2008 Honda Accord Service Repair Manual by 163215

INTRODUCTION - How to Use This Manual T h i s m a n u a l is divided

—

General Information

—

Into m u l t i p l e s e c t i o n s . T h e f i r s t p a g e of

each s e c t i o n is m a r k e d w i t h a black t a b t h a t lines u p w i t h its

Specifications

corresponding t h u m b index tab o n this page and the back cover.

specs

Y o u can quickly find the first page of each section w i t h o u t l o o k i n g t h r o u g h a full t a b l e o f c o n t e n t s . T h e s y m b o l s p r i n t e d at the t o p c o m e r of each page can also be used as a quick

Maintenance

reference system. Each section includes: 1. A table of c o n t e n t s , or a n e x p l o d e d v i e w i n d e x s h o w i n g :

"Engine Electrical

* Parts d i s a s s e m b l y sequence, * Bolt t o r q u e s a n d t h r e a d sizes. * Page r e f e r e n c e s t o d e s c r i p t i o n s in text, 2. D i s a s s e m b l y / a s s e m b l y p r o c e d u r e s a n d t o o l s . 3.

Inspection,

Testing/troubleshooting.

Repair.

Adjustments,

Engine Mechanical

MDBh

Engine Cooling

• Safety Messages

Fuel and Emissions

Y o u r s a f e t y , a n d t h e s a f e t y o f o t h e r s , is v e r y i m p o r t a n t , T o h e l p you make i n f o r m e d decisions, w e have provided safety messages, and other safety information throughout this manual. O f c o u r s e , it is n o t p r a c t i c a l o r p o s s i b l e t o w a r n y o u a b o u t all t h e hazards associated w i t h servicing this vehicle. Y o u m u s t use your o w n good judgment, Y o u w i l l f i n d i m p o r t a n t safety i n f o r m a t i o n in a variety of f o r m s including: • Safety Labels — on the vehicle. * S a f e t y M e s s a g e s — preceded by a safety alert s y m b o l £ ^ and one of three signal words, DANGER, W A R N I N G , or CAUTION, These signal w o r d s mean:

Suspension

_ik _ D A _ N_G E _R

Y o u W I L L b e K I L L E D o r S E R I O U S L Y H U R T if

IBfli'lIIIIlSI

Y o u C A N b e K I L L E D o r S E R I O U S L Y H U R T if

| F ^ | | i | | | 3 3

Y o u C A N b e H U R T if y o u d o n ' t f o l l o w

(IncfudingTPMS)

you don't follow instructions. you don't follow instructions,

B r a k e s

instructions, Instructions — h o w t o service this vehicle correctly and safely.

A l l i n f o r m a t i o n c o n t a i n e d i n t h i s m a n u a l is b a s e d o n t h e l a t e s t p r o d u c t i n f o r m a t i o n available

at t h e t i m e o f p r i n t i n g . W e r e s e r v e

*Heatsng, Ventilation, and Air Conditioning

t h e r i g h t t o m a k e c h a n g e s at a n y t i m e w i t h o u t n o t i c e . N o p a r t o f this publication m a y be r e p r o d u c e d , or stored in a retrieval s y s t e m , or t r a n s m i t t e d , in a n y f o r m b y a n y m e a n s , e l e c t r o n i c , mechanical, photocopying, recording, or otherwise, w i t h o u t the prior written p e r m i s s i o n of the publisher. This includes text,

'Bocly;Eleetrica

figures, and tables. A s y o u r e a d t h i s m a n u a l , y o u w i l l f i n d i n f o r m a t i o n t h a t is p r e c e d e d b y a j NOTICE j s y m b o l . T h e p u r p o s e o f t h i s m e s s a g e is to help p r e v e n t d a m a g e t o y o u r vehicle, o t h e r p r o p e r t y , or t h e environment.

First E d i t i o n 11/2008

H O N D A IViQTOR C O , , LTD,

S e r v i c e P u b l i c a t i o n Office

Specifications apply to U S A and Canada As s e c t i o n s w i t h * Include SRS c o m p o n e n t s ; s p e c i a l p r e c a u t i o n s a r e r e q u i r e d w h a n servicing. I p l g f l l H m a r k e d s e c t i o n s are n o t i n c l u d e d in t h i s f l t i f i t l m a n u a l , s e e V o l u m e 2.

2008-09 Accord

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) T h e A c c o r d S R S i n c l u d e s a d r i v e r ' s airbag in the s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in the d a s h b o a r d a b o v e the glove box, s e a t belt t e n s i o n e r s in the front s e a t belt retractors, s i d e curtain a i r b a g s in the s i d e s of the r o o t a n d s i d e airbags in the front s e a t - b a c k s . Information n e c e s s a r y to s a f e l y s e r v i c e the S R S is i n c l u d e d in this S e r v i c e M a n u a l . Items m a r k e d w i t h a n asterisk ( * ) on the contents page include or are located near S R S c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , or r e p l a c i n g t h e s e i t e m s r e q u i r e s s p e c i a l p r e c a u t i o n s a n d tools, a n d s h o u l d be d o n e by an authorized Honda dealer.

â&#x20AC;˘ T o a v o i d r e n d e r i n g the S R S inoperative, w h i c h c o u l d lead to p e r s o n a l injury or death in the e v e n t of a s e v e r e frontal or s i d e c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d be d o n e by a n authorized Honda dealer. * I m p r o p e r s e r v i c e p r o c e d u r e s , including incorrect r e m o v a l a n d installation of the S R S , c o u l d lead to p e r s o n a l injuryc a u s e d by unintentional d e p l o y m e n t of the a i r b a g s , s i d e a i r b a g s , a n d / o r s i d e curtain a i r b a g s . * Do not b u m p or impact the S R S unit, front impact s e n s o r s , s i d e Impact s e n s o r s , or rear s a t i n g s e n s o r w h e n the ignition s w i t c h is in O N (II), or for at least 3 m i n u t e s after the ignition s w i t c h is turned to L O C K (0); o t h e r w i s e , the * s y s t e m m a y fail in a c o l l i s i o n , or the a i r b a g s m a y deploy. â&#x20AC;˘ S R S electrical c o n n e c t o r s a r e identified by y e l l o w color c o d i n g . Related c o m p o n e n t s are located in the steering c o l u m n , front c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , in the d a s h b o a r d a b o v e the g l o v e box, in the front s e a t s , in the roof s i d e , a n d a r o u n d the floor. Do not u s e electrical test e q u i p m e n t on these-circuits.

General Information Chassis and Paint Codes '08 '08 '09 '09

4-door 2-door 4-door 2-door

Model Model Model Model

Identification Number Locations

1-2 - 1-3 1-4 1-5

1-6

Danger/Warning/Caution Label Locations .... 1-7 Under-hood Emission Control Label

1-10

Lift and Support Points

1-11

Towing

1-12

Parts Marking

1-14

General Information Chassis and Paint Codes '08 4-door Model Vehicle Identification Number 1HG CP2 5 3 * 8

l a

A 000001

c d e f g h

- 1000001

J H M i H o n d a Motor C o . , L t d . Honda p a s s e n g e r vehicle

a. Engine T y p e K 2 4 Z 2 : 2.4 L D O H C i - V T E C S e q u e n t i a l Multiport F u e l - i n j e c t e d , 177HP e n g i n e K24Z3:

2.4 L D O H C i - V T E C S e q u e n t i a l Multiport F u e l - i n j e c t e d , 190HP e n g i n e

b. S e r i a l N u m b e r

b. L i n e , B o d y , a n d E n g i n e T y p e CP2: Accord/K24Z2, K24Z3 Body Type and Transmission Type

1000001—:

All m o d e l s e x c e p t P Z E V , p r o d u c e d in

5:4-door S e d a n / 5 - s p e e d Manual 6:4-door S e d a n / 5 - s p e e d Automatic

1400001™:

All m o d e l s e x c e p t P Z E V , p r o d u c e d in

d. Vehicle G r a d e ISeries! U S A models 3: L X , L X P Z E V

Canada models

Marysville Saitama 1500001—:

P Z E V , p r o d u c e d in M a r y s v i l l e

1700001—:

P Z E V , p r o d u c e d in S a i t a m a

3: L X

4: L X - P , L X - P P Z E V

4: L X - P

7; E X , E X P Z E V

7: E X

8: E X - L , E X - L P Z E V e. C h e c k Digit

Transmission Wumber

8: E X - L 88E5

- 8000001

Model Year

8/08 g. F a c t o r y C o d e A ; M a r y s v i f l e , O h i o F a c t o r y in U . S . A . C : S a i t a m a F a c t o r y in J a p a n number h. S e r i a l 000001—: U S A models 800001—: Canada models V e h i c l e Identification Number, Federal M o t o r Vehicle Safety Standard Certification, and Paint Code Label. V e h i c l e Identification N u m b e r , C a n a d i a n SVSotor Vehicle Safety Standard Certification, and Paint Code Label.

m PAINT CODE

1-2

K24Z2

I llll I I b

a . M a n u f a c t u r e r , M a k e , a n d T y p e ©f V e h i c l e 1 H G : H o n d a of A m e r i c a Mfg. Inc., U . S . A . Honda p a s s e n g e r vehicle

Engine Mutnber

a. T r a n s m i s s i o n T y p e 88E5: 5-speed Manual M91A: 5-speed Automatic B90A: 5-speed Automatic b. S e r i a l N u m b e r 8000001 - : 8 8 E 5 1000001—: M91A, B90A

Paint Code Code

Color

USA models

B-92P

N i g h t h a w k B l a c k Pearl

B-536P

R o y a l B l u e Pearl

G-530M

M y s t i c G r e e n Metallic

NH-578 NH-603P-

Taffeta W h i t e White D i a m o n d Pearl

NH-700M

Alabaster Silver Metallic

NH-737M

P o l i s h e d Metal Metallic

R-530P YR-574M

B a s q u e R e d Pearl

NH-731P INTERIOR COLOR CODE

B o l d B e i g e Metallic Crystal Black Pearl

Canada models

O O o

O o

o o o

o o

'08

Model

Vehicle Identification Number

1HG CS1

1 3 * 8

000001

g h

K24Z3

Honda passenger vehicle b. L i n e , B o d y , a n i l E n g i n e T y p e CS1; Accord Coupe/K24Z3 c» B o d y T y p e a n d T r a n s m i s s i o n T y p e 1:2-door C o u p e / 5 - s p e e d M a n u a l 2; 2-door C o u p e / 5 - s p e e d A u t o m a t i c

a. Engine Type K 2 4 A 3 : 2.4 L D O H C i - V T E C S e q u e n t i a l Multiport F u e l - i n j e c t e d , 190HP e n g i n e b. S e r i a l N u m b e r 1 0 0 0 0 0 1 - -: AH m o d e l s e x c e p t P Z E V PZEV 1500001-

Transmission Number

Canada models 7; E X 8: E X - L

- 1400001

a , IVianyfacturer, Rflake, a n d T y p e of V e h i c l e 1 H G : H o n d a of A m e r i c a Mfg. Inc., U . S . A .

d. V e h i c l e G r a d e ( S e r i e s ) U S A models 3; L X , L X P Z E V 7: E X E X P Z E V

Engine Nymber

• 8000001

8: E X - L , E X - L P Z E V e . C h e e k Digit i Model Year 8:'08 g, F a c t o r y C o d e A : M a r y s v i l l e , O h i o F a c t o r y in U . S . A . h. S e r i a l N u m b e r 000001—: U S A models 800001—: Canada models

/ /

.Vehicle Identification N y m b s r , Federal Motor Vehicle Safety Standard Certification, and Paint Code L a b e l Vehicle Identification Number, Canadian M o t o r Vehicle Safety Standard Certification, and Paint Code Label.

Transmission Type 88E5: 5-speed Manual B90A: 5-speed Automatic b. S e r i a l N y m b e r 8000001 - : 8 8 E 5 1000001 —: B 9 0 A

Paint Code Code B-92P G-551P NH-578 NH-7Q0M NH-737M R-94

PAINT CODE

Color

USA modtefs

Canada

o o o o o o

Nighth'awk B l a c k Pear! Belize B l u e P e a r l Taffeta W h i t e Alabaster Silver Metallic r~ P o l i s h e d Metal Metallic S a n Marino Red

•

o o o o

INTERIOR COLOR CODE

1-3

General Information Chassis and Paint Codes (cont'd! '09 4-door Model Engine Number

Vehicle Identification Number

1HG CP2

5 3

cdef

K24Z2

000001

M a n u f a c t u r e r , M a k e , arid T y p e of V e h i c l e 1 H G : H o n d a of A m e r i c a Mfg. I n c . , U . S . A . Honda passenger vehicle J H M : H o n d a Motor C o . , L t d .

U S A models

Canada models

3: L X , L X P Z E V 4: L X - P , L X - P P Z E V 7: E X , E X P Z E V 8: E X - L , E X - L P Z E V

3: L X 4: L X - P

a. Engine T y p e K 2 4 Z 2 : 2.4 L D O H C i - V T E C S e q u e n t i a l Multiport Fuel-injected, 177HP engine K 2 4 Z 3 : 2.4 L D O H C i - V T E C S e q u e n t i a l Multiport F u e l - i n j e c t e d , 190HP e n g i n e Serial Wumber 1 0 0 0 0 0 1 — : All m o d e l s e x c e p t P Z E V , p r o d u c e d in Marysville

Honda passenger vehicle Line, Body, and Engine Type CP2: Accord/K24Z2, K24Z3 B o d y T y p e arid T r a n s m i s s i o n T y p e 5:4-door S e d a n / 5 - s p e e d Manual 6:4-door Sedan/5-speed Automatic Vehicle Grade (Series!

1400001—:

All m o d e l s e x c e p t P Z E V , p r o d u c e d in Saitama

1500001—: 1700001—:

P Z E V , p r o d u c e d in M a r y s v i l l e P Z E V , p r o d u c e d in S a i t a m a

Transmission Nynnfoer

7: E X 8: E X - L

C h e c k Digit Model Year 9: '09

88E5

Factory Code A : M a r y s v i l l e , O h i o F a c t o r y in U . S . A . C : S a i t a m a F a c t o r y in J a p a n h. S e r i a l N u m b e r 000001—: U S A models 800001—: Canada models B«tJiTiP©r, rSG©s38 IV!otor Vehicle Safety Standard Paint Code tabeS. Vehicle identification Number, Canadian Motor Vehicle Safety Standard Certification, and Paint Cod© Label.

Paint Code Code

PAINT CODE

INTERIOR COLOR CODE

Color

NH-731P

C r y s t a l B l a c k Pearl

B-536P

R o y a l - B l u e Pearl

G-530M NH-578

USA

Canada

models

M y s t i c G r e e n Metallic

Taffeta W h i t e White D i a m o n d Pearl Alabaster Silver Metallic

R-530P

P o l i s h e d Metal Metallic ' B a s q u e R e d Pearl

YR-574M

B o l d B e i g e Metallic

NH-737M HDL

- 8000001

Transmission Type 88E5: 5-speed Manual M91A: 5-speed Automatic B90A: 5-speed Automatic Serial dumber 8000001 — : 8 8 E 5 1000Q01-:M91A, B90A

NH-603P NH-700M

1-4

- 1000001

D '09 2-door Model Vehicle Identification Number

1HG CS1

1 3 * 9

c d e

000001

g h

K24Z3

- 1400001

M a n u f a c t u r e r , M a t e , a n d T y p e of V e h i c l e 1 H G : H o n d a of A m e r i c a Mfg. Inc., U . S . A . Honda passenger vehicle Line,. B o d y , a n d E n g i n e T y p e CS1: Accord Coupe/K24Z3 B o d y T y p e arid T r a n s m i s s i o n T y p e 1:2-door C o u p e / 5 - s p e ' e d M a n u a l 2:2-door Coupe/5-speed Automatic Vehicle Grade ISeries) 3: L X , L X P Z E V 7: E X , E X P Z E V 8: E X - L , E X - L P Z E V C h e e k Digit Model Year 9: '09 F a c t o r y C©d@ A : M a r y s v i l l e , O h i o F a c t o r y in U . S . A . Serial Number 000001—: U S A models 800001—: C a n a d a models Vehicle identification N u m b e r , F e d e r a l M&tm Vehicle Safety Standard Certification, and Pal f i t C o d e L a b e l , Vehicle Identification Number, Canadian M o t o r Vehicle Safety Standard Certification, a n d Paint C o d e Label.

