1.2195

36.017

{r.4r7s
(1.4165

{1.1016
(1.2589

(1.2589

(1.0233

26.000
(1.1016
(0.5508

(1.3780

35.016
{1.6142

(1.4961

38.016

38.0161'].4961
(1.6142

41.016
(1.2992

38.016

0.4961

32.016

fl.2598
{0.7089

(1.14r7
(1.0630

14.434

10.5676

(0.003

(0.002

(0.002

(0.004

(0.002
(0.002
(0.002
(0.002

r8

10.004
(2.042

(1.929

49.05
(1.063

-

\2.098

1.534 1.535)
'r.536

1.538 - 1.539)

1.540 - 1.541)
r.542 - 1.543)

39.25

1.544

1.546

1.530 - 1.53r)
'1.532

-

(0.094

(0.57'l

(0.094

{0.945
{0.118

-

0.009)

-

0.005)

-

0.006)

0.020)

-

0.006)

-

0.005)

-

0.007)

-

0.007)

-

0.010)

-

2.043)

-

1.931)
'|.069)

-

2.102)

-

1.537)

1.545)

-

1.547)

-

1.533)

0.102)

-

0.575)

0.102)

-

0.949}

0.r24)

-

0.9052)

-

1.4169)

-

1.2595)

-

1 .22011

-

1.4'l80)

-

1.4172)

-

1.1021)

-

1.2595)

-

1.2595)

1.0236)

-

1.1021)

-

0.5512)

-

1.3786)

-

r.6148}

-

1.49671

-

1.4967)

-

1.6148)

-

1.2998)

-

1.4967)

1.2605)

0.7094)

-

1.1422)
'j.1638)

-

-

0.5683)

length: mm

Unit ol

SERVICE LIMIT

Wear or damage

Wear or damage

Wear or damage

*rd"-"g"

damage

Wear or

Wear or damage
Wear or damage

Wear or
Wear or damage

damage

(in)

(cont'd)

3-11

Standards

Automatic

Transmission

(cont

dl

Regulator

and Service Limits

Transmission

Mainshaft

Thrust washer thickness

Mainshaft
Mainshaft 1st
Mainshatt 1st

Sub-shaft 4th
One-way

Countershaft lst

Parking
Mainshaft feed
Mainshaft
Countershaft leed
Sub-shaft feed
Mainshaft

{29 mm and 35 mm)
Mainshaft
Mainshaft

Countershaft bushing LD.

Sub-shaft
Mainshatt sealing ring

Sealing ring

(cont'dl

MEASUREMENT

gear

2nd

ball bearing left side

gear
gear

gear

clutch contact area l.D.

gear

pip€
piDe

leed

pipe

pip€

sealing ring thickness
bushing LO.

bushing LD.

bushing

l.D.

contact area LD.

-

thrust washer

left side
right

side

thrust washer thickness

gear

A,

O.D.

{at

B, O.O.

{at

(at

O.D.

(at

15 mm trom

O.D.

goove

widlh

Section 14

thickngss 3.97 - 4.00

15 mm

trom end}

30 mm from

l5 mm from

end)

end)

end)

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 - 1.35

4.37 - 4.40

3.45 - 3.55

1.45 - 1.50

3.43 - 3.50

2.93

83.339 - 83.365

66.685 - 66.698

8.97 - 8.98

5.97 - 5.98

7.97 - 7.98

7.97 - 7.98

1.980 - 1.995

6,018 - 6.030

9.000 - 9.015

8.000 - 8.01s

8.000

2.025 - 2.060

35.000 - 35.025 {1.3780 - 1.3782)

STANDARD

{0.156
(0.158

(0.r60
(0.162
(0.164
(0.166

{0.168
{0.170

(0.172

(0.136
(0.057
(0.135

-

(0.115

3.00

{0.353
(0.23s0

(0.3138
{0.3138

(0.0780
(0.2359

(0.3s43
(0.31s0

-

(0.3150

8.015
(0.0797

{NEW}

-

0.'t57}

-

0.159)

-

0.1611

-

0.163)

-

0.'t65)

-

0.167)

-

0.169)

-

0.17r)

-

0.173)

-

0.140)

-

0.059)

-

0.138)

-

0.1181

(3.2810

12.6254

-

0.354)

-

0.2354f

-

0.3142)

-

0.3142)

-

0.07851

-

0.2374)

-

0.3549)

-

0.3156)

-

0.3156)

-

0.0811)

-

3.2821)

-

2.6259)

SERVICE t_tMtT

Wear or

damage

I

I

I

Wear or damage

Wearlor damase
Woar

or damage

t-

t

Wear

or damage

8.95

{0.352t
(0.2341

5.95
(0.313)

7.95
(0.313)

7.9s

1.80

{0.071)

(0.2380)

6.045
(0.356)

9.03
(0.3r6)

8.03
(0.3161

8.03
(0.0821

2.08

(1.3799)

35.050

Shifting device and
parking

brake con-

trol

Servo

body Shift fork shaft bore Lo.

pump

Oil

Reverse
Parking

brako
goar

Parking

Throftlo

cam slopper heighl

Shift fork shaft v6lve

pump

Oil

pump

Oil

pump

Oil

pump

Oil

fork

shift

tinger thickness

ratchet

gear

side clearanc€

gear-to-body

g6ar

driven
shaft

O.D.

pawl

bore LO.

cl€6rance

I.D.

Drive
Driv€n

5.90 - 6.00

27.0 - 27.r

14.000 - 14.010

37.000 - 37.039

0.03 - 0.05

0.210 - 0.265

0.070 - 0.125

14.016 - 1{.034

13.980 - r3.990

{0.232

(1.063-

(0.001

{0.0083 - 0.0104)
(0.0028

-

0.236)

1.067)

(0.5512 ­(1.{567 -

(0.5518 ­{0.5504 - 0.5508)

0.5516)

1.4582) 37.045

-

0.002)

-

0.0049)

0.5525)

5.4O

lWear
t_'--'

0.07

W6ar
Wear

{0.213)

or other

{1:4585}

(0.003)

or damage
or damage

3-12

L

-

Automatic

Springs

Transmission

[t!'tttltttt

MEASUREMENT

Regulator
Regulator
Stator
Modulator

Torque convorter

Cooier
Relief v6lvo
2-3 orifice control
Throttle
Throttle
Throttle
Throttle

1-2 shift
2-3 shift
3-4 shift

'lst-hold

1st accumulator

2nd accumulalor

3rd accumulator

4th accumulator

Lock-up shift

Lock-up timing
Lock-up
CPC
Kick-down
3-2 kick-down
Servo control
4th exhaust
Servo orifice

valve spring
valve spring

r€action spring

valv€

valve sprang

ch€ck

spring

valve B adiusting
valve B spring

B 6pring

valvo

valve I spring
valve sprang
valve spring
valve spring

accumulator

valve spring

B

control

valve spring

valvo spring

valvo

valve

v6lve spring

controlvalve

-

tt

A
I

body

valve

check

valvo spring

sPring

spring

sprang

spdng
spring
sPrang

valve spring

valve spring

spring

spring

Section

spring

14

Wir. Di..

1.8

{0.071}

(0.071)

1.8
(0.217)

5.5

1.3

{0.0s1)

1.1

{0.043}

1.1

{0.043)
(0.043)

1.r
(0.035)

0.9
(0.0281

0.7
(0.055)

1.4
(0.055)

1.4

1.1(0.055)
(0.0351

0.9
(0.0351

0.9

0.9

{0.035)

4.0

{0.157)
(0.098)

2.5
(0.142)

3.6

2.8

2.6

0.9

0.8

0.8

1.3

1.0

1.3

0.9

1.0

0.8

(0.1r0)
(0.102)
(0.035t
(0.0311
(0.031)
(0.051)
(0.039t
(0.051)

{0.035)
(0.039)

(0.031)

STANDAND INEWI

o.D.

(0.579)

14.7
(0.378)

9.6
(1.039)

26.4

9.4

{0.370}

(0.331)

8.4

(0.3:]t)

8.4
(0.3l9)

8.6
(0.2601

6.6
(0.244)

6.2
(0.335)

8.5
(0.335)

8.5
(0.335)

8.5

(0.339)

8.6

(0.299)

7.6

(0.2991

7.6
(0.846t

21.5
(0.642)

16.3
(0.866)

22.0
(0.689)

17.5
(0.642)

16.3

7.6

{0.299)

6.6

{0.260}
(0.260)

6.6
(0.370)

9.4

(0.260)

6.6

(0.339)

8.6

(0.252)

6.4

(0.280)

7.1

(0.260)

6.6

Fr.. L.ngth

(3.488)

88.6

11.011.7321
(1.193)

30.3

37.3

{1.469)
(1.331)

33.8
(1.331)

33.8
(1.461t

37.1
(1.299)

33.0

34.0

fi.339)
(1.634)

41.5
(1.63i1)

41.5

41.6

{1.638}

(1.591)

40.4
57 ,0

12.2111
(2.047)

52.0

71.1

Q.A23l

't05.4

(4.150)
(4.287)

108.9
(4.'142)

105.2

103.3

{4.067)

73.7

12.9021
(2.394)

60.8
(1.5s5)

39.5
(1.390)

35.3
(.1221

2a.5

(1.795t

45.6

34.1

{1.343)
(2.374)

60.3

48.2

{1.898}

Unit

of length:

t{o. of Colh

16.5

2.1

12.1
't2,5

12.5

13.4

14.9

10.5

11.2

12.1

14.5

26.8
E.3

16 + 8.6

15.2

19.'l

21.2

32.0

22.1

25.O

12.1

11.7

17.0

11.5

18.5

33.0

mm

(in)

3-13

Standards and

Differential

Differential Pinion

Differential
prnron gear

ring-to-bearing

Sel
Differential

Starting torque N.m

(Manual

Carrier'to-pinion clearance 81881 engine
Driveshafvintermediate shaft contact area LD.

Carrier to driveshaft clearance 81881 engine
Carrier-to-intermediate shatt clearance

transmissionl Section 15

shaft contact area

Eacklash
t. D.

geaFto-pinion

Pinion

outer race clearance 81881 engin€

taper

roller

{kgfcm,

preload

bearing

lbf.in) Bl8Cl

Service

M€ASUREMENT

LD.

shaft clearance

Limits

81881 engine
818C1 engine

B18C
81881 engine

818C1 engine
BlSC'l engine
B188l engine

818C1 engine

18.000 - 18.016

18.000 18.018

t engine

0.0r3 0.045

0.0'13 - 0.047

28.000 - 28.021

28.005 - 28.025

0.020 - 0.062

0.045

0.050 - 0.087

0.075

0.05 0.15
'18.042

0.055 - 0.095

0 - 0.10

engine 2.1r

STANDARD

,

0.086

-

0.111
(0.002

-

18.066

(0

-

3.04

{21.5

INEW) SERVICE LIMIT

-

(0.7087
(0.7087

(0.0005

(0.0005

\1.1024-1.10321
(1.1026

(0.0008
{0.0018

(0.0020
(0.0030

(0.7103

(0.0022

-

-

0.0018)

0.0019)

0.0024)

-

0.0034)

0.0034)

-

0.0044)

0.006)

0.0037)

0.7093)

0.7094)

1.'1033)

0.7113)

0.004) Adjust

-

r.0,

3

13.0- 18.7) Adjust

o. t

aron,

0.1

{0.006}

Adjust

0.15

{0.006)

Differential

Difterential

carfl€r

Differential
prnron gear

ring-to-bearing

Set

Steering - Section

Steering wheel Rotational

Gearbox Angle of rack-guide-screw loosened from locked

Purnp

Power

steering

tluid

Power

steering

belt*

'

When using a new belt, adjust detlection or tension to new values. Run

Readiust detlection or tension to used belt values.

(Automatic

Pinion
Carrier-to-oinion clearance
Driveshafvintermediate shaft contact are l.D.
Carrier-to-driveshatt clearance

transmissionl Section 15

MEASUREMENT

shatt contact area

l.D.

Backlash
t.D.

gear-to-pinion

Pinion

outer race clearance

shaft clearance

17

MEASUREMENT

play

Staning losd at steering wheel circumference
N

{kgf,

position

pressure

Pump

(kgtlcm,,

kPa
Recommended

Fluid

capacity

(US

qt,

f

Deflection with 98 N
between

Belt tension N
Measured with belt tension

at steering

lbfl

with shut-off valve closed

psi)

fluid

q0

lmp

pulleys

lkgf,

wheel

For
For

(1okgt,22lhfl

lbl)

gauge

circumference

Engine running

overhaul
fluid

change

18.000 - 18.018

0.016 - 0.052

28.00s 28.025

0.025 - 0.066

0.05 - 0.15

18.042 - 18.066

0.059

-

0

-

0
34

20" i

6,400

Honda

1.06

0.79

11.5- 13.5

8.0
390 - 540

740

the engine

STANDARO

{0.0006
(0.0010

(0.002

-

(0.0023

0.095

-

(0

0.r5

10

\3.5,7.71

-

lor 5 minutes

0.006) Adjust

-

0.39)

{0

5'

7.400

165

power

(0.45

(40

880175

steering fluid V

-

55, 88 - 120) with used belt

90. 170 200) with new

(1.12,0.98)
(0.83,0.70)

10.010.31

INEWI SERVICE

-

{0.7087
{1.1026

(0.7r03

0.7094)

-

0.0020)

-

1.1033)

-

0.0026)

-

0.006)

-

0.7113)

-

0.0037)

STANDARD INEWI

-

75.

0.53)with used belt

0.39)with

then turn

920

1. r00)

new

it

off.

belt

0.1

{0.004)

0.12

Adjust

0.15

belt

(0.005)

(0.006)

LIM]T

Suspension

gnment

a

A1lc€lbearing End

Sestion

Camber
Caster

Totaltoe

Front

Rim
Rim runout

18

MEASUFEMENT

Front
Rgar
Front
Front
Rear

whe€lturning angle

play Front

(Aluminum

runout

isteelwhgel)

wheel)

Inward whe€l
Outwsrd wh€el

Roaa

Axial
Radial

Axial
Radisl

-0.

10' 1 1.

-0'

l$igl

15'

1. 10'r t"

0i2(010.081

(0.121ff)

rN 3:i

0o' r 2'

36'

30. 30'

-

(0

0 - 0.05
0 - 0.05

{0

0.002)

-

0.002}

STANDARD INEWI

-

1.0

{0

(0
{0

(0

-

0.03)

-

0.03)

-

0.0{)

-

0.04)

0 - 0.7
0 - 0.7
0 - 1.0
0

STANDARD I]{EWI

2.0

1.5

2.0
r.5

Unit of length: mm

SEBVICE

UMIT

(0.08)
(0.06)
(0.081
(0.061

{in)

Brake Section

trrling

brake

;

oot brake

,adal

Vaster

cylinder

f,,s4 brake Oisc thickness

19

in

Play

strok€ at

lorce

lever
Pedal heighl

play

Free
Piston-to-oushrod

runout

Disc

parallolism

Disc
Pad lhickness

200 N

lwith

Air Conditioning Scction

Ar conditioning Lubricant capacity mf

type: NO-OlL8

resistance at 68'F

with

98

pulleys

(kgf,

Compressor

Compressor
b€h'r

.1:

When using a

Readiust detlection

'2:

81881 engine

'3:

818C1 engine

Lubricant
Lubricant capacity

Lubricant tvge: ND-O|L8
Stator coil

Pulley-to-pressure
Detlection

betlveen
Belt t€nsion N

Measured with belt lension

new bek, adjust dellection

or tension to lsed

MEASUREMENT

44 lbt)

kgf,

{20

floor mat removod)

clearance

22

MEASUREMENT

(ll

oz)

-

38899

{P/N

(ll

m{

oz}

(P/N

plate

clearance

(10

N

kgf, 22 lbf)

lbl)

or tension to

beh values.

-

38899

(20'C)

0

gauge

new values. Run the engine

Front
Re6r

Front
R6ar
Front and
Front
Roar

Cond€nser
Evaporator
Line or hose
Receiver

PR7 - A0l)

-

A01)

PR7

To

b€

nolchsa

(6.30)

160

M/T

155

(6.50)

1-5(0.04-0.20)

-

0.4

0

20.9 - 21.1

8.9 - 9.1

rear

-

9.5

7.0- 8.0

(5/6)

25
40

t1

(lBt

10

(1/31

10

140';u

3.4- 3.8

0.5 r 0.15

-

7.5

-

8.5

-

5.0
390 - 540 {r0 - 55, 88

340 - 490 {35 - 50,
740 - 880 {75 - 90,

STANDARD {NEWI

0.2)

t0.82

-

-

pulled

6

INEWI

-

0.83t

0.36)

-

0.41}

0.31)

STANDABO IT{EWI

lockod when

-

(0

STANDARD

{0.35

10.5

{0.37

{0.27

1/3)

(4-23';")

r 0.006)

{0.02

-

9.5 {0.30

10.5

7.0

tor 5 minules ihen turn

0.37)with used b€lt*'

-

0.41}with t/sod

{0.33

-

0.28) with

{0.20

77 - 110} with used belt*3

170 - 200) with new belt

new

-

120} with used beh*'

-10

it

belt'3

belt

ott.

SERVICE LIM]T
(0.75)

19.0

(0.31)

8.0

(0.004)

0.10

(0.00a)

0.r0

(0.0006t

0.015

(0.06)

r.6

(0.06)

1.6

3-15

Standards and

Service

Limits

ll

il

Electrical

lgnilion

coil Rat€d voltago V

lgnition

wire

plug

Spark

Section

Primary

Secondary
Resistance ar 68"F

Tvpe
Gap

lgnition

timing

Alternator

Alternator

Staner Output

*1:

Do not

*2r

When

b€lt'2

adiust the

using a new belt, adjust d€tl€ction

Readiust

de{lection or tension to usod

At idling

"

BTDC

Deflecrion wilh
between

Eelt t€nsion N
Measured with

Ourput
Coil resistance
Slip ring O.D.

Brush length
Erush spring tonsion N

Mica depth
Commulatot runout
Commutator O.D.
Brush length
Brush spring tension

gap,

23

MEASUREMENT

winding resistance at 58'F

winding resistance

(20'C)

(Red)-

rpm

N

98

pulleys

l3.5 V

replace spark

{10

(kgf,

lbf)

belt tension

at hot A

(rotor)

(new)

plug

it it is

or tension to new valu€s. Run

belt

(20'C)

O

(20"C)

6t 68'F

k0 25 max.

kO

B18Bl engine
B18Cl engine

M/T 16" r 2.

kgf,22lbll

gsuge

at 68"F

(kgt,

out of spec.

values.

{20"C}

lbf)

N

lkgt,

0

lbf)

tho engine lor 5 minutes thon

-

0.6

0.8

12.4 - 19.2

STANDARD

See Section 23

1.0 - 1.1

16" t 2"

9.0 - 11.0

6.0 - 8.0
340 - 490

690 - 880

{0.039

-750

-750

(0.35

{0.24

-

{35

-

{70

r 50
r 50

-

STANDARD

90

2.9

14.4

t0.57)
(0.41)

r0.5

3.210.33, 0.73)

-

-

30.0

-

15.5

(0.02

-

(0

0.0008)

(1.177
(0.s9

fi.8

0.5 - 0.8
0 - 0.02

29.9

15.0

17.7 - 23.5

STANDARD {NEWI

INEW} SEN$CE UM]T

-

0.043}

1.3

{0.051)rl

(Neurra0
|!]or

-

0.31} with new

50, 77
90,

L?.lposition)

0.43) with

-

110) with used bolt

-

154

198} with now boh

us6d b6li

b6lt

INEWI SENUCE UMTT

tnn

ro.rrr

(0.06t

1.5

0.03)

-

1.r81)

-

0.61)

-

2.4,4.0 - 5.3)

turn

it

off.

(0.0081

0.2

0.05

29.0

10.0

t0.@2)
(1.142)

(0.39)

Design Specifications

vENSTONS

:'

,rerght

'le,ght

:\GINE

(usA)

{CANADA)

Overalllength
Ov€rallWidth

Overall Height

Wheelbase

Track
Ground Clearance
Seating Capacity

cross

Gross
Type

F/R

V€hicle Weight

Vehicls Weight Rating {GVWR)

]TEM

Rating

{GVWR)

3 DOOR

4 DOOR
3 DOOR

4 DOOR

DOOR

3
4 DOOR

81881 engine

METRIC

4.380 mm

4.525 mm
'1,710

1,335 mm
1,370 mm

2,570
2,620

't,475/1,470
150 mm

Four

1,670 kg

Water-cooled,

mm

mm

mm

mm

(3

DOOR)

gasoline

ENGLISH NOIES

172.1in

178.1 in

67.3

52.6

101.2 in

103.1

5|8.1/57.9 in

Five

4-stroke DOHC

engine

(4

DOOR)

3,680lbs

in
in

in

Cylinder

Bore and Stroke
Displacement

Compression

L!brication Systom

OilPump Displacement
Wster Pump

FuelRequired

Arrangement

Ratio

Displacement

818C1 engine

81881
818C1
81881
B18C I
81881
B 18C1
81881
818C1

81881
B18C 1
81881
B 18C1
91881

818C1 engine

engrne
engane
engrne

engine

engine
engine
engine
engine

engrne

engrne
engine
engine
engine

Watercooled, 4-stroke

VTEC

Inline 4-cylinder, transverse

81.0 x 89.0

81.0
1,834 cm3
1,797

Eelt driven, OOHC

Forced and wet sump, trochoid

140 f
140 f

x 87.2 mm

cm3

Belt driven, DOHC

4 valve

50,
71 f

UNLEADED

Premium UNLEADED

{53
{75

(148
(148

Octane

gasoline

mm

(mf

)

(m{)

9.2:1

10.0 : 1
4 valve

per

qt,

US
US

US
US

44 lmp

qt,

62

qt,

123 lmp

qt.

123 lmp

gasoline

Numb€r or higher

engine

cylinder

lmp

with 86 Pump

DOHC

3.19 x 3.50

3.19 x 3.43 in
112 cu-in
110 cu-in

per

cylinder

VTEC

qt)/minute'l
qt)/minute"

qt)/minute*!

qt)/minute*'

gasoline

in

pump

wilh

STARTER

CLUTCH

TRANSMISSION

'1:

At 6,000 engine

'2:

At 7,600 engine

rpm

rpm

Typo

NormalOutput
NominalVoltage
Hour

Direction of Rotation

Weight

Clutch
Clutch Facing

Transmission Type

Primary

Rating

Type

Area

Reduction

Pump Octane

91

Clockwise

3.7 k9

M/T Single

203 cm'

M/T

Synchronized

plate

Electronically controlled

4-speed automatic.

Number or higher

Gear reduction

1.4 kW
12V

30 seconds

as viewed

dry,

Torq!e

5-speed forward,

Diract 1 : 1

converter

lrom

|

diaphragm spring

I

31 sq-in

1 rcverse

g6ar

8.3lbs

end

1 reverse

(cont'd)

3-17

Design Specifications

{cont'd}

lTEM METRICI€iIGLISHINOTES

TRANSMISSION Type

Ratio 1st

G6ar

Fin6l Reduction

Type Automatic

Ratio

Gear

Final R€duction

AIR
CONDITIONING

STEERING
SYSTEM

SUSPENSION

Cooling Capacity 3,570 Kcal/h 14,166 BTU/I
Compr6ssor

Cond6ns€r
Evaporator Type Corrugatod tin

Blower Type

Temperature Control Airmix type
Compressor Clutch Type

Refrigerant Type

Type

Ratio

Overall
Turns, Lock-to-Lock
Sreering Wheel Dia.

Type Front

Absorb€r, Front

Shock

and

Engine

2nd
3rd
4th
5th
Rov€rs€

Gear type
Gear ratio

'l6t
znd

3rd
4th
Revelse

Goar typo
Gear

Type/Make

No. ol Cylinder
CaPtcity
Max.

Spsed

Lubricant
Lubricrnt Type

Type

Motor Input
Speed Contro
Max. Capachy

Powor

Ou.ntity

Roar

Rear

C6pacity

Consumption

typo

ratio

Manual

81881

3.230

1.900

1.269

0.966
o.711

3.000

4.266 4.400

transmission

|

Single helicalge.r

transmission

2.722

1.464

0.97s

0.638

1.954

helic6lgoar

Single

4.357

swash-plare/NIPPoNDENSO

10

150 ml

/rcv

| 9.15 cu-in/r€v

7,600 rpm

140

mf

ND-O|L8

(P/N

Corrugated fin

Sirocco tan

200

450 m3/h

Dry,

40 W max./12 V

zoo-Ss

Power

380

Independent double wishbono,
Independont

Telescopic,

4-speed

plate, poly-V-b€lt

singlo

HFC-134a

assisted,

mm

coil spring with st6bilizer
coil spring

hydraulic nitrogen

1-2Bll oz

|
I

l.;3 tmp oz

38899 - PR7 - A01)

v

w12

15,900 cu lvh

|

at 68"F {20'C)

(R-134a)

24.7-l.aoe

I

rack

and

16.1

2.98
|

wishbong.

double

with

stabilizer

818C1

3.230
r.9(X)

1.360

1.034

0.'t87

3.000

driv6

pinion

15.0 in

gas-tilled

3-18

WHEEL
ALIGNMENT

BRAKE

SYSTEM

TIRE Size

ELECTRICAL 8attery

*1:

RS, LS

*2:

GS-R

*3:

RS

*1:

LS,

GS-R

*5:

high mount brake light installed in rcar spoiler.