PAINT CODE

Engine Wyinber

a. Engine T y p e K 2 4 A 3 : 2.4 L D G H C i - V T E C S e q u e n t i a l Multiport F u e l - i n j e c t e d , 190HP e n g i n e b, S e r i a l d u m b e r 1 0 0 0 0 0 1 — : All m o d e l s e x c e p t P Z E V 1500001—: P Z E V

Transmission dumber

88E5

• 8000001

Transmission Type 88E5: 5-speed Manual B90A: 5-speed Automatic Serial Number 8000001 - ~ : 8 8 E 5 1000001™: B90A

Faint Code Code

Color

USA moduls

Canada moduls

B-551P NH-578 NH-700M NH-737M R-94

Belize B l u e Pearl Taffeta W h i t e Alabaster Silver Metallic P o l i s h e d Metal Metallic S a n Marino Red

NH-731P

C r y s t a l B l a c k Pearl

o o o o o o

INTERIOR COLOR CODE

1-5

General Information

1-6

Danger/Warning/Caution Label Locations

Front Passenger's C o m p a r t m e n t ; S R S W A R D I N G lIMFOBIVIATIOISi

SRS I N F O R M A T I O N USA models

PASSENGER AIHSAG MODULE DAGGER

SRS W A R N I N G INFORMATION

FRONT PASSENGER AIRBAG WARMING TAG (CHILD S E A T ! USA models

SIDE A I R B A G M O D U L E DANGER

S T E E R I N G C O L U M N NOTICE

Steering

MONITOR

FRONT SEAT BELT TENSIONER CAUTION

NOTICE

Whmek

Rear P a s s e n g e r s C o m p a r t m e n t : C A B L E HEEL

CAUTION

/ DRIVER A I R B A G IVfODULE D A N G E R

ROOF-SIDE A I R B A G IVIODULE D A N G E R

DRIÂ¥ER AIRBAG IVIODULE D A N G E R

(cont'd)

1-7

General Information Danger/Warning/Caution Labe! Locations (cont'd) 2-door Front Passenger's C o m p a r t m e n t :

STEERING C O L U M N NOTICE

Steering Wheel:

1-8

M O N I T O R NOTICE

TENSIONER CAUTION

Bear Passenger's C o m p a r t m e n t :

i w n i Mfljli

2-door Model:

4-door Model:

SRS WARNING

EMISSION CONTROL INFORMATION and ENGINE COOLANT INFORMATION

SRS W A R N I N G

EMISSION CONTROL INFORMATION and ENGINE COOLANT INFORMATION

AIR CONDITIONING INFORMATION

\ RAOFATOR C A P D A N G E R

/ /

AIR CONDITIONING INFORMATION

\ RADIATOR CAP DANGER

BATTERY DANGER

, SIDE AIRBAG C A U T I O N Located o n driver's and passenger's doorjamb

HI â&#x20AC;¢i

BATTERY DANGER

SIDE A I R B A G C A U T I O N Located on driver's and passenger's doorjamb

a is

> >,'

4 | r ^

TIRE I N F O R M A T I O N

1-9

Genera! Information Under-hood Emission Control Label Emission Group Identification

Test Group and Evaporative Family

Example:

Test Group:

MUX

a b

V 02,4

YB3

a. Model Year 8: '08 'OS M o d e l C O M F O R M S T O R E G U L A T I O N S : 2008 M Y

9: '09 b. M a n u f a c t u r e r S u b c o d e HNX: H O N D A

'09 M o d e l C O M F O R M S T O R E G U L A T I O N S : 2009 M Y

c. F a m i l y T y p e V: L D V dâ&#x20AC;&#x17E; D i s p l a c e m e n t G r o u p e. S e q u e n c e C h a r a c t e r s T K R : '08 m o d e l ( U L E V ) E M C : '08 m o d e l ( S U L E V / P Z E V ) Y B 3 : '09 m o d e l ( U L E V ) T C 3 : '09 m o d e l ( S U L E V / P Z E V )

Evaporative Family:

MUX

a b

R 0150

c d

VEA

a. Model Y e a r 8: '08 9: '09 b. M a n u f a c t u r e r S u b c o d e HNX: H O N D A c. F a m i l y T y p e R: Refueling d. C a n i s t e r W o r k i n g C a p a c i t y G r o u p e. S e q u e n c e C h a r a c t e r s B C A , B B A : '08 m o d e l V E A , V Z A : '09 m o d e l

1-10

Lift and Support Points N O T E ; If y o u a r e g o i n g to r e m o v e h e a v y c o m p o n e n t s s u c h a s s u s p e n s i o n or t h e fuel tank f r o m the rear of the v e h i c l e , first s u p p o r t t h e front of t h e v e h i c l e w i t h tall safety s t a n d s , W h e n s u b s t a n t i a l w e i g h t is r e m o v e d f r o m the r e a r of the v e h i c l e , t h e c e n t e r of gravity c a n c h a n g e , c a u s i n g t h e v e h i c l e to tip f o r w a r d on the lift.

Vehicle Lift 1 > Position t h e lift b l o c k s (A) u n d e r the v e h i c l e ' s front s u p p o r t p o i n t s (B) a n d rear s u p p o r t points C O .

Floor Jack 1. W h e n lifting t h e front of the v e h i c l e , s e t the parking brake. W h e n lifting the rear of the v e h i c l e , put the shift l e v e r in r e v e r s e for m a n u a l t r a n s m i s s i o n , o r in the P position for a u t o m a t i c t r a n s m i s s i o n . â&#x20AC;˘ 2. B l o c k the w h e e l s that a r e not being lifted. 3. Position the floor j a c k u n d e r the front jacking bracket (A) or the rear j a c k i n g bracket (B). C e n t e r the j a c k i n g bracket on the j a c k lift platform (G), a n d j a c k up t h e v e h i c l e high e n o u g h to fit the safety s t a n d s under it,

2. R a i s e t h e lift a f e w i n c h e s , a n d rock the v e h i c l e gently to be s u r e it is f i r m l y s u p p o r t e d . 3, R a i s e the lift to its full height, a n d i n s p e c t the v e h i c l e s u p p o r t points for s o l i d c o n t a c t w i t h the lift blocks,

Safety Stands T o support: t h e v e h i c l e o n s a f e t y s t a n d s , u s e the s a m e s u p p o r t p o i n t s IB a n d C ) a s for a v e h i c l e lift. A l w a y s u s e s a f e t y s t a n d s w h e n w o r k i n g on or u n d e r a n y v e h i c l e t h a t Is o n l y s u p p o r t e d by a j a c k .

4, Position the s a f e t y s t a n d s u n d e r the s u p p o r t points, a n d a d j u s t t h e m s o the v e h i c l e is l e v e l 5. L o w e r the v e h i c l e onto the s t a n d s .

1-11

General information Towing If t h e v e h i c l e n e e d s to be t o w e d , call a p r o f e s s i o n a l towing service. Never tow the vehicle behind another v e h i c l e with j u s t a rope or c h a i n . It is v e r y d a n g e r o u s . Emergency Towing T h e r e are three p o p u l a r m e t h o d s of t o w i n g a v e h i c l e . F l a t - b e d E q u i p m e n t â&#x20AC;&#x201D; T h e operator l o a d s the v e h i c l e o n the b a c k of a truck. T h i s Is t h e b e s t w a y of t r a n s p o r t i n g t h e wehiele. T o a c c o m m o d a t e flat-bed e q u i p m e n t , the v e h i c l e is e q u i p p e d with front t o w i n g h o o k s (A), front tie d o w n h o o k s l o t s (B), rear t o w i n g hook fC), a n d rear tie d o w n h o o k s l o t s (D). T h e t o w i n g h o o k s c a n be u s e d with a w i n c h to pull the v e h i c l e onto t h e truck, a n d t h e tie d o w n hook s l o t s c a n b e u s e d to s e c u r e t h e v e h i c l e to the truck. Front:

Rear:

W h e a l Lift E q u i p m e n t — T h e t o w truck u s e s t w o pivoting a r m s that g o u n d e r t h e t i r e s (front or rear) a n d lifts t h e m off t h e g r o u n d . T h e other t w o w h e e l s r e m a i n o n t h e g r o u n d . T h i s i s art a c c e p t a b l e w a y of t o w i n g t h e vehicle, S l i n g - t y p e E q u i p m e n t — T h e t o w truck u s e s m e t a l c a b l e s with hooks on the ends. T h e s e hooks go around parts of t h e f r a m e or s u s p e n s i o n , a n d t h e c a b l e s lift that e n d of the v e h i c l e off the g r o u n d . T h e v e h i c l e ' s s u s p e n s i o n a n d b o d y c a n be s e r i o u s l y d a m a g e d if t h i s m e t h o d of t o w i n g i s a t t e m p t e d . T h i s m e t h o d of t o w i n g the vehicle is unacceptable,

* I m p r o p e r t o w i n g p r e p a r a t i o n will d a m a g e the t r a n s m i s s i o n . F o l l o w t h e a b o v e p r o c e d u r e e x a c t l y . If y o u c a n n o t shift the t r a n s m i s s i o n or start the e n g i n e (automatic t r a n s m i s s i o n ) , the v e h i c l e m u s t be t r a n s p o r t e d on .a flat-bed. • T r y i n g to lift or t o w t h e v e h i c l e by the b u m p e r s will c a u s e s e r i o u s d a m a g e . T h e b u m p e r s a r e not d e s i g n e d to s u p p o r t the v e h i c l e ' s w e i g h t

If the v e h i c l e c a n n o t b e t r a n s p o r t e d b y a flat-bed, it s h o u l d be t o w e d w i t h the front w h e e l s off the g r o u n d . If t h e v e h i c l e Is d a m a g e d , a n d m u s t b e t o w e d with t h e front w h e e l s on t h e g r o u n d , or with all four w h e e l s o n the ground, do this: Manual Transmission * R e l e a s e the parking brake. • Shift t h e t r a n s m i s s i o n in neutral. * L e a v e the ignition s w i t c h in A C C E S S O R Y (I) s o t h e s t e e r i n g w h e e l d o e s not lock, • M a k e s u r e all a c c e s s o r i e s a r e t u r n e d off to m i n i m i z e battery c u r r e n t d r a w . Automatic Transmission * R e l e a s e t h e parking b r a k e , * S t a r t the e n g i n e , * S h i f t to D, t h e n to N. * T u r n off t h e e n g i n e . * L e a v e the ignition s w i t c h in A C C E S S O R Y (!) s o t h e s t e e r i n g w h e e l d o e s not lock. * M a k e s u r e all a c c e s s o r i e s a r e t u r n e d off to m i n i m i z e battery c u r r e n t d r a w . It is b e s t to t o w t h e v e h i c l e no farther t h a n 50 m i l e s (80 k m ) , a n d k e e p t h e v e h i c l e s p e e d b e l o w 35 m p h 155 k m / h ) .

1-13

General Information Parts Marking T o deter v e h i c l e theft, c e r t a i n m a j o r c o m p o n e n t s a r e m a r k e d w i t h the v e h i c l e Identification n u m b e r I V I M l O r i g i n a l parts h a v e s e l f - a d h e s i v e l a b e l s . R e p l a c e m e n t b o d y parts h a v e g e n e r i c s e l f - a d h e s i v e l a b e l s . T h e s e l a b e l s s h o u l d not be r e m o v e d . T h e original e n g i n e or t r a n s m i s s i o n VIN plates a r e not t r a n s f e r a b l e to the r e p l a c e m e n t e n g i n e or transmission. N O T E : B e c a r e f u l not to d a m a g e the parts m a r k i n g labels d u r i n g body repair. M a s k the l a b e l s before repairing the part.

1-14

Specifications Standards and Service Limits Engine Electrical .................... .. ......................... Engine Assembly ... ... ....................... .. .... Cylinder Head _____ Engine Block ......... ....... ... ............ Engine Lubrication .............. * ............ Cooling System ................... ............. ......... -Fuel and Emissions ............ ................ Ciutch .............. • . Manual Transmission and M/T Differentia! ............... Automatic Transmission and A/T Differential . .. Steering .......... .......................... ................... . Suspension . ......... . Brakes Air Conditioning ......................... ...

2-2 2-2 2-3 2-4 2-5 2-5 2-6 2-6 2-7 2-9 2-15 2-15 2-16 2-16

Design Specifications Dimensions (4-door) ............ ................................ Dimensions (2-door) ........ Weight (4-door) . .. .. Weight (2-door) Engine ............. _____ Starter ... . Clutch . . Manual Transmission ...... .... .... Automatic Transmission ...... ... .......... ... Steering ....................... ...................... .. Suspension ...... Tires • Wheel Alignment ...... Brakes ......... Air Conditioning .... ............... ................ Electrical Ratings .... ............ Body Specifications ............. .............. . «*.

2-17 2-17 2-17 2-17 2-17 2-17 2-18 2-18 2-18 2-18 2-18 2-18 2-18 2-19 2-19 2-20 2-21

Standards and Service Limits Engine Electrical

_____

fWI@iisijreiTi@rit

!t@tn Ignition coil

Rated v o l t a g e

Sparkplug

Type

Standard or M e w

Qualification

Service Limit

12V

Firing order

1-3-4-2 All models

NGK:ILZKR7B-11S

e x c e p t PZEV

DENSO:SXU22HCR11S

PZEV

NGK: DILZKR7A11GS

8±2°BTDC

Gap

1 . 0 - 1 . 1 m m ( 0 . 0 3 9 - 0 . 0 4 3 in.)

Ignition t i m i n g

A t idle

M/T(in neutral),

Check t h e r e d m a r k

A / T {in N o r P)

Drive belt

Tension

Alternator

Output

Auto-tenssoner A t 13.5 V a n d

105A

normal engine temperature Coil ( r o t o r ) r e s i s t a n c e

Starter

A t 68 °F (20 °C)

3.4-3.8 Q

S l i p r i n g O.D.

14.4 m m (0.57 in.)

14.0 m m (0.55 in.)

Brush length

10.5 m m (0.41 in.)

1.5 m m (0.06 in.)

Brush spring tension

3.2 N (0.33 kgf, 2.4 Ibf)

Output

1.6 k W

Commutator mica depth

0.4—0.5 m m ( 0 . 0 1 6 - 0 . 0 2 0 in.)

0.15 m m (0.006 in.)

Commutator runout

0.02 m m (0.001 in.) m a x .

0.05 m m (0.002 in.)

C o m m u t a t o r O.D.

2 8 . 0 - 2 8 . 1 m m ( 1 . 1 0 - 1 . 1 1 in.)

27.5 m m (1.08 in.)

Brush length

11.1 —11.5 m m ( 0 . 4 4 0 - 0 . 4 5 3 in.)

4.3 m m (0.17 in.)