Except

Camber
Caster

TotalToe

Type Front

Pad Surface Area Front
Parking Brake Type

Starter
Alternator

Fuses

Headlights
Front

Front Turn SignauParking Lights
Rear Turn Signal Lighls
Stop/Ta illig hts
High Mount Brake Light'5
Fear
Back-up Lights
Liconse Plate Lights
Ceiling
Cargo

Trunk Lights

Spotlights
Glove Box Light
Gauge
Indicator Lights
lllumination and Pilot Lights
Heater lllumination Lights

ITEM METRICIENGLISHIM)TES

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

In

Under-hood

Side

Side

Lights

Area Lights

Lights

ABS Fuso/Rolay Box

Marker Lights

Marker Lights

(3

DOOR)

DOOR)

l4

Front

and

Spare Tire

Front
Rear
Front
Front
Rear

Rear
Rear

r€ar

High

omm

In 2 mm

Power-assisted selt-adiusting

PoweFassisted self-adjusting solid disc

io.u cm. x z | /,/5 so tn x z

21.0

Mechanical actuating, rear two wheel brakes

cm,

7.5

7.5 A,

v - 0.84 w, 0.91 w, 1.12 W,

12 V - 0.84 W. 0.91 W, 1.4 W. LEO

-0.10'

-0.45'
1'1o'

|
I

ventilated disc

x2 |

P195/60R14 858*1
P195/55R15

T115t0D14*3
T135/70O15.4

I2V-36AH6HR

'12

-'1.4

V

12V-90A

A, 10 A, 15 A, 20 A,
10

A. 15 A, 20 A, 30 A,

50 A, 100 A

10A, 15A,20A,40A

12V-6sW{HB3}
12V-55W(HB4)

12V-3CP

-32n

12V

-32

12V

-32n

12V

-21W

12V
12V-3CP

-32

12V
12V-8W
12V-5W
12v-3.4W
12V-3.4W
12V-5W
12V-3.4W
12V-3.4W

12V-1.4W

ln

3.26 sq

84V*2

kW

CP

CP

CP

CP

oin

in

0.08

in x 2

A

30

40 A

1.r W, 3 W

sAE
sAE
sAE 1
sAE
sAE
sAE
sA€

168
1157

't

55

1157

7440

168
1156

3-19

Il

Body

Specifications

I

il

3 DOOf,:

Unit: mm

(in)

. DOOR:

Unit

mm

{inl

3-21

Maintenance

Lubrication
Maintenance

Points

Schedule

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

." 4'4

Lubrication Points

For the details

ol

procedure (such

No.

I Engine

Transmission

3 Brake

4

line
Clutch line
Power

steering
Release fork
Throttle

8

C.uise cont.ol

wire end

{Dashboard

I

Throttle

10

Cruise control

'I 'l

Brake master

12

Clutch master

13

Engine

14

Batte.v terminals

15

Fuel fill lid

to

Hatch

17

Door

18

Door

19 Rear

20 Power
21 Air

cable end

hood hinges

hinges

hinges.

oDen detent

brake calioers

steering

conditioning compressor

lubrication

Assembly/Reassembly,

as

LUBRICATION

(lncludes

points

and type of lubricants

POII\ITS

Anti-lock brake

gearbox

(Manual

transmission)

{Dashboard

lower

actuatot wire end

lower

holel

Danel

(Throttle

linkl

actuator cable end

cvlinder

cylinder

Dushrod

pushrod

and engine hood latch

or trunk hinges

upper and lowet

system

Replacement,

Manual
Automatic

linel

Danel holel

lActuator

link)

to be spplied,

reter to the illustrated

Overhaul, Instatlation,

API Service

grade

II"

The

oil container

s€al shown

Grade: Use SG or

oil.

may

below. Make

Engines.'

SAE Viscosity;
API

Service Grades:

See chan below.

SAE Viscosity: 1O
Honda Premium
Automatic

Brake fluid
Bfake tluid
Steoring

grease

Supe. High

Silicone

grease

.Multi-purpose

Rust-p,eventive

power

Honda
Retrigerant

(For

Relrigerant: HFC-134a

Formula or DEXRON@ II

transmission fluid

DOT3 or DOT4
DOT3

or

P/N

Temp Urea

grease

agant

steering tluid-V

oit ND-otL8

index

etc.)

contained in

LUBRICAI\IT

"Energy

SH

also display

sure it

the API

says'For

SF or SG

W-3O or 1O W-4O

DOT4

08733-BO7OE

Grease

|PlN

(P/N

O8798*9OO2)

38899-pR7-A01)

(R-134a))

and various

each section.

Conserving

Certification

Gasoline

work

API

CERTIFICATION

SEAL

-20

-30 -20 -'to

0 20

Recolnmendod
Engine
ambient tgmpelalure

r}()

o 10

engine oil

oil viscosity tor

60 ao

20

rangos

30

loooF

40"c

o

@

@

@

@

,6\

a,\

@

o@

@

@

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4-3

t

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Maintenance

r.r

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Schedule

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4-6

Engine

Engine
Cylinder

Engine
Engine
Intake

Removal/lnstallation

Head/Valve

Block
Lubrication

Manifold/Exhaust

Cooling

....

Train

System

...''........

..'............

5-1
6-1

......7-1

.........

8-1

...... 9-1

.......

1O-1

Engine

Removal/lnstallation

Special

Engine
Mount/Bracket

Tools

Removal/lnstallation

........

Torque

.".....5-2

..."........

..' 5-16

5-3

ru

il

Special

No.

Rst.

o

Tools

Tool Numbor Dascription

I

07MAC-SLOO200

Oty Pag€ R€terenco

Ball Joint Remover, 28 mm

Engine

Removal/lnstallation

@

a

Make sure

hoisl brackots

ly

and

sitions

a

Mak€ sure
you

CAUTION:

a
r

a

a

NOTE:
circuit.

-

-

-

Atter service,
on.
tomer's

1. Remove

on

wotking

are

fendet

Use
sudaces.
Unspecified
Unplug
the couplor
oamage.

Mark all
Also, be
or hoses,

tho widng

wiring and

Anti-theft

Be sure
Disconnecting
Removing
hood tuse/relay

Removing

the word

When

5-digit

jacks

and safety

tho engine

car willnot

tho

under

covals

itsms alo

connectots

tha connector

and

sulo that

interfere

or

radios

get

the customer's

to

the batterY.

No. 32

the

box.

radio

the

reconnect

"CODE"

code

hood

the

stands

attachod

arg

(se€

ssction

roll off

it'

to avoid

common

to

hoses

not contact

do

thsy

oth€l

with

have a

(7.5

A)

power

is displayed,

to restore

(see

section

ploper-

placed

aro

the correct

to

1).
tallwhile

and

stands

damaging

carefully

portion

misconnection.

avoid

parts.

theft

coded

code

fuse from

the radio

to
radio operataon.

2O).

painted

holding

while

to

other

ptotection

number

the

and

the cus-

enter

po-

avoid

wiring

beJore

under-

turn

Remove

2.

it

Disconnect

the

Disconnect
fuse/relay

the strut

positive terminal.

brace

ERACE

STRUT

battery

the

the battery

box and

under-hood

1.25 mm

8 x
24

negative terminal

cables

(2.4

N.m

17 rbt.ft)

from the undel-hood

fuse/relay

ABS

kgf.m,

lirst. then

box.

6 x

9.8

7.2

l.O mm

(1

N.m
rbl.ftl

BATTERY

.O kgf'm,

CABLES

{cont'd)

5-3

Engine

Removal/lnstallation

(cont'd)

m

Remove
semblv

and the bracket.

the intake

6 x 1.O

9.4 N.m

air duct,

mm

{l.O

air

cleaner housing

ksf.m,

7.2 tbf,ftl

as-

7.

Remove
right

side

8. Relieve
on the tuel

the

engine wire

of engine

pressure

fuel

filter

harness

compartment.

by loosening

about

one turn

connectoE

6 x'l.O mm

9.8 N-m

the

{see

ll.0

service

section

on the

kgt.m.

bolt

1 1).

Remove

canister

the

evaporative

hose

and

emission

vacuum

THROTTI.E

hose.

VACUUM

(EVAp)

HOSE

BODY

control

@
fuel

system.

Drain

fuel

CAUTION:

a

Before
pressule

a

Place

prossurized

9. Remove
SERVICE

15 N.m

BAITJO
33 N.m
25 tbt.ftt

BOLT

(1.5

EOLT

13.4

oo not

Keep

open flame

only into

disconnocting

as doscribed

a shop

towel ov61

tuel from

the fuel

kgt.m, 11

kgt.m,

feed

amoke

an approved

tbt.ftl

whito

away trom

any fu€l line.

above.

the fu6l

spraying

hose.

working

wo.k

container.

reliovo

filter

to

ovel tho

on

tho

arsa.

the tuol

prevont

aogine.

1O. Remove

hose.

return

1.O mm

6 x

11 N.m {1.1

rbt.ltl

8.O

the brake

kgl'm,

booster vacuum

BRAKE BOOSTER
VACUUM

hose and fuel

HOSE

't2.

Remove
nal and clamps
oartment.

1.0 mm

6 x

9.8 N.m
tbt.ftl

7.2

the engine

on

.O kgf.m,

{1

wire harness

the left side

ENGINE
HABNESS

connectors,

termi-

ot engine com-

WIRE

't

1.

Remove

the throttle

then slip the cable

NOTE:

a

Take care
it. Always replace
one,

a

Adjust the

1 1).

tion

LOCKNUT

BETURN

cable by

end out of

not to bend

loosening the

the accelerator

the cable

any kinked

throttle cable when

HOSE

locknut.

linkage.

when removing

cable with

installing

a new

(see

sec-

13. Remove

1.25 mm

8 x
24

17

N.m
lbf.Irl

(2,4

the cruise

kgl.m,

control actualor.

CRUISE
ACTUATOR

CONTROL

AOJUSTING

NUT

5-5

Engine

Removal/lnstallation

(cont'd)

14.Remove the
Remove the

remove

a

Do not disconnect the P/S hoses.

8 r 1.25
24 N.m

(2.4

the

mm

engine

adiusting

power

kgf.m.

ground

steering

17 lbl.ftl

cable at the body end.

bolt and mounting bolt, then

(P/Sl

belt and

pump.

(Manusl

17.
cylinder and

a

6 x 1.O rl|m

ll N.m { 1.1 kgt.m,

8.0

transmission)

Do not disconnect

pipe/hose

the

Remove the clutch

assembly.

pipe/hose

SLAVE CYLINDER

assembly.

x 1.25 mm

8

24 N.m

17 lbt.ftl

{2.4

slave

kgl.m,

Loosen

6.
remove the air conditioning

IDLER PULLEY BOLT

10 x 1.25 mm

44 N.m

the

14.5

pulley

idler

kgt.m, 33

lbl.ftl

bolt and adjusting bolt,

(A/C)

compresso. belt.

A/C

COMPRESSOR

then

BELT

18. Remove the transmission
cramp.

6 x 1.O mm

1l N.m

I tbt.ftl

,1 kgt.m,

11

ground

cable and

hose

5-6

Remove

19.

@@

to avoid

cap

20. Raise

radiator cap.

the

u""

scalding

the hoist

whan

care

by

full height.

to

removing

hot engine

the ladiatol

coolant

ol ateam.

Remove the

25.
heater hoses.

upper and

lower radiator

UPPER

hoses and the

RADIATOR

Remove the

21.

front

mm

1.O

6 x

N.m

9.8

7.2 tbf.ft)

tires/wheels

(1.0

kgf'm'

the splash

and

shield.

(Automatic

26.

hoses.

transmission)

LOWER
HOSE

Remove

RADIATOR

the ATF

cooler

Drain the engine

22.

a

Loosen the

Drain the transmission
plug

Drain

24.

a new wasner.
CAUTION:

a new

using

the engine

Do not overtighten

coolant

drain

washer.

oil.

(see

page

plug

in the

fluid. Reinstall

oil or

Reinstall the

1O-5).

radaator.

drain

drain

tho

the dtain

plug

using

plug.

HOSE

{cont'd)

5-7

*l

Engine

Removal/lnstallation

(cont'dl

27. Remove the radiator

28. Remove
a

the A/C compressor.

Do not disconnect A/C hoses.

'1.25

8 x
24 N.m

assembly

mm

kgf.m,

t2.4

{see

17 lbl.ftl

page

1O-4),

8188l engine:

GASKET
Replace.

SELF.LOCKING

x 1.25 mm

I

16 N.m
12 tbf.ft)

Replace.

(1.6

kgt.m,

NUT

8

x 1.25

N.m

N.m

mm

12.4 kgf.m,

GASKET
Replace.

(5.5

24
17 tbt.trl

10 x 1.25 mm
54
40 tbt.ttl
Replace.

kgl.m,

29. Disconnect
nector,

B'l8Cl

Replace.

SELF-LOCKING
8 x 1.25

16 N.m
12 tbl.ftl

Replace.

then remove

engine:

NUT

mm

kgf.m,

11.6

the heated

exhaust

EXHAUST
PIPE A

oxygen sensor

pipe

A.

Ho2s

CONNECTOR

I x 1.25 mm
24 N.m

rbt.ftt

17

SELF

10 x 1.25 mm
54 N.m
Replace.

(5.5

ksf.m.4O lbf'ltl

(HO2Sl

(2.4

kgf.m,

con-

30.

1.25

I x
22 N-m

Remove

mm

kgf.m,

12.2

the shift rod and extension rod

'16

lbf.ftl

SHIFT

{M/T).

ROD

5-8

Remove the shift cable

31.

(A/T).

34. Remove

the driveshatls.

1.25 mm

x

I

f.m

22
16 tbl.ftl

SHIFT CAALE

covER

Remove the damper

32.

kgl'rn'

12.2

locx usiea

Replace.

tork.

x 1.0

6

14

SHIFT

mm

N.m

t1.4

CABLE

CONTROL
LEVER

kgf.m,

10 lbl'ftl

CAUTION:

a

Do not

pull

on

como apan.

a

Uso caro

Pult it

oil soal or

whsn

slraight

intormodiato

NOTE: Coat all
clean engine
driveshaft

oil or

ends.

tho ddv$halt,

prying

out tho assombly.

tho CV

to avoid damaging

shaft dust

precision

grease.

tinished

plastic

Tie

ioint

differantial

th6

seal.

surfaces

over the

bags

mav

with

Disconnect

33.

ing
procedure.

NOTE:
each other.

special tool.

the

Adjust

the suspension

Refer to

section 1 8

the tool so

lower arm

the

iaws

balljoints

proper

tor the

parallel

are

us-

to

12 x

1.25 mm

mm

REMOVER
oTMAC-S100200

28

(cont'd)

5-9

I

I

I

I

I

I

Engine

(cont'd)

Lower the hoist.

35.

36. Attach the chain hoist to the engine.

Removal/lnstallation

37, Remove

MOUNT BOLT

the left and right

LEFT

FRONT

MOUNT

front mounts and brackets.

12 t 1.25 nn
59 N.m
43 lbf.trl
Replace.

{6.0

kgt.m,

Remove the

39.

1.25 mm

10 r

Replace.

side engine

mounr.

WASHERS

Replace.

SIDE ENGIITE

38. Remove

1.25 mm

12 r

59
Replace.

N.m

(6.0

the

rear

mount bracket,

rbf.ftl

43

MOUNT

REAR

MOUNT/BRACKET

12 r

1.25 m|n
59 N.m
43 tbt.frl
Replace.

{6.0

kgt.m,

Remove

40.

41. Check

that the engine
hoses,
wi.ing.

42. Slowly
in), Check
disconnected

Raise the engine

43.
car.

the transmission

TRA
MOUNT

is completely

fuel and engine

the engine

raise

coolant

once again

the engine

from

all the

mount

SM|SS|OI{

free of

hoses, and

approximately

all hoses

that

w8y and

remove

vacuum

electrical

150 mm

and wires

it trom the

(6

are

14 x 1.5 mm
118 t{.m
R6place.

(12.O

kgt.m,86.8

lbl.ft}

(cont'dl

5-11

Engine Removal/lnstallation

ENGITIE

SIDE
MOUNT

5-12

Engine

Install

Installation

the engine
Reinstall the
Failure to
noise and

tollow these

vibration, and reduce

1. Install
bolt/nuts on
bolt loose.

A/T:

in the reverse order of

mount bolts/nuts

procedures

the transmission

the transmission

removal.

in the following

may cause

bushing

mount, then

side.

12 x 1.25 mm
64 N.m
47 rbf.ft)

life.

tighten the

Leave the mount

(6.5

sequence.
excessive

kgt.m,

the engine

Install
bolt/nuts
loose.

the engine

on

mount, then

side

side.

Leave the

x 1.25 mm

10

N.m

52

rbf.Itl

38
Replace.

tighten

{5.3

the

mount bolt

kgf.m,

M/T:

12 x 1.25

64 N.m
47 tbt.frl

16.5

mm

kgl.m,

Tighten the mount bolt on

3.

A/T:

M/T:

the transmission

rbf'ftt

nn

(7.5

kgl.m,

12 x 1 .25
74 N.m
54

mount.

1.25 mm

12 x

N.m

74
54 tbt.ftl

(7.5

kgt.m,

{cont'd)

5-13

Engine

Removal/lnstallation

(cont'dl

4. Tighten the

mount bolt on the side

engine

mount.

Install the right

6.
bolts in the

front mount/bracket,

numbered sequence

tighten the

then

as shown

(O-@).

.tE

m'

lbt.ttl

mm

(7.5

kgf.m,

{@

@).

12 x 1.25
74 N.m
54

5. Install the rear mount bracket, then tighten the bolts
in the numbered sequence as shown

A/T:

M/T:

12 x 1.25 mm

O

64 N.m
Replace.

kgt.m,47 lbf.ftl

16.5

@

'10

44

10 x

@

44 N.m
33 tbt.fr)

x 1.25 mm
N-m

'1.25

(4.5

(4.5

mm

kgt'm,

kgf.m,

12

@

59
Replace.

x 1.25 mm
N.m

{6.0

kgf'm,

43 lbl'It)

12 r 1.25

59

.m

mm

16.0

kgl.m,

12

O

83 N'm

x 1.25

(8.5

mm

kgf.m,

61 lbt.frl

Insrall

numbered

the

the left front

sequence

mount,

as shown

then tighten

(O-@),

the bolts in

a

Check that
driveshaft

the sp.ing clip on the

clicks into

place.

end of each

12 x 1.25 ]n]n

O

N.m

83

Replace.

10 r 1.25 mm

@

44 N.m

kst.m,61 lbt.ftl

18.5

(4.5

kgf.m, 33 lbt.ftl

12

@

59 N.m

43
Replace.

r 1.25 mm

tb{.ftl

{6.0

kgl.n,

GAUTION:

a

Bleed air trom the cooling
with

a

Adjust the th.ottle cable

a

Check

a

Check that the
smoothlv,

a

Adiust
Alternator belt {s€e
P/S
A/C

a

Inspect tor fuel

.

Uso oow spring clips.

the heater valve open

the clutch

the tension of

pump

comoressor

After assembling
nition switch
that the
lV two seconds and
Repeat
check
line.

pedal

transmission shifts

belt

{see

belt

leakage

(do

pump

Juel

this

operation

for fuel leakage at any

system at

(see

play

tree

the following drive belts.

section

section

(see

section

(see

fuel line

not operate

operates

the tuel line

two or

the bleed bolt

(see

page

section

section

lsee

23).

17).

22).

section

parts,

1 1).

turn on

th€ starter) so

for

approximat€-

pressurizes.

three times and

point

in the

10-5).

1 1).

into

12).

gear

the ig-

fuel

k-

(cont'd)

5-15

Mount/Bracket

Torque

il

Mount and Bracket

TRANSMISSION

I

Eolts/Nuts

MOUNT:

Torque

Valve Specification:

I

I

SIDE ENGINE MOUNT:

Torqus Spocifications:
A: 10 x

B:

C: 14 x

D:

E: 12 x 1.25 mm

F: 10

G:
H: 12 x
lr 12 x

1.25 mm
(6.O

N.m

59

12 x 1.25 mm

N.m

59
Reolace.

118

Replace.

12 x 1.25 mm

74 N.m
64 N.m

52
Replace.

10 x 1.25 mm

rt4

83 N.m

64
Reolace.

{6.0

1.5 mm

N.m

{12.O

{7.5

(6.5

x 1.25 mm

N.m

{5.3

(4.5

N.m

1.25 mm
(8.5

1.25 mm
(6.5

N.m

kgf.m, 43 lbf.ft)
kgt.m.

kgt.m,86.8

kgf.m, 54
kgf.m,

kgl.m,

kgf.m, 33
kgt.m. 61

kgf.m, 38

43 lbt.ft}

lbt.tt}

lbf.tt}

47 lbf.ftl

38 lbt.ft}

lbf.ft)

lbl.ft)

lbf.tt)

/>

LEFT FRONT MOUNT:

{cont'd)

5-17

Mount/Bracket

Torque

(cont'd)

REAR STIFFENER

'1.25

57
42

/14

32

x
N.m

15.8

rbf.ft)

x 1.25
N.m

{4.5

tbt.ftl

M/T: 12

A/T: 10

mm

kgf'm,

mm

kgf.m,

8x1.25mm
24 N.m

17

12.4

tbt.ftt

kgf'm,

ALTERNATOR

SIDE

BRACKET

BRACKET

ENGINE

x 1.25 mm

10

MOUNT

FRONT
(B18Cl

'12

.25 mm

x 1

57 N.m

42 tbf.fr)

STIFFENER

engin€ onlyl

kgt.m,

15.8

1.25 mm

8 x
24 N.m

17 tbf.ft)

(2.4

kgf.m,

t-*i;

f--^,c*;"*".*-

lq
I

10 x
44 N.m
33

rbr.ftt

-4M

1.25 mm 10 x 1.25
kgf.m, 44

{4.5

33

N.m

rbr.tt)

mnl

(4.5

kgf.m,

P/S PUMP

1.25 mm

10 x

N.m

44

'11

N.m

lO r
54

40 tbf.ft)

(4.5

(1.1

kgl'm,8

1.25 mm
(5.5

N'm

kgf'm, 33

-

kgl.m,

BRACKET

lbf'ft|

Ghinein"onvt

ddv

lbf'tt)

O

HEAT
INSULATOR

(818C1

5-18

Cylinder

Head/Valve Train

81881

Speciaf
Valve Clearance

Adiustment

Valve Seals

Replacement

removal not required) ..................... 6-5

Reconditioning

Timing

lllustrated
Inspection
Tension Adiustment
Removal
Installation

Crankshaft

Replacement

engine

Tools

(cylinder

gelt

Index ............................... 6-7

Pulley Bolt

head

........................ 6-9

.................6-10

.............6-2

............6-3

......6-27

.............. 6-9

.............6-12

.........6-8

Special

-

Tools

t

I

Ref. No.

o
o

o

@
@

Tool

I

07GAD
07JAB
OTMAB

07757
07947 - 6570100
07984

Numbrr

-

PH70100

-

001020A

_

PY3O1OA

-

PJ 10 toA

-

657010C

o

Ocacription

Valve Guide lnstaller
Holder Handle
Pulley Holder Attachment,
Offset
Valve Spring Compressor
Valve Guide Driver,
Valve

Reamer, 6,6 mm

Guide

Attachment

6.6 mm

HEX 50 mm,

@

Oty

1
1

1
1
1
1

Prgc R.terencc

I

6-8
6-8

6-22

6-25,26

6-26

e:=-4-b4altltgt r-l-:ff:-b

o

@

Valve Clearance

Adjustment

NOTE:
.

Valves should
temperature of
Adjustment is the same for both
valves.

.

After adjusting,

177 N.m

1. Remove cylinder head cover.

ADJUSTING SCREW LOCATIONS:

be adjusted cold; at a cylinder
less

retorque the crankshaft

(18.0

kgim, 130

100'F

than

lbf.ft).

INTAKE

EXHAUST

(38"C).

intake

exhaust

and

pulley

head

bolt to

2.

Number 1 Diston

the No. 1

Set

page

6-12).

top, and the TDC

the

with

align

TDC mark

cover.

pulley

should align

tower

cover.

piston

"UP"

TDC

the

at TDC:

"UP"

TDC

at top dead center

mark

on the

grooves

groove

(painted

with

MARKS

GROOVES

pulley

on the

on timing belt back

white) on the crankshaft

pointer

(TDC)

should be at

pulley

the timing belt

on

(see

should

CRANKSHAFT
PULLEY

TDC MARKS
lPeinted

whitel

6-3

Valve Clearance

Adjustment

a

Adjust valve clearances on No. 1 cylinder.
lntlkc: 0.08 - o.l2 mm

Exhru3t

4.

Loosen lhe locknut and turn the adjusting screw

feeler

until

amount of drag.

lcont'dl

0.16 - 0.20

gauge

slides back and fonh with a slight

-

(o.(Xxl

mm

{0.0,05

LOCKNUT9x0.?5mm

N.m

25

12,5

0.qr5 in)

-

0.008 in}

kgf.m,

18lbt'ft|

7. Rotate
bring No. 4

pointing

be

cylinder.

il

Numb€r

piston

the crankshaft 180'counterclockwis€ to

piston

straight down. Adjust valves

at TDC:

TDC. The'UP"

to

"UP'MARKS

mark should

No. 4

on

Tighten
Repeat adjustment if necessary.

6.

Rotate ths crankshaft 180" counte.clockwise
(camshaft pulley

be on the exhaust side. Adjust valves on No. 3 cylin­der.

I{umbcr 3

EXHAUST CAITISHAFT
PULI,IY

the

pidon

locknut

and

turns 90'). The

!t TDC:

.UP'

MANKS

recheck clearance again.