Engine Assembly Item Compression

2-2

Measurement

S t a n d a r d o r New

Qualification Minimum

930 kPa (9.5 k g f / c m , 135 psi)

Check t h e engine w i t h t h e starter

Maximum

200 kPa (2.0 k g f / c m , 28 psi)

cranking

variation

Pressure

Cylinder Head MeBSiifSinsiit

Qualification

Standard or N e w

Service Limit 0.05 m m (0.002 in.)

Head

Warpage Height

103.95—104.05 m m ( 4 . 0 3 3 - 4 . 0 9 6 in.)

Camshaft

End play

0 . 0 5 - 0 . 2 0 m m ( 0 . 0 0 2 - 0 . 0 0 8 in.)

0,4 m m (0.02 in.)

No. 1 journal

0 . 0 3 0 - 0 . 0 8 9 m m ( 0 . 0 0 1 2 - 0 . 0 0 3 in.)

0,15 m m (0.006 in.)

No. 2,3, 4,5

0 . 0 6 0 - 0 . 0 9 9 m m ( 0 . 0 0 2 - 0 . 0 0 4 in.)

0,15 m m (0.006 in.)

0,03 m m (0.0012 in,) m a x .

0,04 m m (0.002 in.)

Camshaft-to-holder oil clearance

journals

•

Total runout C a m lobe height

Intake, p r i m a r y

33.744 m m (1.3285 in.)

Intake, m i d

35.456 m m (1.3959 in.)

Intake,

33.744 m m (1.3285 in.)

secondary AfS m o d e l s

34.291 m m (1.3500 in.)

e x c e p t PZEV

Valve

C l e a r a n c e (cold)

S t e m OX).

Stem-to-guide clearance

V a l v e seat

Width

S t e m installed height

Valve spring

Free l e n g t h

PZEV

34.232 m m (1.3477 in.)

Intake

0 . 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.)

Exhaust

0.25-0.29 m m (0.010-0.011 in.)' •5,445 m m (0.214 in.)

Intake

5 . 4 7 5 - 5 . 4 8 5 m m ( 0 . 2 1 5 6 - 0 . 2 1 5 9 in.)

Exhaust

5 . 4 5 0 - 5 . 4 6 0 m m ( 0 . 2 1 4 6 - 0 . 2 1 5 0 in.)

5.42 m m (0.213 in.)

Intake

0.030—0.055 m m ( 0 . 0 0 1 2 - 0 . 0 0 2 2 in.)

0.08 m m (0.003 in.)

Exhaust

0 . 0 5 5 - 0 . 0 8 0 m m ( 0 . 0 0 2 2 - 0 . 0 0 3 1 in.)

0.11 m m (0.004 in.)

Intake

1 . 2 5 - 1 . 5 5 m m ( 0 . 0 4 9 - 0 . 0 6 1 in.)

2.00 m m (0.079 in.)

Exhaust

1 . 2 5 - 1 . 5 5 m m ( 0 . 0 4 9 - 0 . 0 6 1 in.)

2.00 m m {0,079 in.)

Intake

4 4 . 0 - 4 4 . 5 m m ( 1 . 7 3 - 1 . 7 5 in.)

44.7 m m (1.76 in.)

Exhaust

4 4 . 0 - 4 4 . 5 m m ( 1 . 7 3 - 1 . 7 5 in.)

44,7 m m (1.76 in.)

Intake

NIPPON H A T S U J O : 47.15 m m (1.858 in.) CHUO HATSUJO: 47.14 m m (1.856 in.)

Exhaust Valve guide

ID.

Instclted height

Rocker a r m

48.42 m m (1.906 in.)

Intake

5 . 5 1 5 - 5 . 5 3 0 m m ( 0 . 2 1 7 1 - 0 . 2 1 7 7 in.)

5.55 m m (0.219 in.)

Exhaust

5 . 5 1 5 - 5 . 5 3 0 m m ( 0 . 2 1 7 1 - 0 , 2 1 7 7 in.)

5,55 m m (0.219 in.)

Intake

1 5 . 2 - 1 6 . 2 m m ( 0 . 5 9 8 - 0 . 6 3 8 in.)

Exhaust

1 5 . 5 - 1 6 . 5 m m (0.610—0.650 in.)

Arm-to-shaft clearance

Intake

0 . 0 1 8 - 0 . 0 5 9 m m ( 0 . 0 0 0 7 - 0 . 0 0 2 3 in.)

0.08 m m (0.003 in.)

{All m o d e l s e x c e p t PZEV)

Exhaust

0 . 0 1 8 - 0 . 0 5 6 m m ( 0 . 0 0 0 7 - 0 . 0 0 2 2 in,)

0.08 m m (0.003 in.)

Intake

0 , 0 1 8 - 0 . 0 5 9 m m ( 0 . 0 0 0 7 - 0 . 0 0 2 3 in.)

Exhaust

0 . 0 1 8 - 0 . 0 5 9 m m ( 0 . 0 0 0 7 - 0 . 0 0 2 3 in.)

Arm-to-shaft

clearance

2-3

Standards and Service Limits Engine Block Measurement

item Block

Qualification

Bore diameter

Standard or

Hew

0.07 m m (0.003 in.) m a x .

Warpage of deck' A or I

87.010~~87.020 m m ( 3 . 4 2 5 6 - 3 . 4 2 6 0 in,) 87.070 m m (3.4280 in.)

BorSl

8 7 . 0 0 0 - 8 7 . 0 1 0 m m ( 3 . 4 2 5 2 - 3 . 4 2 5 6 in.) 8 7 . 0 7 0 m m (3.4280 in.)'

Bore taper

0.02 m m (0.0008 in.)

Reboring limit Piston

0.25 m m (0.010 in.)

Skirt O.D. at 11 m m (0.4 in.) f r o m

N o letter o r A

8 6 . 9 8 0 - 8 6 . 9 9 0 m m ( 3 . 4 2 4 4 - 3 . 4 2 4 8 in.) 86.930 m m (3.4224 in.)

b o t t o m o f skirt

Letter B

8 6 . 9 7 0 - 8 6 . 9 8 0 m m ( 3 . 4 2 4 0 - 3 . 4 2 4 4 in.) 86.920 m m (3.4220 in.)

C l e a r a n c e in c y l i n d e r Ring g r o o v e w i d t h

Piston ring

Piston pin

Service Limit 0.10 m m (0.004 in.)

0 . 0 2 0 - 0 . 0 4 0 m m ( 0 . 0 0 0 8 - 0 . 0 0 1 6 in.)

0.05 m m (0.002 in.)

Top

1 . 2 4 5 - 1 . 2 5 5 m m ( 0 . 0 4 9 0 - 0 . 0 4 9 4 in.)

1.265 m m (0.050 in.)

Second

1 . 2 3 0 - 1 . 2 4 0 m m (0.0484—0.0488 in.)

1.26 m m (0.050 in.)

Oil

2 . 0 0 5 - 2 . 0 2 5 m m ( 0 . 0 7 8 9 - 0 . 0 7 9 7 in.)

2.55 m m (0.100 in.)

Ring-to-groove clearance

Top

0 . 0 6 0 - 0 . 0 8 5 m m ( 0 . 0 0 2 4 - 0 . 0 0 3 3 in.)

0.13 m m (0.005 in.)

Second

0 . 0 4 0 - 0 . 0 6 5 m m ( 0 . 0 0 1 6 - 0 . 0 0 2 6 in.)

0.13 m m (0.005 in.)

Ring end g a p

Top

0 . 2 0 - 0 . 3 5 m m ( 0 . 0 0 8 - 0 . 0 1 4 in.)

0.60 m m (0.024 in.)

Second

0 . 5 0 - 0 . 6 5 m m ( 0 . 0 2 0 - 0 . 0 2 6 in.)

0.70 m m (0.028 in.)

Oil

0 . 2 0 - 0 J O m m ( 0 . 0 0 8 - 0 . 0 2 8 in.)

0.75 m m (0.030 in.)

O.D.

2 1 . 9 6 1 - 2 1 . 9 6 5 m m ( 0 . 8 6 4 6 - 0 . 8 6 4 8 in.) 21.953 m m (0.8643 in.)

Pin-to-piston clearance

—0.005 t o + 0 . 0 0 2 m m

0.005 m m (0.0002 in.)

( - 0 . 0 0 0 2 0 t o + 0 . 0 0 0 0 8 in.) Connecting rod

Crankshaft

Pin-to-rod clearance

0 . 0 0 5 - 0 . 0 1 5 m m ( 0 . 0 0 0 2 - 0 . 0 0 0 6 in.)

Small-end bore diameter

2 1 . 9 7 0 - 2 1 . 9 7 6 m m ( 0 . 8 6 5 0 - 0 . 8 6 5 2 in.)

Large-end bore diameter

51.0 m m (2.01 in.)

End play installed o n crankshaft

0 . 1 5 - 0 . 3 5 m m ( 0 . 0 0 6 - 0 . 0 1 4 in.)

Main journal diameter

N o . 1,2, 4 , 5

0.02 m m (0.0008 in.)

0.40 m m (0.016 in.)

5 4 . 9 8 4 - 5 5 . 0 0 8 m m ( 2 . 1 6 4 7 - 2 . 1 6 5 7 in.)

journals No. 3 journal

Crankshaft

4 7 . 9 7 6 - 4 8 . 0 0 0 m m ( 1 . 8 8 8 8 - 1 . 8 8 9 8 in.)

R o d / m a i n Journal t a p e r

0.005 m m (0.0002 in.) m a x .

0.010 m m (0.0004 in.)

Rod/main journal out-of-round

0.004 m m (0.0002 in.) m a x .

0.010 m m (0.0004 in.)

End play

0 . 1 0 - 0 . 3 5 m m ( 0 . 0 0 4 - 0 . 0 1 4 in.)

0.45 m m (0.018 in.)

Runout

0.03 m m (0.0012 in.) m a x .

0.04 m m (0.002 in.)

0 . 0 1 7 - 0 . 0 4 1 m m ( 0 . 0 0 0 7 - 0 . 0 0 1 6 in.)

0.050 m m (0.0020 in.)

0.025—0.049 m m (0.0010—0.0019 in.)

0.055 m m (0.0022 in.)

0 . 0 3 2 - 0 . 0 6 6 m m ( 0 . 0 0 1 3 - 0 . 0 0 2 6 in.)

0.077 m m (0.0030 in.)

M a i n bearing-to-journal oil clearance

bearing

No. 1,2,4,5 journals No. 3 journal

Rod bearing clearance

2™4

5 4 . 9 7 6 - 5 5 . 0 0 0 m m ( 2 . 1 6 4 4 - 2 . 1 6 5 4 in.)

Rod journal diameter

Engine Lybrieation Item Engine oil

S t a n d a r d or N e w

Qualification

Measurement Capacity

Engine overhaul

5.3 L (5.6 U S q t )

Oil c h a n g e

4.2 L (4.4 U S qt)

Service Limit

including filter Oil change

4.0 L (4.2 U S qt)

w i t h o u t filter Oil p u m p

0 . 0 5 - 0 . 1 5 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.) Q. 1 5 - 0 . 2 1 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.)

0.23 m m (0.009 in.)

0 . 0 3 5 - 0 . 0 7 0 m m ( 0 . 0 0 1 4 - 0 . 0 0 2 8 in.)

0.12 m m (0.005 in.)

hoysing-to-outer rotor

0.19 m m (0.008 in.)

Inner-to-outer rotor clearance Pump

radial clearance P u m p housing-to-rotor axial clearance diameter

Balancer shafts, j o u r n a l

No. 1 j o u r n a l , f r o n t

1 9 . 9 3 8 - 1 9 . 9 5 0 m m ( 0 . 7 8 5 0 - 0 . 7 8 5 4 in.) 19.92 m m (0.784 in.)

shaft N o . 1 j o u r n a l , rear s h a f t

2 3 . 9 3 8 - 2 3 . 9 5 0 m m ( 0 . 9 4 2 4 - 0 . 9 4 2 9 in.) 23.92 m m (0.942 in.)

No, 2 journal, f r o n t and

3 2 . 9 4 9 - 3 2 . 9 8 1 m m (1.2972—1.2977 in.) 32.93 m m (1.296 in.)

rear s h a f t s 0.005 m m (0.0002 in.) m a x .

Balancer shafts, Journal taper Front

0 . 0 8 3 - 0 . 1 0 8 m m ( 0 . 0 0 2 5 - 0 . 0 0 4 3 in.)

Rear

0 . 0 6 3 - 0 . 1 0 8 m m ( 0 . 0 0 2 5 - 0 . 0 0 4 3 in.)

0.14 m m (0.006 in.)

Balancer shafts, shaft-to-bearing

No. 1 journal, front

0 . 0 5 0 - 0 . 0 8 2 m m ( 0 . 0 0 2 0 - 0 . 0 0 3 2 in.)

0.10 m m (0.004 in.)

clearance

shaft N o . 1 J o u r n a l , rear s h a f t

0 . 0 5 0 - 0 . 0 8 2 m m ( 0 . 0 0 2 0 - 0 . 0 0 3 2 in.)

0.10 m m (0.004 in.)

No. 2 journal, front and

0 . 0 8 0 - 0 . 1 2 0 m m ( 0 . 0 0 2 4 - 0 . 0 0 4 7 in.)

0L15 m m (0.006 in.)

Balancer shafts, e n d play

0.14 m m (0.008 in.)

rear s h a f t s Balancer shaft bearings, LB.

No. 1 journal, front

2 0 . 0 0 0 - 2 0 . 0 2 0 m m ( 0 . 7 8 7 4 - 0 . 7 8 8 2 in.) 20.03 m m (0.789 In.)

shaft No. 1 j o u r n a l , rear shaft

2 4 . 0 0 0 - 2 4 . 0 2 0 m m ( 0 . 9 4 4 9 - 0 . 9 4 5 7 in.) 24.03 m m (0.946 in.)

No, 2 journal, front and

3 3 . 0 2 1 - 3 3 . 0 6 9 m m ( 1 . 3 0 0 0 - 1 . 3 0 1 9 in.) '33.09 m m (1.303 in.)

rear shafts Relief v a l v e , o i l p r e s s u r e w i t h o i l C

t e m p e r a t u r e at 176 T (80 C)

Coaling

70 kPa (0.7 k g f / c r n , 1 0 psi) m i n .

A t 3,000 r p m

3 0 0 kPa (3.1 kgf/cnf, 44 psi) m i n .

rstem Measurement

Radiator

A t idle

Coolant capacities (including

Qualification M/T: e n g i n e o v e r h a u l

engine,, h e a t e r , h o s e s , a n d reservoir)

M/T: c o o l a n t c h a n g e

U s e H o n d a L o n g Life A n t i f r e e z e / A/T: engine overhaul

Coolant Type 2 N O T E : If t h e v e h i c l e is r e g u l a r l y driven in v e r y l o w t e m p e r a t u r e s ( u n d e r - 3 1 T {-35

A/T: coolant change

*C)), a h i g h e r

S t a n d a r d or N e w DENSO

8.2 L (2.17 U S gal)

TRAD

8.1 L (2.14 U S gal)

DENSO

6.1 L (1.61 U S gal)

TRAD

6 . 0 1 ( 1 . 5 9 U S gal)

DENSO

8.1 L (2.14 U S gal)

TRAD

8.0 L (2.11 U S gal)

DENSO

6,0 L (1.59 U S g a l )

TRAD

5 . 9 L ( 1 . 5 6 U S gal)

concentration of c o o l a n t s h o u l d be u s e d (see p a g e 10-8). Coolant

Coolant capacity

0 . 6 8 L ( 0 . 1 8 0 U S gal)

reservoir Radiator cap

Opening pressure

Thermostat

Opening temperature

9 3 - 1 2 3 kPa ( 0 . 9 5 - 1 . 2 5 k g f / c r n , 1 4 - 1 8 psi) Begins t o open Fully o p e n

V a l v e lift a t f u l l y o p e n

1 6 9 - 1 7 6 °F ( 7 6 - 8 0 °C) 194 T (90 V) 8.0 m m (0.31 in.) m i n .