"UP"

mark should

INTAKE

CAMSHAFT

PULLEY

8. Rotate the crankshaft 180' co u nie rclockwise

piston

No.

bring
be on the intake side. Adjust valves on No. 2 cylin­oer.

Numbor 2

NOTE:
cover.

pirton

Refer to

2

page

to TDC.

!t TDC:

-UP"

MARKS

6-31 when installing cylindor hEEd

The

"UP"

mark should

to

Valve

Seals

Replacement

NOTE: Cylinder
procedure.

procodure

The

valve spring

car
Y AAA$-2A

1. Turn the crankshaft

2. Remove

3.

4. Loosen

5.

718" attachment).

@@

always
right tool
whilo 3ltrgu8rding

pistons

Remove the distributor.

c8mshaft

Remove the camshaft

camshaft

u!€ agproved

for cach

are at top

the cylinder

and disconnect

pulleys.

holder, the camshaft

(cylinder

removal is not

head

below applies

shown

compressor

whcn u3ing

tool!, cquipmcnt

d€ad center

head

when using the

(Snap-on

this tool, a:

cyr

Protcction.

hclps incraa3.

iob

so that

the No. I and the

(TDC).

head cover.

the timing

holde, bolts, then

and

removal not

required in this

in-

YA8845 with

with any tool,

th.

Using

produstivity

lnd the u3c1'

No' 4

belt from

r€move the

rocksr arms.

the

requiredl

Select the
ment and fasten the attachment

the lever arm

Position the
into
to keep the
and

Position the lever arm under

lever is
sor attachment
spring being

on the lever as shown.

NOTE:

prevent

der h€ad.

7E in. diameter

with the speed

piston

plug

spark

th€

valv€ closed while cgmpressing

removing the

psrpendicular

rests on toD of the

compressed. Use

Put shop towels

the valve keepers

OIL PASSAGE

at TDC and

hole. Pump air

valve keepers.

to the shEft and

long compressor attach-

No. 4 hole of

to the

pin

supplied.

insert an air adaptor

into

the cross shaft

rstainer

the rear

over the oil
from falling

cylinder

the

springs

so the

ths compres-

for

position

passag€s

into the cylin-

th€

slot

to

lntakc V!lv6

6. Using

7.

the 6 mm bolts

the two up.ights

camshaft
Insort the cross

the two up.ights.

Sclls

holde.s.

supplied

to the

The uprights

shaft through

cylinder head

with the tool,

8t the end

fit as shown.

the bottom

mount

hole ot

OIL PASSAGES

(cont'd)

6-5

Valve

Seals

Replacement

'11.

Using a downward
press

the valve

the valve

spring.

-

Repeat
Remove

'14.

Installthe valve
Install

reverse order

16.

Repeat steps

ExhaGt

17.

Using the 6 mm
the two uprights
camshaft holders.

18.

Insert the
the two uprights.

step l1 for the other

the valve

the springs, the retainers

Valvs Soals

cross shaft through

(cylinder

motion

spring and remove

stem. Slowly release

(see

seals

(see

seals

removal.

of

9 to l5 for the

bolts supplied with

to the cylinder head

The uprights

head removal

on the lever arm.

valve in that

page

6-22).

page

6-23).

and

other three cylinders.

fit as shown.

the bottom hole

com-

the keepers from

pressure

the keepers in

the tool, mount

on the

cylinder.

at the end

of

not required)

21. Position
lever is
sor attachment rests
spring
on

NOTE: Put
prevent

der head.

the lever

perpendicular

being compressed.

lever

the

the valve

(cont'dl

arm unde. the

to the shaft

on top

as

shown.

shop towels

keepers from

OIL PASSAGE

cross shaft

and the compres-

of the retainer

Use the rear

over the

oil

falling into

so the

for the

position

passages

slot

to

the cylin-

19.

Select the 7/8 in.
ment

and fasten

the lever
Position

20.
into

the spark

keep

to
and removing

diameter

the attachment

arm with

the

the valve

the speed

piston

plug

closed while

the valve keepers.

short compressor

pin

at TDC

and insert

hole. Pump

attach-

to the No. 4

supplied.

air into

compressing springs

hole of

an air adaptor

the cylinder

Using a downward
press

the valve
the valve
spring.

Repeat

step 22 for

27.

Remove
Install
Install

reverse
Repeat
NOTE:

neao

the valve seals

the valve seals

the springs,

order of removal.

steps 20 to 26

Reler to

cover.

motion

spring and remove

stem. Slowly release

the other valve in

the retainers

page

on the lever

(see

page

6-22).

(see

page

6-23).

and the keepers

on the other

6-31 when installing

arm, com-

the keepers

pressure

that cylinder.

three cylinders.

from

on the

cylinder

in

Timing

Belt

lllustrated

NOTE:
.

Refer to

.

Mark the direction

.

Replace

a

Do

.

Clean the

page

6-12

the rubber

not uss the middle

middle cover and

NUT

CAP

6xl.0mm

(1.0

N'm

9.8

Index

positioning

for

of rotation

seals tor oil

cover and lower cover

kgf.m,7.2lbtft)

\o

pulley

crankshaft

on the belt before

and

removing.

leakag€ between the cylinder

for storing itsms disassembled.

lower cover before

installation.

WASHER

damaged

when

Replaco
or deteriorated.

CYLINDER
Refer to

installing.

BACK OOVER

HEAD COVER

pago

RUBBER SEALS

Replace when damaged

or deleriorsled.

8 x 1.25 mm
37 N.m

before

head and cover.

when

6-31

13.8

installing belt.

kgl.m,27 lbf'ft)

5/r N.m
do not r€move,

AD.'USTING
10 x t.25

For adjustrnent

mm

15.5

BOLT

kgl.m,

only,

,o

lbtft)

6x1.0mm

N,m

9.8

11.0

7.2 lbl.frl

TIMIMi BELT

Inspection,

Adlustment,

Replacement,

NOTE:
O

O
O

When installing

tighten

loosen bolt,
retighten it to

kg{.m,

page

6-9

pago

6-9

page

6"10

a new crankshaft

the crankshaft

pulley

177 N.m

(18.0

lnstallwith

facing in.

surface
Clean.

BELT

TIMING

PULLEY

DBIVE
Remove any

clean,

and

196 N'm

bolt to

kgt.m, 130

concave

oil

and/or

lbf'ftl.

with concave

lnstall

facing out,

surface
Remove any oil

ctean.

ano

new bolt:

(20.0

kgf'm,

LOWEn
COVER

145 lbf'ft),

COVER

6x1.0mm

(1.0

9.8 N'm

BOLT

'14

x 1,25 mm
lt7 t{.m
Replacsmenl,

118.0

kg{.m. t.2

ALTERNATOR

BELT
Adjustm6nt,
Soction

CRANKSHAFT
PULI"EY
Romov6 any oil
and clgaa
timing bolt

plato

kgl.m,
page

lbf.tt}

23

on thg

guide

side.

130lbtftl

6-8

6-7

t

I

Crankshaft

Pulley Bolt

Replacement

NOTE:
.

Crankshaft

14 x
177 N.m

.

When installing a new crankshaft and/or
bolt:

pulley

1.25 mm
(18.0

bolt size and torque

130 lbf.ft)

kgt.m.

value:

new

pulley

When installing the bolt,
flang€ with engin€ oil, but don't

pulley.

and

lubricate the threads and

lubricate

the washe.

pulley

tiglten

Q

tbnft).
loosen the bolt,

O

retighten it to 177 N.m

O

the

HOI-DER HANDII
o'JAB

bolt to

(18.0

-oo1020A

196 N.m

kgf'm.

(20.0

kgf.m, 145

130 lbf.ft).

PULI.TY
HEX 50

lubricat€

Don't

HOI.I'€R ATTACHi'ENT,

mm.

OFFSET

-

PY3010A

washer.

SOCrET
COMMERCI,ALLY

WRENCH,

AVAILABI.I

19 mm

Timing

Belt

Inspection

Remove

.

Inspect
soaking.

NOTE:
.
.

the cylinder

Reler to

Replace the
Rsmove any

page

the timing

head cover.

when

6-3'l

for cracks and

belt

if oil or coolant

belt

oil or solvent

installing.

soaked.

gets

that

oil or coolant

the belt.

on

Tension

CAUTION:
cngin.

NOTE:
.

The tensionet

sion
ing adjustment.

.

Always
viewed

may

sion.

3.

4. Set

Always

cold.

to the belt

rotate

trom the

result in

Remove

when

6-31

Set the

Rotate
bslt.

No.

the c.ankshaft

the No.

Adjustment

timing belt

Ediust

is spring-loaded

automaticallv

the crankshaft

pulley

side

improper adjustment

the cylinder

installing.)

piston

1

piston

I

head

TDC

at

5 - 6

at TDC.

tonsion

to apply

making the

after

counterclockwise

Rotating

cover.

(see

page

revolutions to

with tho

proper

it

clockwise

ot the belt

(Refer

to

6-12).

ten-

follow-

when

ten-

page

set the

After

177 N'm

to

inspecting,

('18.0

retorque

kgf'm, 130

the crankshaft

Rotate

inspscr

and

lbt'ft).

pulley

bell.

pulley

bolt

Loosen

5.
Rotate the

6.
the

Tighten the

7.

8.

After
to 177

the adiusting

crankshaft

camshaft

adjusting

adjusting,

(18.0

N.m

pulley.

retorque

kgl.m.

ADJUSNNG
54 N.m

rbr.ftl

a0

adiustment

For

not remove,

do

Direction
rolatlon.

bolt

counterclockwise

bolt to

130 lbf.ft).

ol

1/2 turn

the

(180')

the specified

crankshaft

BOLT

(5.5

kqf.m,

onlv

3-teeth

torque.

pulley

only,

on

bolt

6-9

Timing

Removal

Belt

NOTE:
.

Turn

the crankshaft

top

d6ad

page

&12).

a

Inspect
bolt

1. Remove

2. Loosen

MOUivNNG
8 x 1.25 mm
2a

the

page

{see

remove

N.m

12.4

Loosen
bolt,

then

oressor belt.

pulley

(TDC)

center

pump

water

10-9}.

thawhe€lwell

ths adjusting

power

the

BOLTS

kgf.m,

the adjusting

remove

steering

1 7 lbt frl

the air conditioning

so the No.

before removing

when removed

splash shield

bolt and mounting

{P/S)

bolt and idler

1

the

(see

pump

belt.

AA,USNNG

pulley

piston

is

(see

belt

the timing

page

6-18).

bolts,

then

bracket

(A,/C)

com-

at

4,

Remove

Remove

Loosen
remove

the adjusting
the alt€rnator

MOUNTING NUT
10 x 1.25 mm
a,l N.m

the

the sid6 sngine mount.

10

x 1.25 mm

52 N.m

Replace.

kgl.m,33

{4.5

cruise control

kgr'm,38

{5.3

nut and mounting

belt.

ADJUSNNG
8 x 1.25 mrr
2a

N.m

17 rbl.ftl

lbfftl

actuator

lbtft}

EELT

(see

page

nut,

l2.a

then

NUT

lef.m,

6-18).

I

IDLER PUI.IEY BRACKET

BOLT
l0 r 1.25 mm
a/a N.m

kgf.m.33

{1.5

ADJUSTING

lbf'ft}

12 x 1.25 mm

74 N.m

17.5

s4 tb{.ftl

kgt m,

1. Remove
.

Refer to

Remove

8.
page

6-8).
Remove the
NOTE:
.

Do not use
storing

.

Clean the
installation.

NUT 6

CAP

N.m

9.8

11.0

the cylinder

page

6-31 when

the

Dulley

middle cover

middle cover and

the

disassembled.

items

middle cover

mm

x 1.0

7.2

rbl.ftl

WASHER

Replace

or

head cover.

installing.

and crankshaft

bolt

and the

and

damaged

when

pulley

lower cover.

lower cover

lower cover

(see

for

before

CYLINDEF

COVER

page

Reter to
installing.

10. Loosen the adjusting
1'1. Push the tensioner

ing belt, then
Remove

12.

NOTE: Push the tensioner
loosen the belt.

HEAD

when

6-31

to

retighten the bolt.

the timing

belt

180'.

bolt

remove tension

from the

ADJUSTING BOLT
10 x 1.25 mm
54 N.m

/r0

lbf.ftl

For

pulleys.

pulley

kg{.m,

15.5

adjustment only,

from the

to

tim-

Remove

anY

oiland

NMING
GUIOE
lnstallwith
surface

and

clean

BELT

PLATE

concave

facing

clean.

6x1.0mm

(1.0

9.8 N.m

BELT

TIMING
Adiustment,

KE

LOWEB @VER

out.

kgtm,7.2lbt'ftl

Page

6I

MIDOLE COVER

6x1.0mm

N.m

9.8

CRANKSHAFT
Remove
and
timing belt
plate

any oil

clean on ihe

guide

sido.

kgJ m,

11.0

PULLEY

7.2 lblftl

6x1.0mm

('1.0

N.m

9.8

kgt.m,7.2 lbl

fr)

6-11

Timing

Installation

Install

the timing belt in

Only key

points

Belt

are described

the revorce

here,

order of removal;

NOTE:
installation.