2-5

Standards arid Service Limits Fuel and Emissions M @iisij r f i t n l i n t

Item Fuel p r e s s u r e

Qyallfieatson

regulator

disconnected

Fuel t a n k

Capacity

E n g i n e idle

Idle s p e e d w i t h o u t l o a d

Standard or New 2

3 3 0 - 3 8 0 kPa ( 3 . 4 - 3 . 9 k g f / c m , 4 8 - 5 5 psi)

Pressure w i t h r e g u l a t o r v a c u u m hose

7 0 L (18.5 U S gal) M / T (in n e u t r a l )

780:1:50 r p m

A / T (in N o r P)

800±50 rpm

Idle s p e e d w i t h h i g h e l e c t r i c a l l o a d

M / T (in n e u t r a l )

780±50 rpm

(A/C s w i t c h O N , t e m p e r a t u r e set t o

A / T (in N or P)

800±50 rpm

m a x c o o l , b l o w e r f a n o n H i g h , rear w i n d o w defogger O N , and headlights on high beam)

Clutch lt®m Clutch pedal

IVl©asiJr@iTi6iit Height f r o m floor

Qualification

Standard or

Hem

Service Limit

174 m m (6.85 in.)

Stroke

1 3 0 - 1 4 0 m m ( 5 . 1 2 - 5 . 5 1 in.)

Flywheel

Runout on clutch mating surface

0.05 m m (0.002 in.) m a x .

Clutch disc

Rivet h e a d d e p t h

1 . 1 5 - 1 . 7 5 m m ( 0 . 0 4 5 - 0 . 0 6 9 in.)

0.7 m m (0.03 in.)

Thickness

7 . 3 0 - 7 . 9 0 m m ( 0 . 2 8 7 - 0 . 3 1 1 in.)

6.0 m m (0.24 in.)

Warpage

0.03 m m (0.001 in.) m a x .

0.15 m m (0.006 in.)

Evenness of the height of the

0.6 m m (0.02 in.) m a x .

0.8 m m (0.03 in.)

Pressure plate

diaphragm spring fingers

2-6

0.15 m m (0.006 in.)

specs Manyal Transmission arid M/T Differential Item

IVi e a s u r e i r i e f i t

Qualification

S t a n d a r d or M e w

Manual

Capacity

Fluid change

1.9 L (2.0 U S qt)

transmission

U s e H o n d a IV1TF

Overhaul

2.0 L (2.1 U S qt)

Service Limit

fluid Mainshaft

End play

0 . 1 1 - 0 . 1 7 m m (0.004—0.007 In.)

D i a m e t e r o f b a l l b e a r i n g c o n t a c t area

2 7 . 9 8 7 - 2 8 . 0 0 0 m m ( 1 . 1 0 1 9 - 1 . 1 0 2 4 in.) 27.93 m m (1.100 In.)

Adjust

( t r a n s m i s s i o n h o u s i n g side) D i a m e t e r o f 4th/5th g e a r d i s t a n c e

3 1 . 9 8 4 - 3 2 . 0 0 0 m m ( 1 . 2 5 9 2 - 1 . 2 5 9 8 in.) 31.93 m m (1.257 in.)

collar contact area Diameter of needle bearing contact

3 8 . 9 8 4 - 3 9 . 0 0 0 m m ( 1 . 5 3 4 8 - 1 . 5 3 5 4 in.) 38.93 m m (1.533 In.)

area D i a m e t e r o f ball b e a r i n g c o n t a c t area

2 7 . 9 7 7 - 2 7 . 9 9 0 m m ( 1 . 1 0 1 5 - 1 . 1 0 2 0 in.) 27.92 m m (1.099 in.)

(clutch h o u s i n g side) D i a m e t e r o f b u s h i n g c o n t a c t area

2 0 . 8 0 - 2 0 . 8 5 m m ( 0 . 8 1 9 - 0 . 8 2 1 In.)

20.75 m m (0.817 In.)

Runout

0.02 m m (0.001 In.) m a x .

0.05 m m (0.002 in.)

Mainshaft

ID.

3rd, 4th, a n d 5th

Clearance

2nd-3rd

0 . 0 8 - 0 . 1 6 m m ( 0 . 0 0 2 - 0 . 0 0 6 In.)

0.25 m m (0.010 in.)

gear

E n d p l a y ( d i s t a n c e c o l l a r side)

4th, 5th

0 . 0 6 - 0 . 1 6 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.)

0.25 m m (0,010 in.)

fvlainshaft

4 4 . 0 0 9 - 4 4 . 0 2 5 m m ( 1 . 7 3 2 6 - 1 . 7 3 3 3 in.) 44.08 m m (1.735 in.)

Thickness

2 3 . 9 2 - 2 3 . 9 7 m m ( 0 . 9 4 2 - 0 . 9 4 4 in.)

23.80 m m (0.937 in.)

I.D.

3 2 . 0 0 - 3 2 . 0 1 m m ( 1 . 2 5 9 8 - 1 . 2 8 0 2 In.)

32.02 m m (1.261 In.)

4th/5th g e a r

O.D.

distance collar

Length

3 8 . 9 8 9 - 3 9 . 0 0 0 m m ( 1 . 5 3 5 0 - 1 . 5 3 5 4 in.) 38.94 m m (1.533 in.) A

5 1 . 9 5 - 5 2 . 0 5 m m ( 2 . 0 4 5 - 2 . 0 4 9 in.)

2 4 . 0 3 - 2 4 . 0 8 m m ( 0 . 9 4 6 - 0 . 9 4 8 in.)

M B S distance

ID.

2 8 . 0 0 - 2 8 . 1 0 m m ( 1 . 1 0 2 - 1 . 1 0 6 In.)

collar

Length

2 3 . 9 5 - 2 4 . 0 5 m m ( 0 . 9 4 3 - 0 . 9 4 7 In.)

Countershaft

D i a m e t e r o f b a l l b e a r i n g c o n t a c t area

3 0 . 0 2 0 - 3 0 . 0 3 3 m m ( 1 . 1 8 1 9 - 1 . 1 8 2 4 In.) 29.97 m m (1.180 in.)

28.12 m m (1.107 in.)

(transmission h o u s i n g side) D i a m e t e r o f 1st g e a r d i s t a n c e c o l l a r

3 9 . 9 3 7 - 3 9 . 9 5 0 m m ( 1 . 5 7 2 3 - 1 . 5 7 2 8 In.) 39.88 m m (1.570 In.)

contact area Diameter of needle bearing contact

4 0 . 0 0 0 - 4 0 . 0 1 5 m m ( 1 . 5 7 4 8 - 1 . 5 7 5 4 In.) 39.95 m m (1.573 in.)

area (clutch h o u s i n g side) Runout

0.02 m m (0.001 in.) m a x .

0.05 m m (0.002 in.)

3 5 mm s h i m - t o - b e a r i n g i n n e r race

0 . 0 4 — 0 . 1 0 m m ( 0 . 0 0 1 6 - 0 . 0 0 3 9 In.)

Adjust

clearance 5 2 . 0 1 0 — 5 2 . 0 2 9 m m ( 2 . 0 4 7 6 - 2 . 0 4 8 4 In.) 52.08 m m (2.050 in.)

C o u n t e r s h a f t 1st

LD.

and 2nd gear

End play (distance collar side)

1st

0 . 0 6 - 0 . 1 6 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.)

0.25 m m (0.010 in.)

Clearance

2nd—3rd

0 . 0 6 - 0 . 1 6 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.)

0.25 m m (0.010 in.)

Thickness

C o u n t e r s h a f t 1st

1st

2 2 . 9 2 - 2 2 . 9 7 m m ( 0 . 9 0 2 - 0 . 9 0 4 in.)

22.87 m m (0.900 in,)

2nd

2 7 . 9 2 - 2 7 . 9 7 m m ( 1 . 0 9 9 - 1 . 1 0 1 in.)

27.87 m m (1.097 in.)

3 9 . 9 5 - 3 9 . 9 6 m m ( 1 . 5 7 2 8 - 1 . 5 7 3 2 In.)

39.97 m m (1.574 in.)

LD,

4 6 . 9 8 9 - 4 7 . 0 0 0 m m ( 1 . 8 5 0 0 - 1 . 8 5 0 4 in.) 46.94 m m (1.848 in.)

and 2nd gear distance collar

Length

1st

2 3 . 0 3 - 2 3 . 0 8 m m ( 0 . 9 0 7 - 0 . 9 0 9 In.)

2nd

2 8 . 0 3 - 2 8 . 0 8 m m ( 1 . 1 0 4 - 1 . 1 0 6 in.)

(cont'd)

2-7

Standards and Service Limits Manual Transmission and M/T Differential (cont'd) fVI@asyr@rn@tit

Item R e v e r s e idler gear

Qualification

S t a n d a r d o r Mew

Service Limit

I.D.

2 0 . 0 1 6 - 2 0 . 0 4 3 m m ( 0 , 7 8 8 0 - 0 . 7 8 9 1 in.) 20.90 m m (0.823 in.)

Gear-to-reverse idler gear shaft

0 . 0 3 6 - 0 . 0 8 4 m m ( 0 . 0 0 1 4 - 0 . 0 0 3 3 in.)

0.16 m m (0.006 in.)

0 . 7 0 - 1 . 4 9 m m ( 0 . 0 2 8 - 0 . 0 5 9 in.)

0.4 m m (0.016 in.)

0 . 7 0 - 1 . 1 9 m m ( 0 . 0 2 8 - 0 . 0 4 7 in.)

0.3 m m (0.012 In.)

0 . 5 0 - 1 . 0 4 m m ( 0 . 0 2 0 - 0 . 0 4 1 in.)

0.3 m m (0.012 In.)

0 . 9 5 - 1 . 6 8 m m ( 0 . 0 3 7 - 0 . 0 6 6 in.)

0.6 m m (0.024 In.)

clearance Synchro ring

Ring-to-gear clearance

Ring pushed against gear

Double cone

Outer synchro

synchro and

clearance

ring-to-synchro

cone

triple cone

Synchro cone-to-gear clearance

synchro

Ring pushed against gear Ring pushed against gear

Outer synchro ring-to-gear clearance

Ring pushed against gear

Shift fork

Finger thickness

7 . 4 - 7 . 6 m m ( 0 . 2 9 - 0 . 3 0 in.)

Fork-to-synchro sleeve clearance

0 . 3 5 - 0 . 6 5 m m ( 0 . 0 1 4 - 0 . 0 2 6 in.)

Reverse shift

Fingerwidth

1 3 . 4 - 1 3 . 7 m m ( 0 . 5 2 8 - 0 . 5 3 9 in.)

fork

Fork-to-reverse idler gear clearance

0 . 2 0 - 0 . 5 9 m m ( 0 . 0 0 8 - 0 . 0 2 3 in.)

Shift a r m

I.D.

1 3 . 9 7 3 - 1 4 . 0 0 0 m m ( 0 . 5 5 0 1 - 0 . 5 5 1 2 in.)

Fingerwidth

1 6 . 9 - 1 7 . 0 m m . ( 0 . 6 6 5 - 0 . 6 6 9 In.)

Shift arm-to-shift fork clearance

0 . 2 - 0 . 5 m m ( 0 . 0 0 8 - 0 . 0 2 0 in.)

Select lever

Fingerwidth

1 4 . 8 5 - 1 4 . 9 5 m m ( 0 . 5 8 5 - 0 . 5 8 9 in.)

C h a n g e lever

Shaft-to-select lever clearance

0 . 0 5 - 0 . 2 5 m m ( 0 . 0 0 2 - 0 . 0 1 0 In.)

Groove width

1 5 . 0 0 - 1 5 . 1 0 m m ( 0 . 5 9 1 - 0 . 5 9 4 In.)

Shaft-to-shift a r m clearance

0 . 0 1 3 - 0 . 0 7 0 m m ( 0 . 0 0 0 5 - 0 . 0 0 2 8 in.)

Backlash

0 . 0 2 8 - 0 . 1 0 3 m m ( 0 . 0 0 1 1 - 0 . 0 0 4 1 in.)

M/T differential

80 m m s h i m - t o - b e a r i n g o u t e r race

0 - 0 . 1 0 m m ( 0 - 0 . 0 0 3 9 in.)

80 m m shim

c l e a r a n c e in t r a n s m i s s i o n h o u s i n g

M/T differential

1.0 m m (0.039 In.)

1.2 m m (0.047 in.)

0.6 m m (0.024 In.)

0.50 m m (0.020 in.)

0.1 m m (0.004 In.)

carrier

2-8

Adjust

Automatic Transmission and A/T Differential Standard or N e w

item

Service Limit

Automatic

Capacity

Fluid change

2.5 L (2.6 U S qt)

transmission

Use Honda ATF-Z1

Overhaul

6.5 L (6.9 U S qt)

Line pressure

A t 2,000 r p m i n

927-™985 kPa

NorP

{ 9 . 4 5 - 1 0 . 0 5 k g f / c m , 1 3 4 - 1 4 3 psi)

(8.95 kgf/cm , 127 psi)

A t 2,000 r p m in

9 1 7 - 9 9 5 kPa

867 kPa

( 3 . 3 5 - 1 0 . 1 5 k g f / c m , 1 3 2 - 1 4 4 psi)

(8.85 k g f / c m , 1 2 6 psi)

A t 2,000 r p m in

9 1 7 — 9 9 5 kPa

867 kPa

( 9 . 3 5 - 1 0 . 1 5 k g f / c m , 1 3 2 - 1 4 4 psi)

(8.85 kgf/crn , 126 psi)

A t 2,000 r p m i n

9 1 7 - 9 9 5 kPa

867 kPa

3 r d gear in D

( 9 . 3 5 - 1 0 . 1 5 k g f / c m , 1 3 2 - 1 4 4 psi)

(6,85 kgf/cm% 126 psi)

4th clutch pressure

A t 2,000 r p m i n

9 1 7 - 9 9 5 kPa

867 kPa

4 t h g e a r an D

.(9.35—10.15 k g f / c m , 1 3 2 - 1 4 4 psi)

(8.85 k g f / c m , 1 2 6 psi)

5th d u t c h pressure

A t 2,000 r p m i n

9 1 7 - 9 9 5 kPa

867 kPa

5th gear in D

(9.35—10.15 kgf/cm ..132~-144 psi)

(8.85 k g f / c m , 1 2 6 psi)

2,100 r p m

1,950-2,250 rpm

fluid ATF pressure

1st clutch p r e s s u r e

2nd clutch pressure

3 r d clutch p r e s s u r e

Torque converter

Stall speed

877 kPa 2

Check w i t h vehicle o n level g r o u n d Clutch

Clearance b e t w e e n clutch end-plate

1st

1.38-1.58 m m (0.054—0.062 in.)

and t o p disc 2nd

1.14-1.34

( 0 , 0 4 5 - 0 . 0 5 3 in.) 3rd

1.23-1.43

( 0 . 0 4 8 - 0 . 0 5 6 in.) 4th, 5th

0.93—1.13 m m

1st, 2 n d , 3 r d

45.1 m m (1.78 in.)

43.1 m m (1.70 in.)

4 t h , 5th

33.5 m m (1.32 in.)

31,5 m m (1.24 in.)

( 0 . 0 3 7 - 0 . 0 4 4 in.) Clutch return spring free length

Clutch disc thickness Clutch plate thickness

Clutch wave-plate phase difference

1.94 m m (0.076 in.) 1st, 3 r d

1.6 m m (0.063 in.)

W h e n discolored

2nd

2.0 m m (0.079 in.)

W h e n discolored

4th, 5th

2.0 m m (0.079 in.)

W h e n discolored

1st

0 . 1 5 - 0 . 2 0 m m ( 0 . 0 0 6 - 0 . 0 0 8 in.)

0.13 m m (0.005 in.)

2nd, 3rd, 4th, 5th

<2PLCS>

0 . 1 0 - 0 . 2 0 m m ( 0 . 0 0 4 - 0 . 0 0 8 in.)

0.08 m m (0.003 in.)

<2PLCS>

(cont'd)

2-9

Standards and Service Limits Automatic Transmission and A/T Ddifferential I cont'd) Item C l u t c h (cont'd)

fÂĽIeÂŤisijrefÂĽi0tTt 1st c l u t c h e n d - p l a t e t h i c k n e s s

2nd clutch end-plate thickness

3rd, 4th, 5th clutch end-plate thickness

2-10

Qualification

Standard or New

Service Limit

Markl

2.6 m m (0.102 in.)

W h e n discolored

Mark 2

2.7 m m (0.106 in.)

W h e n discolored

SVSarkS

2.8 m m (0.110 in.)

W h e n discolored

Mark 4

2.9 m m (0.114 in.)

W h e n discolored

MarkB

3.0 m m (0.118 in.)

W h e n discolored

Mark 6

3.1 m m (0.122 in.)

W h e n discolored

Mark?

3.2 m m (0.126 in.)

W h e n discolored

Mark 8

3.3 m m (0.130 in.)

W h e n discolored

Mark 9

3.4 m m (0.134 in.)

W h e n discolored

M a r k 10

2.4 m m (0.094 in.)

When discolored

M a r k 11

2.5 m m (0.098 in.)

When discolored

Mark 1

2.6 m m (0.102 in.)

W h e n discolored

Mark 2

2.7 m m (0.106 in.)

W h e n discolored

Mark3

2.8 m m (0.110 in.)

W h e n discolored

Mark 4

2.9 m m (0.114 in.)

W h e n discolored

Mark5

3.0 m m (0.118 in.)

W h e n discolored

Mark6

3.1 m m (0.122 in.)

W h e n discolored

Mark?

3.2 m m (0.126 in.)

W h e n discolored

Markl

2.1 m m (0.083 in.)

W h e n discolored

Mark 2

2.2 m m (0.087 in.)

W h e n discolored

MarkS

2.3 m m (0.091 in.)

W h e n discolored

Mark 4

2.4 m m (0.095 in.)

W h e n discolored

Mark 5

2.5 m m (0.098 in.)

W h e n discolored

Mark6

2.6 m m (0.102 in.)

W h e n discolored

Mark?

2.7 m m (0.106 in.)

W h e n discolored

Mark 8

2.8 m m (0.110 in.)

W h e n discolored

Mark 9

2.9 m m (0.114 in.)

W h e n discolored

specs Item Mainshaft

Measurement

Qualification

Diameter of needle bearing contact

A t stator shaft

area

ID. o f g e a r s

End play o f gears

4 1 x 83 m m t h r u s t w a s h e r t h i c k n e s s

Standard or N e w

Service Limit

2 2 . 9 8 4 — 2 3 . 0 0 0 m m ( 0 . 9 0 5 - 0 . 9 0 6 in.)

When worn or damaged

A t 5th gear

51.975—51.931 m m { 2 . 0 4 8 - 2 , 0 4 7 In.)

When worn or damaged

A t 4th gear collar

3 3 . 9 7 5 - 3 3 . 9 9 1 m m ( 1 . 3 3 7 6 - 1 . 3 3 8 2 in.) When worn or damaged

5th gear

5 7 . 0 0 0 - 5 7 . 0 1 9 m m ( 2 . 2 4 4 1 - 2 . 2 4 4 8 In.) When w o r n or damaged

4th gear

4 0 . 0 0 0 - 4 0 . 0 1 6 m m ( 1 . 5 7 4 8 - 1 . 5 7 5 4 in.) When worn or damaged

5th gear

0 . 0 4 - 0 . 1 0 m m ( 0 . 0 1 6 - 0 . 0 4 0 in.)

4th g e a r

0 . 1 - 0 . 2 2 m m ( 0 . 0 0 4 - 0 . 0 0 9 in.)

No. 1

4.450 m m (0.1752 in.)

When worn or damaged

No. 2

4.475 m m (0.1762 in.)

When worn or damaged

No. 3

4.500 m m (0.1772 in.)

When w o r n or damaged

No. 4

4.525 m m (0.1781 in.)

When w o r n or damaged

No. 5

4.550 m m (0.1791 in.)

When w o r n or damaged

No. 8

4.575 m m (0.1801 in.)

When w o r n or damaged

No. 7

4.600 m m (0.1811 in.)

When worn or damaged

No. 8

4.625 m m (0.1821 in.)

When worn or damaged

No. 9

4.050 m m (0.1831 in.)

When worn or damaged

N o . 10

4.675 m m (0.1841 in.)

When worn or damaged

N o . 11

4.700 m m (0.1850 in.)

When worn or damaged

N o . 12

4.725 m m (0.1860 in.)

When w o r n or damaged

N o . 13

4.750 m m (0.1870 in.)

When w o r n or damaged

N o . 14

4.775 m m (0.1880 in.)

When worn or damaged

N o . 15

4.800 m m (0.1890 in.)

When worn or damaged

4th gear collar length

6 6 . 3 - 6 6 . 4 m m ( 2 . 6 1 0 - 2 . 6 1 4 in.)

Length o f 4th gear collar flange f r o m

1 9 . 1 5 - 1 9 . 3 0 m m ( 0 . 7 5 4 - 0 . 7 6 0 in.)

When w o r n or damaged

end

Countershaft

Sealing ring thickness

1 . 9 1 - 1 . 9 7 m m ( 0 . 0 7 5 - 0 . 0 7 8 in.)

1.86 m m (0.073 in.)

W i d t h of sealing ring groove

2 . 0 2 5 - 2 . 0 6 0 m m ( 0 . 0 7 9 7 - 0 . 0 8 1 1 in.)

2.080 m m (0.0819 in.)

C l u t c h f e e d p i p e O.D,

7.97—7.98 m m ( 0 . 3 1 3 8 - 0 . 3 1 4 2 in.)

7.95 m m (0.313 in.)

Clutch feed pipe bushing I D .

8 . 0 0 0 - 8 . 0 1 5 m m (0.3150—0.3156 in.)

8.030 m m (0.3161 in.)

Diameter of needle bearing contact

At torque

area

converter

3 6 . 0 0 5 - 3 6 . 0 1 5 m m ( 1 . 4 1 7 5 - 1 . 4 1 7 9 in.) When worn or damaged

housing

L D . of g e a r s

End play of gears

Collar, 3 5 x 47 x 7.8 m m t h i c k n e s s

A t 4th gear

3 4 . 9 8 2 - 3 4 . 9 9 8 m m ( 1 . 3 7 7 2 - 1 . 3 7 7 9 in.) When w o r n or damaged

A t reverse gear

3 9 . 9 7 9 - 4 0 . 0 0 0 m m ( 1 . 5 7 4 0 - 1 . 5 7 4 8 in.) When w o r n or damaged

4th gear

4 1 . 0 0 0 — 4 1 . 0 1 6 m m ( 1 . 6 1 4 2 - 1 . 6 1 4 8 in.) When w o r n or damaged

Reverse gear

4 6 . 0 0 0 — 4 6 . 0 1 6 m m (1.8110—1.8116 in.) When w o r n or damaged

5th gear

0 . 0 0 - 0 . 4 8 m m ( 0 . 0 0 0 - 0 . 0 1 9 in.)

4th gear

0 . 0 4 — a 12 m m ( 0 . 0 0 2 - 0 . 0 0 5 in.)

Reverse gear

0 . 1 0 - 0 . 2 5 m m ( 0 . 0 0 4 - 0 . 0 1 0 in.) 7.8 m m (0.31 in.)

Collar, 37 x 41 x 54.3 m m l e n g t h

5 4 . 2 5 - 5 4 . 3 0 m m ( 2 . 1 3 6 - 2 . 1 3 8 in.)

Reverse selector h o b w i d t h

2 5 . 4 5 - 2 5 . 6 5 m m (1.002—1.010 in.)

R e v e r s e s e l e c t o r h u b O.D.

5 5 . 8 7 - 5 5 . 9 0 m m ( 2 . 2 0 0 - 2 . 2 0 1 in.)

When worn or damaged

(cont'd)

2-11

Standards and Service Limits Automatic Transmission and A/T Differential (cont'd) IVi@asyF#nn©iit Secondary shaft

Diameter of needle bearing contact area

I.D. o f g e a r s

End play of gears

37 x 58 m m t h r u s t w a s h e r t h i c k n e s s

40 x 51.5 m m t h r u s t w a s h e r t h i c k n e s s

Qualification

Standard or N e w

Service Limit

A t 1st g e a r

3 9 . 9 8 6 - 3 9 . 3 9 9 m m ( 1 . 5 7 4 2 - 1 . 5 7 4 8 in.) When worn or damaged

A t 2 n d gear

3 9 . 9 8 6 - 3 9 . 9 9 9 m m ( 1 . 5 7 4 2 — 1 . 5 7 4 8 in.) When worn or damaged

A t 3rd gear collar

3 6 . 9 7 5 - 3 6 . 9 9 1 m m (1.4557—1.4563 i n .

When worn or damaged

1st g e a r

47.000-47.016 m m (1.8504-1.8510 in.

When w o r n or damaged

2nd gear

46.000—46.016 m m (1.8110—1.8116 in.

When worn or damaged

3rd gear

4 3 . 0 0 0 - 4 3 . 0 1 6 m m ( 1 . 6 9 2 9 - 1 . 6 9 3 5 In.) When worn or damaged

1st g e a r

0 . 0 4 - 0 . 1 2 m m ( 0 . 0 0 2 - 0 . 0 0 5 In.)

2nd gear

0 . 0 4 - 0 . 1 2 m m ( 0 . 0 0 2 - 0 . 0 0 5 In.)

•3rd g e a r

0 . 1 0 - 0 . 2 2 m m ( 0 . 0 0 4 - 0 . 0 0 9 In.)

No. 1

3,900 m m (0.154 in.!

Ho. 2

3.925 m m (0.155 in,

When worn or damaged

No, 3

3.950 m m (0.156 in.;

When w o r n or damaged

No. 4

3.975 m m (0.156 i n .

When worn or damaged

No. 5

4.000 m m (0.157 in.;

When worn or damaged

No. 6

4.025 m m (0.158 in,

When w o r n or damaged

No. 7

4.050 m m (0.159 in.;

When worn or damaged

No. 8

4.075 m m (0.160 in.;

When worn or damaged

No. 9

4.100 m m (0.161 in.;

When w o r n or damaged

N o . 10

4.125 m m (0.162 in,

When worn or damaged

N o . 11

4.150 m m (0.163 in.;

When worn or damaged

N o . 12

4.175 m m (0.164 in,

When worn or damaged

N o . 13

4.200 m m (0.165 i n .

When worn or damaged

N o . 14

4.225 m m (0.166 in.'

When w o r n or damaged

N o . 15

4.250 m m (0.167 in.

When worn or damaged

N o . 16

4.275 m m (0.168 in,

When w o r n or damaged

N o . 17

4.300 m m (0.169 in.

When worn or damaged

N o . 18

4.325 m m (0.170 in.

When worn or damaged

N o . 19

4.350 m m (0.171 in.

When worn or damaged

N o . 20

4.375 m m (0.172 in.'

When worn or damaged

No. 1

4.80 m m (0.189 in.)

When w o r n or damaged

No. 2

4.85 m m (0.191 in.)

When w o r n or damaged

No. 3

4.90 m m (0.193 in,)

When worn or damaged

No. 4

4.95 m m (0.195 in.)

When worn or damaged

No. 5

5.00 m m (0.197 in.)

When worn or damaged

No. 6

5.05 m m (0.199 in.)

When worn or damaged

3rd gear collar length

4 3 . 9 - 4 4 . 0 m m (1.728—1.732 in.)

Length of 3rd gear collar flange f r o m

5 . 2 5 - 5 . 4 0 m m ( 0 . 2 0 7 - 0 . 2 1 3 in.)

When worn or damaged

end Sealing ring thickness

1 . 9 1 - 1 . 9 7 m m ( 0 . 0 7 5 2 - 0 . 0 7 7 6 In.)

1.86 m m (0.0732 In.)

W i d t h o f s e a l i n g ring g r o o v e

2 . 0 2 5 - 2 . 0 6 0 m m ( 0 . 0 7 9 7 - 0 . 0 8 1 1 in.)

2.080 m m (0.0819 in.)

1 1 . 4 7 - 1 1 . 4 8 m m (0.4516—0.4520 in.)

11.45 m m (0.4508 in.)

6 . 9 7 - 6 . 9 8 m m ( 0 . 2 7 4 4 - 0 . 2 7 4 8 In.)

6.95 m m (0.2736 in.)

11.500-11.518 m m (0.4528-0.4535 in.

11.530 m m (0.4539 In.)

7 . 0 1 8 - 7 . 0 3 0 m m ( 0 . 2 7 6 3 - 0 . 2 7 6 8 in.)

7.045 m m (0.2774 in.)

C l u t c h f e e d p i p e O.D.

3rd clutch feed pipe 1st c l u t c h f e e d pipe

C l u t c h f e e d p i p e b u s h i n g I.D.

3rd clutch feed pipe 1st c l u t c h f e e d pipe

A T F g u i d e c o l l a r o f s e a l i n g ring c o n t a c t LD.

2-12

2 9 . 0 0 0 - 2 9 . 0 2 1 m m ( 1 . 1 4 1 7 - 1 . 1 4 2 6 In.) 29.05 m m (1.144 in.)

specs Item Idler g e a r s h a f t

Wessiirsifieiit Diameter of needle bearing contact

Gynlificnti©!"! End cover side

Service Limit

Standard or New

3 2 . 0 0 3 — 3 2 . 0 1 3 m m ( 1 . 2 6 0 0 - 1 . 2 6 0 4 in.) When worn or damaged

area Thickness of cotters

1.39—1.42 m m (0.055—0.056 in.)

Reverse idler

Reverse idler gear shaft diameter at

1 4 . 9 9 - 1 5 . 0 0 m m ( 0 . 5 9 0 - 0 . 5 9 1 in.)

gear

needle bearing contact area

When worn or damaged

LD.

2 0 . 0 0 7 — 2 0 . 0 2 0 m m ( 0 . 7 8 7 7 - 0 . 7 8 8 2 in.) When worn or damaged

LD, o f r e v e r s e i d l e r g e a r s h a f t c o n t a c t

1 4 . 8 0 0 - 1 4 . 8 1 8 m m ( 0 . 5 8 2 7 - 0 . 5 8 3 4 in,)

area o n t r a n s m i s s i o n h o u s i n g

ATF pump

Stator shaft

LD, o f r e v e r s e i d l e r g e a r s h a f t h o l d e r

1 4 . 8 0 0 - 1 4 . 8 2 4 m m ( 0 . 5 8 2 7 - 0 . 5 8 3 6 in.) When worn or damaged

ATF p u m p thrust clearance

0 . 0 3 - 0 . 0 6 m m ( 0 . 0 0 1 - 0 . 0 0 2 in.)

0.07 m m (0.003 in.)