L Position

Cl€an the middle

shown

before installing

A. Set the

top dead center
t€eth side
pointer

L Align the TDC

tevs,

NOTE:
No. 1
with the holes
insert

cover and lower

the crankshaft

crankshaft so that

on the oil

To set

piston,

5,0 mm

(TDC).

of the timing

pump.

marks

the camshafts
align

the holes in the

in No. l

pin punches

PIN PUNCHES,

cover

and th€ camshaft

the timing belt.

the No. 1

at

the

mm

g.oovo

pulley

and

TDC

holes.

exhaust

position

Align the

belt d.ive

intake

on

camshaft holders

in

5.0

before

pulleys

oiston is at

camshafts

as

on the

to the

pul-

for

and

O

2. lnstall the
snown.

timing

O
Adjusting

Exhaust
lev.

timing belt

belt drive

pulley

camshaft

*

@

pulley

tightly in

pulley

Water

+

Intake

@

the sequence

{crankshaft)
pump pulley

camshaft

+

-

@
@

pul-

6-12

TDC

mark align6d

pointer

on

back cover,

with the

TDC MARK

Cylinder Head

lllustrated

CAUTION: To
rsmoving

NOTE:

I x 1.25 mm
22 N.m

16 rbf.ft)

avoid damaging the

it.

new

Use

kgt.m,

12.2

lndex

O rings and

cylind6r hoad, waii until

gaskets

when reassembling.

e

et

ongin€ coolant

CAP NUT 6 x 1.0

N.m

9.8

kgtm,7.2lbtftl

11.0

CYLINDER HEAD
COVER
Refer to
installang.

mtn

page

temporature drop3

6-31 when

RUBBER
Replace

or

SEAL

when

doteriorated.

damaged

below lOO"F

(38"C)

b€fore

I x 1.25

mm

24 N.m

17 rbt.tr)

EXHAUST CAMSHAFT
HOI.DER

RUBBER CAP
Replace for oil
leakage.

EXHAUST
CAMSHAFT

LOCKNUT
25 N.m
18 tbtfiJ

ROCKER ARM

12.4

{2.5

kgf.m,

kgf.m,

-.\

--_r,_

See section

__.|._

-

6tal --,

ffi;r

INTAKE CAMSHAFT HOI.DER

O-RING
Roplace.

KEY

/./

SEAL
Replace.

"

@6

6x1.0mm

9.8

8 x 1.25 mm
37 N.m

13.8

N.m

kgl.m,7.2lbf.ft)

{1.0

INTAKE CAMSHAFT
Inspection,

SEAL

Installation,
Replace.

'@

t

I x 1.25 mm
37 N.m
27 rbtftt

CAMSHAFT PULLEYS
Removal,
Installation,

kg{.m,27

page

page

lbfftl

6

19
6,30

page

page

(3.8

5-21

6-30

kgt.m,

CAUTION:

In h.ndling

r

m.t!l

gr3kct,

trko

clrc not

to fold it or

dlmaga tho

contact

surfacr ol

thr

gaskat.

XEEPERS

VAIVE

SPRING

RETAINER

r*#:-3

STEM SEAL
VALVE SPRING

SEAT

EXHAUST
GUII'E

CYLINDER
{3 LAYERS

Reolac6.

EXHAUST

VALVE

HEAD GASKET

METALI

OF

VALVE

\n

\.\...i6

--------ig

TX)WEL PIN

END
6:t

,16

CONTROL

OIL
ORIFICE
Clean.

PIVOT

N.m

lbl.ftl

l6.a

BOLT

kst'm,

N.m

18,5

tbf.ftl

threads.

HEAD

kgl'm,

CYUNDEB

BOLT
&t
61
Apply engine
the

oilto

JI

ED..-

$----

S----

€.----

DOWEL

O.RING

Replac€.

VALVE

I

--../

PIN

KEEPERS

SPf,ING

nrAxE
twtAKE

valvE

INTAKE

Insp€ction,
R6placom6nt,
Reaming,

CYUNDER
Warpage,

INTAKE

Replacement,

RETAINEB

vaLvE SPRING

STEM SEAL

vALvE

VAI-VE

pago

pag€

HEAD

page

VALVE

sEAT

GUIT'E

S24

pago

6-26

6-28

Page

6-25

6_22

SPRING

6-15

Gylinder Head

Removal

I

t

Engine removal is not required for
CAUTION: To

until

tho ongino coolant temporature drops

beforo loo36ning

{38"C)
NOTE:

.

Inspect

neao.

.

Turn the crankshaft
at top

.

Mark all emissions hoses

.

Anti-theft radios have
Be sure to

-

Disconnecting

-

Removing
hood fuse/relay

-

Removing the radio.

After

on.
When
tomer's 5-digit

1. Disconnect

2. Drain
.

Remove the radiator

avoid damaging tho cylinder head,

rotainin0

the

the timing belt before removing

pulley

dead center

get

service, reconnect

the word

the engine coolant

(TDCI (page

the customer's

the battery.

the No. 32

box.

"CODE"

code to

negative

the

so that the No. 1

before disconnecting

a coded theft

code number before.

(7.5

A) fuse irom

oower to the

is displayed,

restore

terminalfrom

(see

cap to speed draining.

procedure.

this

bolow 100"F

bolts.

the cylinder

piston

6-12).

protection

the under-

radio

and turn it

enter the cus-

radio operation.

the battery.

page

10-5).

wait

is

them.

circuit.

5, Remove the intake

Remove

evaporative

the breather

emission

air duct.

hose, water

(EVAP)

bypass hose and

control

canister hose.

3. Relieve fuel

@
systom, keep opon flame

area. Drain fuol

4. Disconnect

SERVIC€ BOLT

pressure

Do not

the fuel feed hose.

(see

Section 1 1).

smoke whils working on tusl

or spark away trom work

only inlo an approvod

containsr.

WASHERS
Replace.

Remove the
ventilation

fuel return hose and

(PCV)

hose.

positive

crankcase

Remove the throttle

9.
Remove the throttle

10.
mission

only).

NOTE:
.

Take

care
it. Always
one.

.

Adjust the

cable when

cable.

control cable

not to bend

the cable

replace any kinked

throttle cable

installing

and throttle

(see

section 11 and

(automatic

trans-

when removing

cable with a

control

14).

new

HOSE

Remove

hose and

bypass

the brake

vacuum

VACUUM

booster

hose.

HOSE

vacuum hose,

BOOSTER

ERAKE
VACUUM HOSE

water

THROTTLE

CONTROL

CABLE

Remove the

11.
harness clamps

wire

intake manifold.

a
a
a

fuel injector connectors

Four
Intake air temperature
Engine coolant

necror

TDC/CKP/CYP

a

lgnition coil connector

gauge

a

ECT

a

Throttle

a

Manifold absolute Dressure
nector

a

ldle air control
EVAP

purge

a

engine

wire harness connectors

trom the cylinder

(lAT)

sensor

temperature

connector

sensor

sending unit connector

position

(TP)

(lAC)

sensor

valve

connector

control solenoid

ATI'USTING

head and

connector

(ECT)

sensor

connector

(MAP)

sensor con-

valve connector

and

the

con-

HOSE

(cont'dl

6-17

Cylinder

Head

I

Removal

12. R€move the spark
the cvlinder head.

Remove the upper

water bypass hose.

WATER BYPASS

(cont'dl

plug

caps and distributor

radiator hose, heater

UPPER RAI'IAYOR

hose

from

and

15. Remove the engine
Remove
remove the
pump.

.

Do not disconnect the P/S

adjusting bolt and mounting bolts, then

the

power

ADJUSTING

BOLT

ground

steering

cable.

(P/S)

hoses.

pump

6x1.0mm

N.m

9.8
tbf.ftl

7.2

belt 8nd P/S

tgfm,

11.0

14. Remove th6 solash shield.

8 x 1.25 mm

.m

(2.akstm,

24

Remov€ the air conditioning
(see

R€move the alternator belt

17.

Ramove the cruise control actuator.

t8

pags

17lbf.ftl

6-10).

8 x 1.25 mm
2a N.m

12.4

kgt m,

P/S PUMP

(Ay'Cl

(see

page

compressor

6-10).

belt

9.8 N.m
t.2 tbr.frt

{1.0

kgt

m.

sHtEut

ACTUATOR

19. Remove the side engine

x 1.25 mm

10
52

N.m

(5.3

kgt'm, 38

lbf'ft)

mount.

WASHERS

ENGINE

SIDE
MOUNT

Remove the timing

Remove

the camshaft

(see

belt

pulleys

page

6-10).

and back cover.

20. Remove

the cylinder

head cover.

12 x 1.25 mm
74 N.m

rbtftl

5{

CYLINDEB HEAD

{7.5

kgf.m,

23. Remove the

BACK COVER

exhaust manifold.

SELF.LOOKING

x 1.25 mm

8

NUT

BRACKET

(cont'd)

6-19

Cylinder

Head

Removal

2,0. Remove the intake msnifold.

IMTAXE

(cont'dl

GASXET

MANIFOLD

Remove
camshaft holde.s.

the camshaft holder bolts,

then

camshafts and rocker

remove

arms.

the

25. Loosen

ADJUSNNG

locknuts

the

SCNEW LOCATN)NS:

and adiusting screws. 27. Remove

the cylinder head bolts.

cvlindsr head.
CAUTION: To

in laquoncc 1/3 turn at I tim6; .apeat
until sll boltr arc loosrncd.

CYLINOER

preyant

HEAD BOLTS

warpago.

LOOSENING

then

unlcr.w thc bolt3

SEOUENCE

remove

the $qurnca

the

Camshafts

Inspection

1.

!

2.

Loosen
Remove
NOTE:

them.

Reinstall the
camshaft

ning

9.8
Seat the

tributor end

Zero
camshaft.

read the end

Camshalt

St.ndard
Seivice

the adjusting

the camshaft

Mark the

holder bolts

with the

(1.0

N.m

kgf.m,7.2 lbf.ft)

camshafts

of the

the dial

push

End

lNow):

Limit:

screws.

holders and

rocker arms before

-

0.006
{0,02

holders.

them toward

back and

mm

inl

in)

camshaft and

in a crisscross

inner bolts.

pushing

by

head with a screwdriver.

indicator against

camshaft

the

play.

Play:

0.05 - 0.15
(0.002

0.5 mm

the rocker arms

removing

Tighten the

pattern,

the

begin-

the dis-

end of the

forth and

10.Remove the
ponion

Camshaft-to
Standard lNewl:

Sarvico

11. lf camshaft-to-holder
ance:

.

And the camshaft
vou

.

lf the camshaft

total

blocks.

camshaft

plastigage

of

Holder Oil

Limit 0.15

must replace the

runout

on each

0.039 - 0.069
(0.0015

mm

has

with the camshaft

holders.

Clearance:

PLASTIGAGE

oil clearance

has already

not been replaced,

Measure the widest

journa..

mm

-

cylinder

0.0027
{0.006

in)

inl

head.

supported

is out of toler

been

replaced,

first check

on V-

Remove the camshaft
head.

NOTE:

turns at a time,

Lift the camshafts
them clean,
camshaft
srvely

Clean the
head,
plastigage strip across

Install the
the

NOTE:

Unscrew

if any

worm

camshaft

then set the

camshaft

values and in the

Do not rotate

the camshaft

in a crisscross

out

inspect the

then

lobes are

journal

camshaft

holders and

sequence

camshafts

holder bolts

ot the cylinder

each

from the cylinder

holder

pattern.

lift ramps.

pitted,

scored,

surfaces

back in

iournal.

torque the

shown on

during

bolts two

head. wipe

Replace the

or exces-

in the cylinder

place.

Insert a

bolts to

page

6-30.

inspection.

Clmshaft
StEndard
Servico Limit:

-

-

Total Runout:

{New):

lf the total runout
erance,

lf the

camshafts and

out of tolerance.

replace the cylinder

total runout

(0.001

mm

0.03
mm

o.Oil

recheck.

{0.002

of the camshafts

is out of tolerance,

lf the oil clearance

replace

the cylinder

inl max'
inl

is within tol-

head.

replace the

is still

head.

6-21

Valves, Valve

Removal

Springs and

Valve

Seals

item

valve

reinstalled in its

can be

plastic

springs as they are

mallet to loosen

NOTE: ldentify valves and
removed so that each
nal

Dosition.

1.

Tap each valve stem with a
valve keepers before installing the spring compres-

sor.

2.

lnstall the spring compressor. Compress spring and
remove vatve Keeper.

VALVE SPRING COMPRESSOR
xo No.3tB.

whh r35 JAW o.

oriqi-

-

07757

PJ10r0A

Installthe special tool as shown.