Clearance b e t w e e n ATF p u m p gear

Drive gear

0 . 2 1 0 - 0 . 2 6 5 m m ( 0 . 0 0 8 3 - 0 . 0 1 0 4 in.)

and body

Driven gear

0 . 0 7 0 - 0 . 1 2 5 m m ( 0 . 0 0 2 8 - 0 . 0 0 4 9 in.)

ATF p u m p driven gear LD.

14.016—14.034 m m ( 0 . 5 5 1 8 - 0 . 5 5 2 5 in.) When worn or damaged

ATF p u m p driven gear shaft O.D.

1 3 . 9 8 0 - 1 3 . 9 9 0 m m ( 0 . 5 5 0 4 - 0 . 5 5 0 8 in.) When worn or damaged

Needle bearing contact LD.

Torque converter

2 7 . 0 0 0 — 2 7 . 0 2 1 m m ( 1 . 0 6 3 0 - 1 . 0 6 3 8 in.) When worn or damaged

side ATF p u m p side

Reverse shift

2 9 . 0 0 0 - 2 9 . 0 2 1 m m (1.1417 - 1 . 1 4 2 6 In.)

S e a l i n g r i n g c o n t a c t area L D .

2 9 . 0 0 0 - 2 9 . 0 2 1 m m ( 1 . 1 4 1 7 - 1 . 1 4 2 6 in.) 29,05 m m (1,144 in.)

Fork finger thickness

5 . 9 0 - 6 . 0 0 m m ( 0 . 2 3 2 - 0 . 2 3 6 in.)

5.40 m m (0.213 in.)

fork When worn or damaged

Path g e a r a n d pa w i Servo body

Regulator valve

Shift f o r k shaft bore LD,

1 4 . 0 0 0 - 1 4 . 0 1 0 m m ( 0 . 5 5 1 2 - 0 . 5 5 1 6 in.)

Shift fork shaft valve bore LD.

3 7 . 0 0 0 - 3 7 . 0 3 9 m m ( 1 . 4 5 6 7 - 1 . 4 5 8 2 in.) 37.045 m m (1.4585 in,)

S e a l i n g r i n g c o n t a c t LD.

2 9 . 0 0 0 - 2 9 . 0 2 1 m m ( 1 . 1 4 1 7 - 1 . 1 4 2 6 in.) 29.05 m m (1.144 in.)

body

Item

M m i s i t f ®im s o t

Qualification

& i a n c m r o o r ro@w Wire Diameter

M a i n v a l v e foody

0.8 m m (0.031 in.)

(0.220 in.)

(1.106 in.)

Shift valve B spring

0.8 m m

5.6 m m

28.1 m m

(0.031 in.)

(0.220 in.)

(1.106 in.)

0.8 m m

5.6 m m

28.1 m m

(0.031 in.)

(0.220 in.)

(1.106 in.)

Shift valve C spring

Relief v a l v e s p r i n g

Lock-up control valve spring

Cooler check valve s p r i n g

Servo control valve spring

Shift valve E spring

5.6 m m

Free L e n g t h

Shift valve A spring

s p r i n g (see p a g e 14-322)

O.D.

28.1 m m

1.0 m m

9.6 m m

34.1 m m

(0.039 in.)

(0.378 in.)

(1,343 in.)

0.65 m m

7.1 m m

23.1 m m

(0.026 in.)

(0.280 in.)

(0.909 in.)

0.85 m m

6.6 m m

27.0 m m

(0.034 in.)

(0.260 in.)

(1.063 in.)

0.7 m m

6.6 m m

35.7 m m

(0.028 in.)

(0.260 in.)

(1.406 in.)

5.6 m m

28.1 m m

0.8 m m (0.031 in.)

. (0.220 in.) •

No. o f C o i l s 15.9

15.9

10.2

12.7

11.3

17.2"

15.9

(1.106 in.)

(cont'd)

2-13

Standards and Service Limits Automatic 1 Iransmission and A/T Ddifferential fcomt^d) Item

M@8siJF@m©fit

Qualification

Standard or N e w W i r e Drarn@t®r

Regulator valve

Stator reaction spring

(see p a g e

Regulator valve spring A

14-324) Regulator valve spring B

T o r q u e converter check valve spring

Lock-up shift valve spring

3rd accumulator spring

1st a c c u m u l a t o r s p r i n g A

1st a c c u m u l a t o r s p r i n g B

Servo body

Shift valve D spring

s p r i n g (see p a g e 14-325)

4th a c c u m u l a t o r s p r i n g B

4th a c c u m u l a t o r s p r i n g A

2nd accumulator spring B

2nd accumulator spring A

5th accumulator spring

Measurement

Item A / T differential carrier

' 35.4 m m

45 mm

body spring

Qualification

O.D.

Ff@B L e n g t h 30.3 m m

(0.177 in.)

(1.394 In.)

(1.193 In.)

1.85 m m

14.7 m m

83.0 m m

(0.073 In.)

(0.579 in.)

(3.268 in.)

16.9

1.6 m m .

9.2 m m

44.0 m m

(0.063 in.)

(0.362 in.)

(1.732 In.)

12.5

1.2 m m

8.6 m m

33.8 m m

(0.047 in.)

(0.339 In.)

(1.331 In.)

1.0 m m

6.6 m m

35.5 m m

(0.039 In.)

(0.260 In.)

(1.398 in.)

2.5 m m

14.6 m m

29.4 m m

(0.098 In.)

(0.575 In.)

(1.157 in.)

2.4 m m

18.6 m m

49.0 m m

(0.094 In.)

( 0 J 3 2 in.)

(1.929 In.)

2.3 m m

12.2 m m

31.5 m m

(0.091 In.)

(0.480 In.)

(1.240 In.)

0.8 m m

5.6 m m

28.1 m m

(0.031 in.)

(0.220 In.)

(1.106 In.)

2.3 m m

12.2 m m

31.5 m m

(0.091 in.)

(0.480 in.)

(1.240 In.)

2.4 m m

18.6 m m

49.0 m m

(0.094 in.)

(0.732 in.)

(1.929 In.)

2.1 m m

10.8 m m

34.0 m m

(0.083 In.)

(0.425 In.)

(1.339 in.)

2.1 m m

16.6 m m

48.7 m m

(0.083 in.)

(0.654 In.)

(1.917 in.)

2.5 m m

14.6 m m

29.9 m m

(0.098 In.)

(0.575 in.)

(1.177 In.)

S t a n d a r d o r Mew

P i n i o n s h a f t c o n t a c t area LD.

1 8 . 0 0 0 - 1 8 . 0 2 5 m m ( 0 . 7 0 8 7 - 0 . 7 0 9 6 In.)

Clearance b e t w e e n carrier a n d p i n i o n

0 . 0 1 3 - 0 . 0 5 4 m m ( 0 . 0 0 0 5 - 0 . 0 0 2 1 in.)

Mo. of Coils 1.92

12.2

18.2

4.9

7.1

6.6 '

15.9

6.6

7.1

8.2

8.4

4.9

Service Limit

0.1 m m (0.004 in.)

shaft D r i v e s h a f t c o n t a c t a r e a I.D.

2 8 . 0 2 1 — 2 8 . 0 5 1 m m ( 1 . 1 0 3 2 - 1 . 1 0 4 4 in.)

Clearance b e t w e e n carrier a n d

0 . 0 7 1 - 0 . 1 1 7 m m ( 0 . 0 0 2 8 - 0 . 0 0 4 6 In.)

0.12 m m (0.005 In.)

2.7—3.9 N-m

Adjust

driveshaft Carrier bearing starting t o r q u e

For n e w b e a r i n g

(preload)

( 2 8 - 4 0 kgf-cm, 2 4 - 3 5 Ibf-in.) For u s e d b e a r i n g

2.5—3.6 N-m

Adjust

( 2 5 — 3 7 k g f - c m , 2 2 - 3 2 Ibf-in.)

A/T differential pinion gear

Final d r i v e n g e a r b a c k l a s h

0 . 0 8 6 - 0 . 1 4 2 m m ( 0 . 0 0 3 4 - 0 . 0 0 5 6 In.)

Backlash

0.05—0.15 m m ( 0 . 0 0 2 - 0 . 0 0 6 in.)

LD.

1 8 . 0 4 2 - 1 8 . 0 6 6 m m ( 0 . 7 1 0 3 - 0 . 7 1 1 3 In.)

Clearance b e t w e e n p i n i o n gear and

0 . 0 5 5 - 0 . 0 9 5 m m ( 0 . 0 0 2 2 - 0 . 0 0 3 7 in.)

pinion shaft

2-14

0.2 m m (0.008 In.)

0.12 m m (0.005 In.)

M@asuF©inCTt

Qualification

R o t a t i o n a l p l a y m e a s u r e d at o u t s i d e

edge w i t h engine running Initial t u r n i n g l o a d m e a s u r e d at

2 9 N (3.0 k g t 6.6 Ibf)

outside edge with engine running Gearbox

A n g l e of rack guide screw loosened

15±5°

f r o m locked position Pump

Output pressure w i t h shut-off valve

8 , 1 4 0 - 8 , 8 3 0 kPa ( 8 3 - 9 0 k g f / c m , 1 , 1 8 0 - 1 , 2 8 0 psi)

closed Power steering

Capacity

Reservoir

fluid

Use Honda Power Steering Fluid

capacity System capacity

0.32 L (0.33 U S qt)

1.05 L (1.11 U S q t )

Suspension item W h e e l alignment

Qualification

Standard or N e w

Camber

Front

Caster

Front (4-door)

Total toe-in

Front

0 ± 2 m m ( 0 ± 0 . 0 8 in.)

Rear

2 ± 2 m m ( 0 . 0 8 + 0 . 0 8 in.)

Service Limit

Rear

Front (2-door)

Front wheel turning angle

Inward Outward

31 5 0

(reference) Wheel

Wheel bearing

A l u m i n u m wheel runout

Axial

0—0.7 m m ( 0 - 0 . 0 3 In.)

Radial

0—0.7 m m (0—0.03 in.)

2.0 m m (0.08 In.) 1.5 m m (0.06 in.)

Steel w h e e l r u n o u t

Axial

0 - 1 . 0 m m ( 0 — 0 . 0 4 in.)

2.0 m m (0.08 in.)

Radial

0—1.0 m m (0—0.04 in.)

1.5 m m (0.06 in.)

End play

Front

0 - 0 . 0 5 m m ( 0 - 0 . 0 0 2 in.)

Rear

0 - 0 . 0 5 m m ( 0 - 0 . 0 0 2 In.)

2-15

Standards and Service Limits Brakes Measurement

Item Parking brake

Qualification

Distance t r a v e l e d w h e n lever p u l l e d

Service Limit

7 t o 9 clicks

w i t h 196 N (20 kgf, 44 Ibf) o f f e r e e B r a k e pedaS

Pedal h e i g h t ( c a r p e t m o v e d aside)

M/T

156 m m (6 1/8 in.)

A/T

160 m m (6 5/16 in.)

Front

2 7 . 9 - 2 8 . 1 m m ( 1 . 1 0 - 1 . 1 1 in.)

26.0 m m (1.02 in.)

2 2 . 9 - 2 3 . 1 m m ( 0 . 9 0 - 0 . 9 1 in.)

21.0 m m (0.83 in.)

8 . 9 - 9 . 1 m m ( 0 . 3 5 - 0 . 3 6 in.)

8.0 m m (0.31 in.)

1 ~ 5 m m ( 1 / 1 6 - 3 / 1 6 in.)

Free p l a y Brake disc

Thickness

•(NISSIN) Front (AKEBONO) Rear

0.04 m m (0.0016 in.)

Runout

0.015 m m (0.0006 in.)

Parallelism Brake pad

Front

Thickness

(NISSIN)

1 0 . 5 - 1 1 . 2 m m ( 0 . 4 1 - 0 . 4 4 in.)

1.6 m m (0.06 in.)

1 0 . 5 - 1 0 . 8 m m ( 0 . 4 1 - 0 . 4 3 in.)

1.6 m m (0.06 in.)

8 . 3 - 9 . 0 m m ( 0 . 3 3 - 0 . 3 5 in.)

1.0 m m (0.04 in.)

•

Front (AKEBONO) Rear

^ir Conditioning Measurement

St© i n

Standard or N e w

Qualification

Refrigerant

Type

HFC-134a (R-134a)

Capacity of s y s t e m

4 0 0 - 4 5 0 g ( 1 4 . 1 - 1 5 . 9 oz)

Refrigerant oil

Type Capacity of c o m p o n e n t s

D E N S O N D - O I L 8 (P/N 38897-PR7-A01 A H o r 38997-PR7-A01) Condenser

25 m L (5/6 fl-oz)

Evaporator

3 5 m L (1 1/5 fl-oz)

Each line a n d

10 m L (1/3 fl-oz)

hose

Compressor

Field c o i l r e s i s t a n c e Puliey-to-armature-plate clearance

2-16

Reserver/Dryer

1 0 m L ( 1 / 3 fl-oz)

Compressor

7 0 - 8 2 m L (2 3 / 8 - 2 7/9 fl-oz)

A t 68 °F (20 O

3.9-4.3 Q 0 . 3 5 - 0 . 6 0 m m ( 0 . 0 1 4 - 0 . 0 2 4 in.)

specs

Design Specifications ftetn DIMENSIONS (4-door)

Specification

Qualification

SVfsnstirfsnriSFit Overall length

4,930 m m (194.1 in.)

Overall width

1,847 m m (72.7 in.)

Overall height

1,475 m m (58.1 in.)

Wheelbase

2,800 m m (110.2 in.)

Track

F r o n t (18 i n c h w h e e l s )

1,580 m m (62.2 in.)

F r o n t (17 i n c h w h e e l s )

1,590 m m (62.6 in.)

Rear (18 i n c h w h e e l s )

1,580 m m (62.2 in.)

Rear (17 i n c h w h e e l s )

1,590 m m (62.6 in.)

Seating capacity

f i v e (5)

DIMENSIONS

Overall length

4,849 m m (190.9 in,)

12-door)

Overall w i d t h

1,848 m m (72.7 in.)

O v e r a l l height

1,432 m m (58,3 in.)

Wheelbase

2,740 m m (107,9 in.)

Track

Front

1,580 m m (82.2 in.)

Rear

1,580 m m (62.2 in.)

Seating capacity

f i v e (5)

WEIGHT

Gross Vehicle W e i g h t Rating

L X , L X PZEV, LX- P,

14-cioor)

IGVWR!

LX- P PZEV

1,350 k g (4,299 lbs)

USA models

E X , E X - L , EX PZEV, E X - L PZEV

Gross Vehicle W e i g h t Rating

LX, L X - P

2,010 k g (4,431 lbs) 1,970 kg (4,343 lbs)

fGVWRI

EX, E X - L

2,030 k g (4,475 lbs)

Canada models WEIGHT

Gross Vehicle W e i g h t Rating

L X , L X PZEV

1,950 kg (4,299 lbs)

12-door)

IGVWR)

E X , E X - L , EX PZEV, EX-L PZEV

2,000 kg (4,409 lbs)

USA models Gross Vehicle W e i g h t Rating

1,970 k g (4,343 lbs)

IGVWR)

E X , EX-L

2,020 k g (4,453 lbs)

Canada models ENGINE

W a t e r c o o l e d , 4 - s t r o k e D O H C i- VTEC g a s o l i n e e n g i n e

Type Cylinder arrangement

I n l i n e 4-cy Under, t r a n s v e r s e

Bore and stroke

8 7 x 9 9 m m (3.43 x 3.90 in.) 3

Displacement

2,354 c m (144 c u in.)

Compression ratio

10.5

Valve train

C h a i n d r i v e , D O H C i-VTEC 4 v a l v e s p e r c y l i n d e r Forced, w e t s u m p , w i t h trochoid p u m p

Lubrication s y s t e m Gil p u m p d i s p l a c e m e n t

A t 6,000 r p m

Water p u m p displacement

A t 6,000 r p m

Fuel r e q u i r e d

54.3 L (57.4 U S q t ) / m i n u t e 8 2 L (87 U S q t ) / m i n u t e . R e g u l a r U N L E A D E D g a s o l i n e w i t h 87 P u m p O c t a n e N u m b e r or higher

STARTER

Type

Gear reduction

Normal output

1.6 k W

Normal voltage

12V

Hour rating

30 seconds

R o t a t i o n of d i r e c t i o n

C l o c k w i s e as v i e w e d f r o m d r i v e e n d

(cont'd)

2-17

Design Specifications Item

Qualification

Measurement

©peciiscaiion

CLUTCH

Type

Single plate dry, d i a p h r a g m s p r i n g

MANUAL

Type

S y n c h r o n i z e d , five-speed f o r w a r d , o n e reverse

TRANSMISSION

Primary reduction Gear ratio

Final r e d u c t i o n

AUTOMATIC

D i r e c t 1:1 3,267

1st 2nd

1.778

3rd

1.154

4th

0.870

5th

0.647

Reverse

3.583

Type'

Single helical gear

Gear ratio

4.389

Type

Electronically-controlled automatic, five-speed f o r w a r d , one reverse, three-element t o r q u e converter w i t h lock-up

TRANSMISSION

clutch Primary reduction Gear ratio

D i r e c t 1:1 1st 2nd

3rd

4th

Final r e d u c t i o n

STEERING

2.651 K24Z2

1.516

K24Z3

1.613

K24Z2

1.037

K24Z3

1.081

K24Z2

0.738

K24Z3

0.772

5th

0.566

Reverse

2.000

Type

Single helical gear

Gear ratio

4.437

Type

H y d r a u l i c p o w e r - a s s i s t e d rack a n d p i n i o n

Overall ratio

13.1

T u r n s , lock t o Sock

2.56

Steering wheel diameter SUSPENSION

Type

Shock absorber

TIRES

Size (4-door)

3 7 0 m m (14.6 In.) Front

Independent d o u b l e w i s h b o n e , w i t h stabilizer, coll spring

Rear

I n d e p e n d e n t mufti I ink w i t h stabilizer, coil s p r i n g

Front

Telescopic, hydraulic, nitrogen gas-filled

Rear

Telescopic, hydraulic, nitrogen gas-filled

F r o n t a n d rear ( L X , L X PZEV,

P215/60R16 9 4 H

L X - P , LX-P PZEV) F r o n t a n d r e a r (EX, E X - L ,

P225/50R17 9 3 V

EX PZEV, EX-L PZEV) Spare Size ( 2 - d o o r )

WHEEL

Camber

ALIGNMENT Caster

Total toe-in

Front w h e e l turning angle

2-18

T135/80D16101M

Front a n d rear

P225/50R17 9 3 V

Spare

T135/80D16101M

Front

0*00'

Rear

~-1

Front (4-door)

3°48'

Front (2-door)

3°47'

Front

0 m m (0 in.)

Rear

2 m m (0.08 in.)

Inward

O u t w a r d (reference)

3 1 °5Q

TO'

specs Item BRAKES

Qualification

Power-assisted self-adjusting ventilated disc

Rear

Power-assisted self-adjusting solid disc

F r o n t (NISSIN)

50,6 c m (7.84 s q i n . ) x 2

Front: (AKEBONO)

45.7 c m (7.08 s q i n . ) x 2

Rear

27.3 c m (4.23 s q i n . ) x 2

Type

Swash plate/DENSO

T y p e of p a r k i n g b r a k e Pad friction surface area

AIR

Compressor

CONDITIONING

Condenser

Front

Mechanical actuating, rear w h e e l s 2

Capacity

154.4 m L (9.42 c u in.)/rev.

M a x i m u m speed

8,400 r p m

Lubricant capacity

7 0 m L ( 2 3/8fl-oz)

Lubricant type

DENSO ND-OIL 8

Type

Corrugated fin

Evaporator

Type

Corrugated fin

Blower

Type

Stabilizer swirling f l o w

Motor type

216W/12V

Speed control

infinitely variable

M a x i m u m capacity

5 0 5 m (17,834 c u f t ) / h

Temperature control Compressor clutch

Air-mix type Type

Dry, single plate, poly V-belt drive

Electrical p o w e r c o n s u m p t i o n

3 5 W m a x i m u m a t 12 V

at 68 T (20 <C) Refrigerant

Type

HFC-134a (R-134a)

Capacity

4 0 0 - 4 5 0 g ( 1 4 . 1 - 1 5 . 9 oz)

(cont'd)

2-19

Design Specifications fVleiisu rennenit

Item ELECTRICAL

Battery

RATINGS Fuse

Specification

Qualification AH m o d e l s e x c e p t PZEV

1 2 V - - 4 7 A h / 2 0 HR (12 V - 3 8 A h / 5 HR)

PZEV

12 V - 6 5 A h / 2 0 HR (12 V - - 5 2 A h / 5 HR)

Under-hood fuse/relay box

100 A , 60 A \ 50 A , 4 0 A , 3 0 A , 2 0 A , 15 A , 7.5 A

Driver's under-dash fuse/relay

20 A , 15 A , 10 A , 7.5 A

box Passenger's under-dash fuse/

20 A , 15 A , 10 A , 7.5 A

relay b o x Light bulbs

Headlight high beam

12V-60W

Headlight l o w b e a m (4-door)

12 V—51 W

Headlight l o w b e a m (2-door)

12V-55W

Front t u r n signal/parking

12V-21/5W

lights (4-door) Front t u r n signal/parking

12 V — 2 4 CP/2.2 CP

lights (2-door) Front side marker light

1 2 V - 3 CP

(4-door) Front side marker light

12V-5W

(2-door) Rear t u r n s i g n a l l i g h t s

Washer reservoir

12V-21W/5W

High m o u n t brake light

12V-21W

Back-up lights (4-door) •

12V-21W

Back-up lights (2-door)

12 V—21 W

License p l a t e l i g h t s

12V-5W

Ceiling light

12V-8W

T r u n k Sight

12V-5W

Front m a p light

12 V - 8 W

A m b i e n t light

LED

V a n i t y m i r r o r Sights

12V-1.1 W

G l o v e b o x Sight

12V-2CP

Door courtesy light

12V-2CP

Gauge lights

LED

Indicator lights

LED

Capacity (4-door U S A models)

2.5 L (2.64 U S q t )

Capacity (All 2-door m o d e l s

4.5 L (4.75 U S q t )

and 4-door Canada models) *:

E x c e p t L X , L X PZEV

2-20

12V-21 W

Brake/tail l i g h t s

pecs Body Specifications 4-door:

1,847 m m 172.6 in.)

4 , 9 3 0 m m f 1 3 4 / 1 in.)

*1:16 inch wheels *2:17

inch w h e e l s

(cont'd)

2-21

Design Specifications Body Specifications (cont'd) 2-door:

2-22

Maintenance Lubricants and Fluids Maintenance Minder General Information Maintenance Main Items Maintenance Sub Items

Lubricants and Fluids

For d e t a i l s of t h e lubrication p o i n t s a n d the t y p e of lubricants to be a p p l i e d , refer to the illustrated i n d e x a n d the v a r i o u s w o r k p r o c e d u r e s ( s u c h a s A s s e m b l y / R e a s s e m b l y , R e p l a c e m e n t O v e r h a u l , Installation, etc.) c o n t a i n e d in e a c h section. Application A

Engine

L y b r i c a i i t ÂŠf F l u i d H o n d a M o t o r Oil: A m e r i c a n H o n d a P/N 0 8 7 9 8 - 9 0 2 3 (5W-20) H o n d a C a n a d a P/N C A 6 6 8 0 6 (5W-20) L o o k for the API certification s e a l o n the oil c o n t a i n e r . M a k e s u r e it s a y s " F o r G a s o l i n e E n g i n e / ' S A E V i s c o s i t y : S e e c h a r t

Manual Transmission

Honda Manual T r a n s m i s s i o n Fluid (MTF): A m e r i c a n H o n d a P/N 08798-9031 H o n d a C a n a d a P/N 0 8 7 9 8 - 9 0 3 1 C A l w a y s u s e H o n d a M T F . U s i n g m o t o r oil c a n c a u s e stiffer shifting b e c a u s e it d o e s not c o n t a i n t h e p r o p e r a d d i t i v e s .

Automatic Transmission

H o n d a A u t o m a t i c T r a n s m i s s i o n Fluid ( A T F - Z 1 ) : A m e r i c a n H o n d a P/N 08200-9001 H o n d a C a n a d a P/N C A 6 6 6 8 9 A l w a y s u s e H o n d a A T F - Z 1 . U s i n g a n o n - H o n d a A T F c a n affect shift quality.

C D

B r a k e s y s t e m (including V S A lines) Clutch s y s t e m (manual transmission)

Shift l e v e r ( m a n u a l t r a n s m i s s i o n )

F G

B r a k e b o o s t e r c l e v i s pin C l u t c h m a s t e r c y l i n d e r c l e v i s pin

H o n d a D O T 3 B r a k e fluid: P/N 0 8 7 9 8 - 9 0 0 8 A l w a y s u s e H o n d a D O T 3 B r a k e F l u i d , U s i n g a n o n - H o n d a brake fluid c a n c a u s e c o r r o s i o n a n d d e c r e a s e the life of the s y s t e m . S u p e r High T e m p U r e a G r e a s e : P/N 0 8 7 9 8 - 9 0 0 2 Multipurpose grease

(manual transmission) H 1 J K

R e l e a s e fork ( m a n u a l t r a n s m i s s i o n ) Battery t e r m i n a l s H o o d h i n g e s a n d h o o d latch F u e l fill d o o r

Trunk hinges'

M N

Shift c a b l e e n d s ( m a n u a l t r a n s m i s s i o n ) C a l i p e r piston b o o t s , c a l i p e r p i n s , a n d boots

H o n d a S i l i c o n e G r e a s e : P/N 0 8 C 3 0 - B 0 2 3 4 M

Power steering s y s t e m

Honda Power Steering Fluid: A m e r i c a n H o n d a P/N 0 8 2 0 6 - 9 0 0 2 H o n d a C a n a d a P/N 0 8 2 0 6 - 9 0 0 2 C

Air conditioning c o m p r e s s o r

A l w a y s u s e H o n d a P o w e r S t e e r i n g F l u i d . U s i n g a n y other t y p e of p o w e r s t e e r i n g fluid or a u t o m a t i c t r a n s m i s s i o n fluid c a n c a u s e i n c r e a s e d w e a r a n d poor s t e e r i n g in c o l d w e a t h e r . C o m p r e s s o r oil: D E N S O N D - O I L 8 (P/N 3 8 8 9 7 - P R 7 - A 0 1 A H or

Coolant system

3 8 8 9 9 - P R 7 - A 0 1 ) for refrigerant H F C - 1 3 4 a (R-134a) H o n d a L o n g Life A n t i f r e e z e / C o o l a n t - T y p e 2: P/N O L 9 9 9 - 9 0 1 1 H o n d a E x t r e m e C o l d W e a t h e r A n t i f r e e z e / C o o l a n t T y p e 2: P/N O L 9 9 9 - 9 0 2 0

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IMOTE: * L u b r i c a t e t h e f o l l o w i n g a r e a s u s i n g the r e c o m m e n d e d l u b r i c a n t s a n d fluids. * In c o r r o s i v e a r e a s , m o r e f r e q u e n t lubrication Is n e c e s s a r y . O

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Maintenance Minder General Information Maintenance Display T h e m a i n t e n a n c e m i n d e r is a n important feature of the information d i s p l a y . B a s e d on e n g i n e a n d t r a n s m i s s i o n o p e r a t i n g c o n d i t i o n s , the A c c o r d ' s o n b o a r d c o m p u t e r ( E C M / P C M ) c a l c u l a t e s the r e m a i n i n g e n g i n e oil a n d the t r a n s m i s s i o n fluid life. T h e s y s t e m a l s o d i s p l a y s the r e m a i n i n g e n g i n e oil life a l o n g with the c o d e s for other s c h e d u l e d m a i n t e n a n c e Items n e e d i n g s e r v i c e . MAINTENANCE MINDER INDICATOR

INFORMATION DISPLAY

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SEL/RESET K N O B

Service Information 1. T h e r e m a i n i n g e n g i n e oil life o n t h e e n g i n e oil life indicator (A) i s d i s p l a y e d a s a p e r c e n t a g e o n t h e

3.. W h e n t h e r e m a i n i n g e n g i n e oil life i s 1 % to 5 % , the m a i n t e n a n c e m e s s a g e " S E R V I C E " (A) a p p e a r s a l o n g w i t h t h e s a m e m a i n t e n a n c e Item c o d e f s ) , w h e n t h e ignition s w i t c h Is O N (II).

i n f o r m a t i o n d i s p l a y . T o s e e t h e c u r r e n t e n g i n e oil life, turn t h e Ignition s w i t c h to O N III), t h e n p u s h

a n d r e l e a s e t h e S e l e c t / R e s e t k n o b r e p e a t e d l y until t h e e n g i n e oil life is d i s p l a y e d .

Oll_LIFE%

BO 4. W h e n t h e r e m a i n i n g e n g i n e oil life is 0 % , t h e e n g i n e oil life indicator blinks.

T h i s d i s p l a y c o m e s o n w h e n t h e Ignition s w i t c h is O N III). A t t h i s point, t h e Indicated m a i n t e n a n c e 2. W h e n t h e r e m a i n i n g e n g i n e oil life is 6 % to 15 % , t h e e n g i n e oil fife i n d i c a t o r w i l l b e d i s p l a y e d for s e v e r a l s e c o n d s w h e n t h e ignition s w i t c h is OSM (II). T h e m a i n t e n a n c e m i n d e r i n d i c a t o r (A) will a l s o c o m e o n a n d t h e m a i n t e n a n c e item c o d e ( s ) for other s c h e d u l e d maintenance items needing s e r v i c e will a p p e a r in t h e i n f o r m a t i o n d i s p l a y .

must be done a s s o o n a s possible.

SERVICI E A

OILLIFE%

* C o m p l e t e list of m a i n t e n a n c e m a i n i t e m s (B) { s e e p a g e 3-7). * C o m p l e t e list of m a i n t e n a n c e s u b i t e m s (C) ( s e e p a g e 3-8), 5. If t h e I n d i c a t e d m a i n t e n a n c e i s not d o n e , t h e e n g i n e oil life indicator s h o w s a negative m i l e a g e , for e x a m p l e " â&#x20AC;&#x201D; 1 0 " blinking o n t h e d i s p l a y . % n e g a t i v e m i l e a g e will d i s p l a y after t h e v e h i c l e is d r i v e n 10 m i l e s (for U S A m o d e l s ) or 10 k m (for C a n a d a m o d e l s ) after t h e d i s p l a y b e g i n s to blink. T h i s m e a n s that t h e Indicated m a i n t e n a n c e item s h o u l d h a v e b e e n d o n e 10 m i l e s (for U S A m o d e l s ) or 10 k m (for C a n a d a m o d e l s ) a g o .

ÂŁ345

OILLIFE%

.'5

SERVICE I A 1 t

_ 1

i n u

(cont'd)

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Maintenance Minder General Information (cont'd) Resetting the Maintenance Information Display NOTE: â&#x20AC;˘ T h e v e h i c l e m u s t be s t o p p e d to reset. * If the required s e r v i c e is d o n e a n d the d i s p l a y is not r e s e t or if the d i s p l a y is r e s e t w i t h o u t d o i n g t h e s e r v i c e , t h e s y s t e m will not s h o w t h e p r o p e r m a i n t e n a n c e t i m i n g . T h i s c a n lead to s e r i o u s m e c h a n i c a l p r o b l e m s b e c a u s e t h e r e will be no r e c o r d of w h e n m a i n t e n a n c e is n e e d e d .