Remove

COMMERCIALLY AVAILABLE
VALVE GUIDE
LISLE P/N

valve

the

seal.

SEAL

5t9d) or KO3350

REMOVER

SEAL
REMOVER

lntaks Valvo Dimonsions

A Standard

I Standard

C Standard lNow): 6.580 - 6.590 mm
C Servico Limit 6.55 mm

D

Standlrd

D

Ssrvice

Exhau3t Valve Dim6nsions

A Standard

B Standard

C

St.ndard

C Servico Limit 6.52 mm

D

Standard

D Service Limit: 1.,[5 mm

(New):
(Nowl:

(N€w):

Limit: 1.15 mm

{New):
(Newl:

(New):

{New):

30.90 - 31.10 mm

-

|.1.217

103.80 - 10'1.10 mm

-

{4.087

{0.2591

1.35 - 1.65 mm

-

10.053

27.90 - 28.10 mm

-

11.098

104.00 - 104.30 mm

-

(4.094

6.550 - 6.500

10.2579

1.65 - 1.95 mm

-

10.065

1.221inl

4.098 inl

-

0.259/r in}
(0.258

0.065 inl
(0.045

1.106 inl

4.106 inl
mm

-

0.2583 inl

(0.257

0.077 inl
(0.057

inl

in)

in)

in)

Installation Sequence

NOTE: Exhaust and

NOTE:
spring
towrrd

intake valve seals ate

valve

Place th€ 6nd

with closelY

cylinder

th€

EXHAUST

SPRING}

{8LACK

Replace.

oI

wound coils

head.

VALVE SEAL

NOT interchangeable.

@/.-uo.**.r..",

@*_-.tt*

SPRNG

NETAINER

NOTE: Installth€

instslling the

beforo

v6lvo

spring

valv6 sesls.

s€ats

PLASTIC

MALIIT

.tIF"F-

6-23

Valves,

Valve

Springs and

Valve Seals

Valve lnstallation

When instaliing valves in the cylinder head, coat
valve stems with oil before insening them into valve

guides,
smoothlv.

When valves and springs are

end of each
proper

tic mallet).

NOTE: Tap the valve stem only along its axis so

not

do

make

and

valve

seating of

the stem.

bend

valves move

sure

in

stem two

valves and valve keepsrs

or three times to snsure

up and down

place,

lightly

PLASNC MALI.IT

tap the

(use

plas-

you

Valve

Guides

Valve Movement

Measure the
tor while rocking the stem in the direction of normal
thrust

lntake Valve Stsm-to-Guide Clearance:
Strndlrd

Ssrvicc
Exhsust Valye Stom-to-Guide Clearance:

Standard
Slrvica

guide-to-stem

(wobble

method).

(Newl:

0.0i1- 0.10
(0.002

Limit: 0.16 mm

0.10 - 0.16 mm

{N€w):

{0.0O'l

Limit:

0.22

Valve extended

clearance with a dial indica-

mm

-

0.004 in)
in)

{0.006

-

0.006 in)

mm

{0.000

in)

10 mm

out from seat

?ur

lf measurement exceeds the service limit, recheck
using a
lf measurement is now within
reassemble using a n€w valve.
lf measurement still exceeds limit, recheck using

alternate
guide,

NOTE: An alternate method of checking

clearance is to subtract the O.D. of the valve stem, mea-

sured with a
guide,

gauge.

Take the measurements in three

stem and three

The

and the smallest stem

the service limit

lntake Valve Stom-to-Guide Clearance:
Standard

Service
Exhaust Valve Stom.to.Guid€ Clearanco:

Standard
Srrvico Limit 0.ll

new

valve.

the service

method below. then replace valve and

if necessary.

guide

micrometer. from

measured with an inside micrometer or ball

places

inside

the valve

diiference between the

(Newl:

0.02 - 0.05
(0.001-0.002

Limit 0.08 mm

(Newl:

0.05 - 0.08 mm
(0.002

largest

measurement

mm

in)

(0.003

-

0.003 inl

mm

10.00't

the

places

guide

should

in)

inl

l.D.

of the

along the valve

guide.

measurement

not

limit,

to stem

valve

exceed

6-24

Replacement

1. As illustrated
dure, use a commercially-available
er attachment

guides.

valve
can be done
conventional

COMMERCIALLY

VALVE

Select the

in the

them

about an

in the removal steps

modified

most

In

using the

hammer.

GUIDE

RGmov.l
VALVE

-

0?942

proper

freezer section of

hour.

to fit the diameter

cases.

Valve

AVAILABI,I

DRIVER

f

|

In3tlllation

rnd

DRIVER,

GUIDE

6570100

replacement

of this

air-impact driv-

tho same

Guide

procedure

Driver and a

-----T_-

--

sz

12.21i^l

6.6 mm

guides

a refrigerator

and chill

proce-

of the

lrl

11.3 mm
in)

lo.il,l

for

4. Working
an air
in) towards the combustion
knock oft some of the
eaSrer.

GAUTIOiI:
o

.

Turn the
the camshaft side

lf a valve
mm

CAUTION:
could drmrgo

from the camshaft side. use

hammer to drive the

Alwrys
wh6n using tho

Hold ths air

vrlvr

woar safety

Eir hammer.

hammsr directly

guidc

head over and drive

guide

(5/16

in) bit, then

prsvont

to

of head.

still

guid$

Drill

tho cylinder

won't move, drill

the driver and

guide

about 2 mm

chamber.

carbon and make

goggles

damaging tho drivor.

try again.

only in oxtremo cases:

or a face shiold

in lins with the

guide

the

hosd if ths

out towatd

it out with a 8

guido

{0.1

This will

removal

You

br"akr.

plate

hot

Use a
head to 300'F
a cooking thermometer.

CAUTION:
.

Do not use a torch;

.

not

Do
excessive

.

To avoid

heated cylinder

the

or oven

(150'Cl.

get

ths head

may loos€n thG

hgat

burns, usa

Monitor the

it may

hoad.

to evenly

hottq than 3OO'F

hoavy

heat

the

temperature

warP the hgad.

valvs soat3.

glov93

whon handling

cylinder

with

1150"C);

GUIDE

VALVE

07942 - 65701q)

Remove

at a time, as

the new

DRIVER,6.6

",

OO

you

(V

O

guide{s}

need them.

mm

/rl -1-- )

from the

o

refrigerator, one

{cont'd)

6-25

Valve Guides

Replacement

7. SliD a 6.5
driver attachment
washer will absorb
the

mm

life of the driver).

{cont'd}

{0.25

over the end

.,F-q-re

tt-T-

II

ttl

DRVEn

Install the new

8,

head; drive each

the

bottoms
to do,

more I|mes.

vou

guide(s)

head. lf

on the

may have to reheat the

in)

some of the

6,5
WASHER

washor and

stsel

mm

one in until

in)

t0.25

from the camshaft

you

have

the correct

of the driver

impact and extend

ATTACHMENT

the attachment

8ll sixteen

head one

{The

of

side

guides

or two

Reaming

For new valve

NOTE:

both reamer

Coat

Rotate the

guide

valve

Continue to
removing it

Thoroughly

remove any cutting

to
Check clearance

.

Verify that

exhaust

REAMER

HANDLE

guides

only.

guide

and valve

reamer clockwise

bore.

rotate the reamet clockwise

from the bore.

wash the

valve

guide

residue.

with a valve

the valve slides

guides

without ex€rting

with cutting oil.

the full

in detergent and

(see

length

page

in the

6-24).

the

of

while

water

intake 8nd

pressure.

Guida

Valv6

lntaks:

Exhru3t:

Instsllod Hcight:

-

0.561

16.25 mm

-

0.640

mm

13.75 - 14.25
(o.sal

-

15.75
{0.620

inl
in}

s

VALVE GUII'E

-

667ot0c

079E4

REAMER, 6.6

MM

Valve Seats

Reconditioning

1. Renew the valve seats
valve seat cutter.

NOTE: lf
them

2. Carefully
material to ensure a

Bevel the upper edge

3.
and the
Check width of seat and

4. Make one
remove

ters.
Valvo Seat

Standard:
Servics

guides

(see

page

cut a

lower edge of the

more very

possible

any

Width

Limit:2.0

SEAT
WIDTH

worn

are

6-251 before cutting

45'

seat,

smooth and concentric seat.

light

burrs

llntake

-

1.55 mm

1.25
mm

in the cylinder

(see

removing only enough

of the seat

seat with the 60' cutter.

adjust accordingly.

pass

with the

caused by the other

Exhaustl:

and

{0.049

inl

10.08

head using a

page

6-24),

the valve seats,

with

the

45"

-

0.061

replace

30o cutter

to

cutter

cut-

inl

The

blue compound, should be
.

lf it is too high
must make a
move it down, then one

cutter

.

lf it is too low
must make a second
move it up, then one

to restore seat width.

NOTE: The

the

Insert intake and exhaust

7.
measure valve stem

Intako
Standard

Service
Exhaust
Standard {Newl:

Service

valve seating surface, as

actual

to restore seat

final cut should always be

45'

cutter.

Valve Stem Install€d

(New): /$.765 - '11.235

{1.604It

Limit:

Valvo Stem lnstalled

Limit

ill.il85

,12.765 - i|:|.235
/B.il85

shown by the

centered on the seat.

(closer

second cut with the 60" cutter

width.

(closer

11.6a37

to the valve edgel,

cut with the 30' cutter to

more cut with the

installed height

-

1.6234 in}

mm

-

1.1022 in1

mm

valve stem),

to the

more cut with the

valves in the

Height:

mm

(1.6:133

(1.7120

inl

Height:

mm

inl

you

you

45"

cutter

made with

head

and

to

45'

resurfacing the seat,

After
seating: Apply
face, and

head, then lift it and snap
severaltimes.

ACTUAL
SEATING
SUBFACE

VALVE
SEAT

PRUSSIAN

Prussian Blue compound

insert valve

in

inspect for even

to the

original

it closed against

location

valve

valve

in the

the seat

lf valve stem

8.
reDlace valve and

limit,

limit, replace cylinder

vice
the head is too deeo.

installed height

recheck. lf still over the

head; the

is

over

the service

ser-

valve seat in

6-27

Gylinder

Head

Installation

t

NOTE: lf camshaft-to-holder

21) are not within specitication,
resurfaced.

lf

camshaft'to-holder

tions, check the

lf warpage
head resurtacing is
lf warpage

(0.008
Maximum

on a height of

is

in), resurface cylinder

resurface limit is 0.2

oil clearances

head for warpage.

is less than 0.05

between

132.0 mm

PRECISION STRAIGHT EOGE

oil clearances

mm

not required.

mm

0.05
head.

(5.20

in).

the head

(0.002

mm

(see

cannot be

within specifica-

are

(0.002

in) cylinder

in) and 0.2 mm

(0.008

in) based

page

6-

Installthe cylinder
NOTE:
.

Always use a new head

.

Cylinder
ctean.

"UP"

.

.
.

.
'1.

mark on the

top.

not

Do

use the
ing items disassembled.
Clean the

lation.
Replace the

Cylinder
must be
NOTE:
.

When handling a
taken

of the

.

Clean the oil control

OOWEL

head in the reverse order of

head and cylinder block

timing belt

middle cover and

middle

cover

washer when damaged or

head dowel

aligned,

not

told it or damage the contact

to

gasket.

PINS

gasket.

surface must be

pulleys

should

lower cover

and lower cover

pins

and the

metal

orifice when

oil control orifice

gasket,

CYLINDER
{3

Replace.

care should

installing.

LAYERS

removal:

be at the

for stor-

before instal-

deteriorated.

be

surface

GASKET

HEAD

OF METALI

orl coNtnol

ORIFICE
Clean.

Measure

Cylinder Hoad
Standard

along edges, and 3

(New):

Height:

131.95

{5.195

ways across center.

-

132.05 mm

-

in}

5.191t

Tighten the cylinder
Jirst step

N.m
the same sequence
NOTE:
.

.

CYLINDER

tighten all bolts,

kgf.m, 22

{3.0

Apply engine oil to the cylinder

the washers.

Use the
as shown.

longer bolts at

HEAD BOLTS

head bolts

lbl.ltJ; in the final step, tighten

to 83

TOROUE SEOUENCE

in two steps. In the

in sequence, to about

(8.5

N.m

positions

@o@@@

O.RING

Replace.

29

in

kgf.m, 61 lbf'ft).

head bolts and

No. 1 and No. 2

Put longer

bolts here.

Install the intake
c.isscross
inner nuts.

CAUTION: Check

taco

ol tho

damagod.
Tighten the intake manifold bracket bolts.

4.

manifold and tighten the nuls in a

pattern

in 2 or 3 steps, beginning

to. fold3 or 3cratchc! on ihc aur-

ga3kot.

Roplscs with a nlw

GASXET
Replace.

with

gaeket

the

CAUTION:

.

Mlka
facing up .nd No. I

(TDCt.

.