Resetting Individual IViaintenance Items 1. C o n n e c t t h e H o n d a D i a g n o s t i c S y s t e m ( H D S ) to t h e data Sink c o n n e c t o r ( D L C ) ( s e e s t e p 2 o n p a g e 11-3). 2. T u r n the ignition s w i t c h to O N (II). 3. M a k e s u r e the H D S c o m m u n i c a t e s - w i t h the v e h i c l e a n d the e n g i n e control m o d u l e / p o w e r t r a i n control m o d u l e ( E C M / P C M ) . If it d o e s n ' t c o m m u n i c a t e , t r o u b l e s h o o t the D L C circuit ( s e e p a g e 11-192). 4. S e l e c t G A U G E S in t h e B O D Y E L E C T R I C A L .with the

1. T u r n t h e ignition s w i t c h O N (II).

HDS. 2. If oil life is m o r e t h a n 15 % , p r e s s the S e l e c t / R e s e t k n o b r e p e a t e d l y until t h e e n g i n e oil life is d i s p l a y e d . 3. P r e s s t h e S e l e c t / R e s e t k n o b for a b o u t 10 s e c o n d s . T h e e n g i n e oil life a n d the m a i n t e n a n c e item c o d e ( s ) will blink.

5. S e l e c t A D J U S T M E N T in t h e G A U G E S with the H D S . 6. S e l e c t S E R V I C E R E M I N D E R in the A D J U S T M E N T with the H D S . 7. S e l e c t R E S E T in the S E R V I C E R E M I N D E R with t h e

N O T E : If y o u a r e resetting the d i s p l a y w h e n t h e e n g i n e oil life is m o r e t h a n 15 % , m a k e s u r e t h e m a i n t e n a n c e items requiring s e r v i c e have been d o n e before resetting t h i s d i s p l a y , 4. P r e s s the S e l e c t / R e s e t k n o b for a n o t h e r 5 s e c o n d s . T h e m a i n t e n a n c e item c o d e ( s ) will d i s a p p e a r a n d t h e e n g i n e oil life will r e s e t to " 1 0 0 . "

OILLIFE%

/DO

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HDS. 8. S e l e c t the individual m a i n t e n a n c e item y o u w i s h to reset.

Maintenance Main Items if m e s s a g e " ' S E R V I C E " d o e s not a p p e a r m o r e than 12 m o n t h s after the d i s p l a y Is r e s e t c h a n g e t h e e n g i n e oil e v e r y year. MOTE: • I n d e p e n d e n t of the m a i n t e n a n c e m e s s a g e s In t h e s m a r t m a i n t e n a n c e d i s p l a y , r e p l a c e the brake fluid e v e r y 3 y e a r s . • I n s p e c t idle s p e e d e v e r y 160,000 m i l e s (256,000 km). • A d j u s t the v a l v e s during: s e r v i c e s A , 6 , 1, 2, or 3 if t h e y a r e n o i s y . Maintenance Main Items Symbol R e p l a c e e n g i n e oil ( s e e p a g e 8-9}= A E n g i n e oil c a p a c i t y w i t h o u t oil filter: 4.0 L (4.2 U S qt), B R e p l a c e e n g i n e oil a n d oil filter ( s e e p a g e 8-10). E n g i n e oil c a p a c i t y w i t h oil filter: 4.2 L (4.4 U S qt). • C h e c k front a n d r e a r b r a k e s ( s e e p a g e 19-3). * C h e c k p a d s a n d d i s c s for w e a r ( t h i c k n e s s ) , d a m a g e , a n d c r a c k s . * C h e c k c a l i p e r s for d a m a g e , l e a k s , a n d t i g h t n e s s of m o u n t i n g bolts. C h e c k p a r k i n g brake a d j u s t m e n t ( s e e p a g e 13-7). C h e c k t h e n u m b e r of c l i c k s (7 to 9) w h e n t h e parking brake l e v e r is pulled w i t h 196 N (20 k g i 44 Ibf) of force. I n s p e c t tie-rod e n d s , s t e e r i n g g e a r b o x , a n d g e a r b o x b o o t s ( s e e p a g e 17-3). * C h e c k s t e e r i n g linkage, * C h e c k b o o t s for d a m a g e a n d leaking g r e a s e , * C h e c k fluid l i n e s for d a m a g e or l e a k s . I n s p e c t s u s p e n s i o n c o m p o n e n t s ( s e e p a g e 18-3). * C h e c k bolts for t i g h t n e s s . * C h e c k c o n d i t i o n of ball joint b o o t s for deterioration a n d d a m a g e . i n s p e c t d r i v e s h a f t b o o t s ( s e e p a g e 18-4). C h e c k b o o t s for c r a c k s a n d boot b a n d s for t i g h t n e s s . I n s p e c t b r a k e h o s e s a n d l i n e s Including V S A fines ( s e e p a g e 19-38), C h e c k t h e m a s t e r c y l i n d e r a n d V S A m o d u l a t o r - c o n t r o l unit for d a m a g e a n d l e a k a g e . I n s p e c t all fluid l e v e l s a n d c o n d i t i o n of fluids. * E n g i n e c o o l a n t ( s e e p a g e 10-6) * C l u t c h fluid ( s e e s t e p 2 o n p a g e 12-6) * M a n u a l t r a n s m i s s i o n fluid ( s e e p a g e 13-5) * A u t o m a t i c t r a n s m i s s i o n fluid ( s e e p a g e 14-230) * P o w e r s t e e r i n g fluid ( s e e p a g e 17-14) * B r a k e fluid ( s e e p a g e 19-3) * W i n d s h i e l d w a s h e r fluid ( s e e p a g e 22-296) Inspect exhaust s y s t e m " (see page S-8). C h e c k catalytic c o n v e r t e r heat s h i e l d s , e x h a u s t p i p e s , a n d muffler for d a m a g e , l e a k s , a n d t i g h t n e s s . I n s p e c t fuel l i n e s ( s e e p a g e 11-336) a n d c o n n e c t i o n s * ( s e e p a g e 11-339). C h e c k for l o o s e c o n n e c t i o n s , c r a c k s , a n d deterioration; retighten l o o s e c o n n e c t i o n s a n d r e p l a c e d a m a g e d parts, N O T E : A c c o r d i n g to state a n d f e d e r a l r e g u l a t i o n s , failure to d o t h e m a i n t e n a n c e i t e m s m a r k e d w i t h a n a s t e r i s k ( * ) will n o t v o i d the c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s . H o w e v e r , H o n d a r e c o m m e n d s that all m a i n t e n a n c e s e r v i c e s be d o n e at t h e r e c o m m e n d e d interval, to e n s u r e long-term reliability.

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Maintenance Minder Maintenance Sub Items Nymber 1 2

Maintenance Sub items Rotate t i r e s , a n d c h e c k tire inflation a n d c o n d i t i o n . F o l l o w t h e pattern s h o w n in the O w n e r ' s M a n u a l . R e p l a c e air c l e a n e r e l e m e n t ( s e e p a g e 11-360). If the v e h i c l e is d r i v e n p r i m a r i l y in d u s t y c o n d i t i o n s , r e p l a c e e v e r y 15,000 m i l e s (24,000 km). R e p l a c e d u s t a n d pollen filter ( s e e p a g e 21-77). * If the v e h i c l e is d r i v e n m o s t l y in a r e a s that h a v e high c o n c e n t r a t i o n s of d u s t , p o l l e n , or s o o t in t h e air, r e p l a c e e v e r y 15,000 m i l e s (24,000 k m ) . * R e p l a c e the filter w h e n e v e r a i r f l o w f r o m the heating a n d air c o n d i t i o n i n g - s y s t e m Is l e s s t h a n n o r m a l . Inspect d r i v e belt ( s e e p a g e 4-29). • •

Look for c r a c k s a n d d a m a g e , t h e n c h e c k t h e position of the d r i v e belt a u t o - t e n s l o n e r indicator. R e p l a c e m a n u a l t r a n s m i s s i o n fluid ( s e e page-13-5) C a p a c i t y : 1.9 L (2.0 U S qt); u s e H o n d a M T F , R e p l a c e a u t o m a t i c t r a n s m i s s i o n fluid ( s e e p a g e 14-231) • C a p a c i t y : 2.5 L (2.6 U S qt); u s e H o n d a A T F - 2 1 . * Driving In m o u n t a i n o u s a r e a s at v e r y l o w v e h i c l e s p e e d s r e s u l t s in h i g h e r t r a n s m i s s i o n t e m p e r a t u r e s . T h i s r e q u i r e s t r a n s m i s s i o n fluid c h a n g e s m o r e f r e q u e n t l y t h a n r e c o m m e n d e d by the m a i n t e n a n c e m i n d e r . If t h e v e h i c l e Is r e g u l a r l y d r i v e n u n d e r t h e s e c o n d i t i o n s , c h a n g e t h e t r a n s m i s s i o n fluid at 60,000 m i l e s (100,000 k m ) , t h e n e v e r y 30,000 m i l e s (48,000 km).

R e p l a c e s p a r k p l u g s ( s e e p a g e 4-20). • U s e I L Z K R 7 B - 1 1 S ( N G K ) or 3 X U 2 2 H C R 1 1 3 ( D E N S O ) for all m o d e l s e x c e p t P Z E V . * U s e D I L Z K R 7 A 1 1 G S ( N G K ) for P Z E V . I n s p e c t v a l v e c l e a r a n c e (cold) ( s e e p a g e 6-9). Intake: 0 , 2 1 - 0 . 2 5 m m ( 0 . 0 0 8 - 0 . 0 1 0 in.), E x h a u s t : 0 . 2 5 - 0 . 2 9 m m (0.010—0.011 in.). R e p l a c e e n g i n e c o o l a n t ( s e e p a g e 10-6). • C a p a c i t y (Including r e s e r v o s r / D E N S O ) : • M/T 6.1 LC1.61 U S gal) * A / T 6,0 L (1.59 U S gal) C a p a c i t y (Including r e s e r v e ! r / T R A D ) : • M/T 6.0 L (1.59 U S gal) * A / T 5.9 L (1.56 U S gal) U s e H o n d a L o n g Life A n t i f r e e z e / C o o l a n t T y p e 2, a n d a d d H o n d a E x t r e m e C o l d W e a t h e r A n t i f r e e z e / C o o l a n t T y p e 2 in s e v e r e c o l d t e m p e r a t u r e .

3-8

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) fif engine electrical maintenance is required) T h e A c c o r d S R S i n c l u d e s a d r i v e r ' s a i r b a g in the s t e e r i n g w h e e l h u b , a p a s s e n g e r ' s a i r b a g in t h e d a s h b o a r d a b o v e the g l o v e box, s e a t belt t e n s s o n e r s in t h e front s e a t belt retractors, s i d e curtain a i r b a g s in t h e s i d e s of t h e roof, a n d s i d e a i r b a g s in the front s e a t - b a c k s . Information n e c e s s a r y to s a f e l y s e r v i c e t h e S R S is i n c l u d e d in t h i s S e r v i c e M a n u a l . I t e m s m a r k e d with a n a s t e r i s k ( * ) o n t h e c o n t e n t s p a g e i n c l u d e or a r e l o c a t e d n e a r S R S c o m p o n e n t s . S e r v i c i n g , d i s a s s e m b l i n g , or r e p l a c i n g t h e s e i t e m s r e q u i r e s s p e c i a l p r e c a u t i o n s a n d t o o l s , a n d s h o u l d be d o n e by a n a u t h o r i z e d Honda dealer.

• T o a v o i d r e n d e r i n g the S R S i n o p e r a t i v e , w h i c h c o u l d lead to p e r s o n a l injury or d e a t h in the e v e n t of a s e v e r e frontal or s i d e c o l l i s i o n , all S R S s e r v i c e w o r k s h o u l d be d o n e by a n a u t h o r i z e d H o n d a d e a l e r . • I m p r o p e r s e r v i c e p r o c e d u r e s , i n c l u d i n g Incorrect r e m o v a l a n d installation of the S R S , c o u l d l e a d to p e r s o n a l injury c a u s e d by unintentional d e p l o y m e n t of the a i r b a g s , s i d e a i r b a g s , a n d / o r s i d e curtain a i r b a g s . • Do not b u m p or I m p a c t t h e S R S unit, front I m p a c t s e n s o r s , s i d e I m p a c t s e n s o r s , or rear s a f l n g s e n s o r w h e n t h e ignition s w i t c h Is In O N (II), or for at l e a s t 3 m i n u t e s after the Ignition s w i t c h is t u r n e d to L O C K (0); o t h e r w i s e , the s y s t e m m a y fall In a c o l l i s i o n , or the a i r b a g s m a y d e p l o y . • S R S electrical c o n n e c t o r s a r e identified by y e l l o w c o l o r c o d i n g . R e l a t e d c o m p o n e n t s a r e l o c a t e d In the s t e e r i n g c o l u m n , front c o n s o l e , d a s h b o a r d , d a s h b o a r d l o w e r p a n e l , In the d a s h b o a r d a b o v e t h e g l o v e b o x , In the front s e a t s , in the roof s i d e , a n d a r o u n d the floor. Do not u s e electrical test e q u i p m e n t o n t h e s e c i r c u i t s .

Engine Electrical Engine Electrical S p e c i a l T o o l s ............................ 4-2

Starting System C o m p o n e n t Location Index .... S y m p t o m Troubleshooting Index ...................................... Circuit Diagram ........................ Starter S y s t e m Circuit Troubleshooting ................... Clutch Interlock S w i t c h T e s t ... Starter Performance T e s t ........ Starter R e m o v a l a n d Installation ............................ Starter O v e r h a u l ......................

4-3 4-4 4-5 4-7 4-9 4-10 4-11 4-12

4-17 4-18 4-19 4-20 4-20

Charging System C o m p o n e n t Location Index .... Symptom; Troubleshooting Index ..................................... Circuit Diagram ........................ C h a r g i n g S y s t e m Indicator Circuit Troubleshooting ....... Alternator a n d Regulator Circuit Troubleshooting .......

8Bao(aa88

aBa88BS

Cruise Control

Ignition System C o m p o n e n t Location Index ...Â» Circuit Diagram ........................ Ignition T i m i n g Inspection ...... Ignition Coil R e m o v a l / Installation Spark Plug Inspection ..............

Alternator Control Circuit Troubleshooting ....... 4-28 Drive Belt Inspection ............... 4-29 Drive Belt R e m o v a l / Installation ............................ 4-30 Drive Belt Auto-tensioner Inspection ...... , 4-30 Drive Belt Auto-tensioner Removal/installation ............ 4-31 T e n s i o n e r Pulley Replacement ........ ........... 4-32 Alternator R e m o v a l and Installation ...................... 4-32 Alternator Overhaul ................. 4-34

4-22 4-23 4-24 4-25 4-27

C o m p o n e n t Location Index .... S y m p t o m Troubleshooting Index ........ ...... Circuit Diagram * ....... Cruise Control Input T e s t ........ * Cruise Control Combination Switch T e s t / R e p l a c e m e n t .... Clutch Pedal Position Switch T e s t ...........................

4-39 4-40 4-42 4-43 4-45 4-45

Engine Mount Control System C o m p o n e n t Location Index .... 4-46 Circuit Diagram .............. . 4-47 Troubleshooting ...................... 4-48

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