Rcphct th! rocksr armr in thsir o.iginal

if

6, Place the

valve

lnstallths camshafts, then installth€ camshaft sosls

7.
with

thrt thc k.ywlyr on tho c.mthlttr lrc

3uro

stems.

open side

ths

rocker

pi3ton

arms on the oivot

(spring)

i3 8t top d.rd clnt.r

facing in.

bolts and ths

potltlom.

x 1.25 mm

E
2ir N.m

17 tbf.ftl

Install the exhaust manifold and tighten

5.
self-locking
steps, beginning with the
.

Use new self-lockiflg

8 x 1.25 mm

(2,a

24 N.m
11 Replace.

nuts in a crisscross

kgf.m,

EXHAUST

kg{.m,

l2.it

inner nuts.

nuts.

SELF.LOCKING NUT
8 x 1.25 mm

N.m

31

8 x 1,25 mm
23 N.m

17 tbl.frt

pattern

(3.2

kgt m,23lbfftl

GASKEI

Replace.

kgf.m.

12.3

the new

in 2

or

Apply liquid

8.
installthe rubber cao.

3

gasket

around the rubber cap, then

m

l0 x 1.25 mm
a,t N.m

14.5

33 tbt.ft)

kgf.m,

1.25 mm

8 x
2il N.m

17 rbtftl

12.4

kg{.m,

(cont'd)

6-29

Cylinder

Head

Installation

9. Apply

No.6 No.5 No.2 No.

liquid
the No. 1 and No. 6 camshaft
them, along with No. 2,3,

NOTE:

"1"

o

or

holders.

.

Do not
camshaft seals.

.

Apply liquid

.

The arrows marked on the camshatt
should

(cont'dl

gasket

"E"

marks are stamoed

apply oil

gasket

point

the timing belt.

to

INTAKE CAMSHAFT HOLDERS

head mating surtaces of

to the

holders, then install

4,

and 5.

to the holder mating surface of

to the shaded areas.

on the camshaft

holders

11. Tighten each bolt in two steps to ensure that the
rockers do not bind on the valves.

6r1.0mm

N.m

9.8

1

kgf.m,7.2lbtft)

11.0

Install keys into camshaft
NOTE: To set the camshafts at TDC

piston,

1
holes in No. 1
pin punches

align the

camshaft

in the holes.

grooves.

holes in

holders

the camshafts

and

position

for No.

with

insert 5.0 mm

the

10. Tighten the camshaft
.

Make sure that the
positioned

on the valve stems.

holders

temporarily.

rocker arms are

properly

KEYS

I r 1.25 mm
37 N.m

6x1.0mm

(1.0

9.8 N.m

7.2 tbtft)

Push camshaft

13.
the retaining bolts to the torque specified.

pulleys

kgf.m,

onto camshafts, then tighten

kgf.m, 27 lbf.ttl

{3.8

14.

Installthe timing belt

Adjust the valve clea.ance

16.

Install the
head cover. Seat the seal
camshaft

the

NOTE:

.

Before

clean the seal and the

.

When installing,
securely
gap.

rubber seal in the

first, th€n work it

outside edges,

installing the rubber seal, thoroughly

in

the corners

RUBAER SEAL

page

{see

make sure the seal is seated

6-12).

(see

page

6-31.

groove

in

into

groove.

of the recass€s with no

of the cylinder

recesses for thg

the

groove

the

around

17. Apply liquid
corners of the recesses.

NOTE:
.

Use liquid

.

Check that the
before applying

.

Do
havs
Instead, reapply liquid
reaidue.

.

After
filling

gask€t

gaskst,

not install

elapsod

assembly,

the engine

to the rubber seal at the eight

Part No. 08718 - 0001.

mating

surfaces are cl€an and

gasket.

liquid

parts

the

sinco applying liquid

wait at lsast 20 minutes before

with oil.

if 20 minutes or mor6

gasket.

gasket

after removing old

dry

CYUNDER
COVER

HEAD

Apply liquid
the shaded areas.

g.sket

to

(cont'd)

6-31

Gylinder

Head

lnstallation

18. When

installing

seal

rubber

camshaft

the
circles).

the

Once
head, slide

rubber seal.

the

cvlinder

the

(cont'dl

the

groove

in the

contacting

head

cover

cylinder

placing

by

surfaces

cover

slightly

head cover,

your

(top

of

on the

is

forth

and

back

the

hold

fingers

on

the semi-

cylinder

to seat

Tighten
tighten

7.2 tbf.ft).

all

the

in 2 or

nuts

in sequence,

nuts,

3 steps.

9.8

to

In the

N'm

final

(1

0 kgf'm,

step,

NOTE:
.

Before

the

shop

.

Do
aDplied.

installing

cylinder

towel.

touch

not

6x1.0mm

9.8

7.2

the

contacting

head

pans where

the

N.m

11.0

tbf.trl

cylinder

kgt'm,

cover,

head

surfaces

gasket

liquid

clean

using

was

a

con-

and

20.

installing,

After
nectors

installed

are

check

correctlY.

that

all tubes,

hoses

6-32

'lllllllllmlmti'""

Cylinder

Head/Valve Train

818C1 engine

Special Tools ............. 6-34

wEc

Troubleshooting Flowchart

WEC

VTEC Pressure
VTEC Solenoid
Rocker Arms

Manual Inspection .....,................. 6-42

Inspection

Tools ....................................,.....,.. 6-/|i|

Valve Glearance

Adiustment ............ 6-44

Timing Belt

lllustrated 1ndex ............................... 6-46

Inspection

Tension

Removal
lnstallation

Crankshaft

Replacement .........6-47

Cylinder

lllustrated Index ............................... 6-53

Removal

Warpage ................6-74

lnstallation

Solenoid

Adiustment

Pulley Bolt

Head

Valve ...................

Switch

Valve Inspection ....

Using Special

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

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

........................ 6-48

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

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

.................6-55

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

6-36
6-38
6-41

6-48

6-4{l
6-51

6-75

Rocker Arms

Removal ................. 6-60

Location .................

lnspection ..............

Arm-to-Shaft
Installation

Camshafts

Inspection .............. 6-65

Valve

Valve

Valves.

Guides

Valve Movement ..............................

Replacement .........6-71

Reaming ................. 6-72

Seals

Reconditioning ......6-73

Valve Springs and Valve Seals
Removal
lnstallation

Valve lnstallation ............................. 6-70

G|earance .................. 6-63

............. 5-64

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

Sequence

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

6-61
6-62

6-70

6-67
6-69

SpecialTools

o

@
@
@

/.\

o

o

@

Tool

07HAH

OTHAH
07JAB
07LAA

OTLAJ
07MAB.

OTMAF

07742
07757

­_

-

001020A

-

PR30100

_

PR3O2OA

_

-

0010100

-

PJ 1010A

Numbar

PJ7010A

PJTOIOB

PY3OlOA

PRgO'IOA

or

Valve Guide

Holder

Tappet

Air Stoppet

Pulley
Offset
Valv€ Spring

Extension

Valve

Valve Spring

Handle

Adiuster

Holder

Guide

Reamer,

Driver, 5.5

Dctcription

mm

5.5

Wrench

Attachment,

Compressor

Compressor

HEX 50

Attachment

mm

Attachment

mm,

Plea

6-72

6-17

&45

6-43

6-11
6-67

6-71,72

6-67

Rctllanca

o

@

@

@

o

o

@

@

6-34

VTEC

Ref€r to

page

11-32

thru

I l-39

beforo troubleshooting.

-g: -mi

\,__-:-/

Iel-

\.---l-l

-l

MIL h.. b..n Fport d on.
Wrth aaavica chack connac,tot
iomp.d,

Oo

tho ongino

(ECM)

Rg3ot Procgduro.

w6rrn up engine to normal op€r-

tsmporature

ating
fan

comog on).

Do th€ Road Test.'

ls MIL on and does it indi-

cato cod€

!5*3ij'i:,*o:",,XTl.Lamp

2,1

l-

Codc 2l i.

21?

indic.t.d.

control module

(the

cooling

(MlL)

indicates Disenostic rrouble code

'

Road Test:
Accelerate in 1st

Hold

thst engine sp€ed
lflhe MIL do6s not coms on during th€
reoeat this test two

lmormitt.m t
!t thi.tim..

tor

Chacl
loo.. wircr !l VTEC .ol.noid
v.lv. lnd ECM.

gear

ilur.,

poor

connactiont ot

to 6n engino spood ovor 6000

tor at least two seconds.

more

tim95.

i.

.yrtom

OK

(Drc)

first road tost,

2r:A

rpm.

problem

in

the

wEc

Turn

Oisconnect tho

lrom the VTEC solenoid

Chock for continuity betw66n

conn6clor terminal and body

9rcUnO.

ignition switch OFF.

tho

1P

'14

ls there

-

30

connsctor

valvo.

1P

07

YES

(To

pago

G37l

R.pl.c. th. VTEC rolonoid v.lvr,

6-36

{From

pag6

636}

ooooooooooooo

ooooooooooooo

ooooooooooo

ooooooooooo

for

Ch6ck
connector t€rminal

nal.

Ch6ck

connector terminal

and body

continuity

for continuity botwoon

ground.

botw6en

and A4 termi-

(harness

'lP

1P

side)

B.9.lr op.n in th. GRI{/YEL
b.tw..n ECM

{Aa}

.od

vTEc

aolanoid valva connac'tor.

wirc

ContinuityT

Sub.titut! .

r.ch!ck. lt .ytnptom/indic!-

|r|d

gor3

tion

n.l Ecttl,

krown-good ECM

away rrplact tha

origi-

Ro.ir .hon i|r th.
b.iw..n
aoldroid

ECM

valv. Gonnac'tor.

GRN/VEL

(A4l

.nd

wirc

VTEC

6-37

wEc

Troubleshooting

page

Refer

-.+-

-

l{{?l-

to

11-32thru

-r";-r­ziz

;l

Malfunction

r:

pressur€

Flowchart

troubleshooting'

beJore

11-39

Indicator

circuit.

Switch

-

Lamp

VTEC

(MlL)

indicates

Pressure

Oiagnostic

Switch

Troubles

Code

(DTC)

problem in the

A

22:

VTEC

-lr@l-

-

MIL

-

With
iump.d,

Do the
(ECM)Reset

Warm !p
ating
comes

ls
cate

1-

|22

har bagn.oportcd

temperstur€

on).

Do the

MIL on

t.rvic.

cod€

engine

Procedure.

engine

Boad

and does

22?

code

chack

it indic.t.d.

22

control

normal

to

(cooling

T€st.'

on.

connactor

module

oper-

fan

it indi'

*

Test:

Road

Accolerato

that engine

Hold

MIL does

lf the

this

reoeat

Intc.mift.nt

thi. tim..

at

for

Chack

rvirat

loo!.

and

3whch

gear

in lst

not come
two

test

failu.o,

pool

connaction3

VTEC

at

ECM.

to an

for at

speed

more limes.

ry3tom

Ptasturo

engine

during

on

OK

ia

least

ol

speed

seconos'

two

the

over

first

6000

road test'

rpm

Turn lhe

Disconnect
lrom

Check
BLK terminal

Check

8LU/8LK
nal.

ignition

VTEC

the

Ior continuity

continuity

for

terminal

(To page

switch

2P connector

the

Pressure

and body

and

39)

6

OFF

switch.

between

ground.

between
D6 termi'

in

opcn

Rcpair
2P connector

tG101l.

BLK wit.

body

rnd

botwcon

ground

6-38

(From

page

6-38)

Check for continuity
terminal

Remove 10 mm sealing bolt and
connect orl

Connect a
tion

Start
to

Check
speeds

rpm,

and body

pressure gauge.

tachometer

11).

the engine and

normal operatrng temperature.

pressure

oil

of 1,000, 3,000 and

between D6

ground.

{soe

warm it up

engine

at

sec-

5,000

Ropair op€n in BLU/BLK $,iro be
tween ECM
tor,

lD6)

o oooooo ooo

oooo ooooo

o

R6pri. short in BLU/BLK wir. bc­tweon ECM
toa,

NOTE:
Keep mgasuring time as short as
running with no load

(D6l

GAUGE JOINT ADAPTER
SNAPON MT2&17
10 x 1.0 mm

.

lJse new washer when

installing the sealing bolt.

2P conn.c-

and

ooo I oooooooo
ooo

oo

I

.nd 2P connec-

(less

than one

oooo

possible

minute).

trt!*Hffi

oo

bocaus€

Oooooo ooooo

o ooooo

D6

I

OIL PRESSURE

\n

\-

engine is

oo oo o

Coitlnuity?

Y AVAILAEII

GAUGE

]L

pressure

ls
(0.5

Turn off the engine.
Check lor continuity
2 terminals on the
switch.

kgflcm',

bolow 50

psi)?

7

VTEC

YES

(To

page

6-40)

kPa

between the

pressure

Inrpoct tho

VTEC

aolanoid

v.lv..

Conlinuity?

vtEc

sot-€NotD

(cont'd)

6-39