Maintenance Lubrication Points MaintenanceSchedule (NormalConditions) MaintenanceSchedule (SevereGonditions)
............4-z ......4-4 ......4-6
LubricationPoints Forthe detailsof lubricationpointsand type of lubricantsto be applied,referto the illustratedindexand variouswork Drocedure(suchas Assembly/Reassembly, Replacement, Overhaul,Installation. etc.)containedin eachsection,
No.
LUBRICAnON POINTS
1
E^g,ne
2
Transmission
LUBRICANT API ServiceGrade:UseSJ "EnergyConserving"or SH "EnergyConservingll" gradeoil, The oil containermay alsodisplaythe API Certification mark shownbelow.Makesure it savs"For Gasoline " Engines. SAEViscositv:Seechartbelow.
Manual
HondaGenuineMTF*1
Automatic
GenuineHondaPremiumFormulaAutomatic TransmissionFluid(ATF)*,
Brakeline (lncludesAnti-lockbrakeline)
GenuineHondaDOT3BrakeFluid13
Clutchline
GenuineHondaDOT3BrakeFluid*3 Steering greaseP/N 08733- 8070E
Powersteeringgearbox 1 8 o
10 11
14
Release fork lManualtransmission) Throttlewire end (Dashboardlower oanelhole) Cruisecontrolactuatorwire end (Dashboardlower Danelhole) Throttlecableend (Throttlelink) Cruisecontrolactuatorcableend (Actuatorlink) Brakemastercvlinderoushrod Clutchmastercylinderpushrod Batteryterminals Fuelfill lid
Supâ‚ŹrHighTemp UreaGrease(P/N08798- 9002) Siliconegrease
Multi-purposegrease
L
17 18
Engin6hood hingesand enginehood latch Hatchhinges8od latchor trunk hingesand latch Door hjnges,upperand lower Door ooen detent
HondaWhite LithiumGrease
to
19
Rearb.akecalipers
Siliconegrease
20
Power steeringsystem
21
Ai|'conditioningcompressor
GenuineHondaPowerSteeringFluid-Vor S*. - PR7- A01AHor Refrigerant oii ND-O|L8{P/N38897 38899-PR7-A01) (ForRefrigerant: (R-134a)) HFC-134a
API SERVICELABEL
r (
(
API CERTIFICATION SEAL
Recommended engineoil Enginâ‚Źoil viscositylor ambrentlemperatureranges
*1: Always use GenuineHonda ManualTransmissionFluid (MTF). Using motor oil can causestiffershifting becauseit does not containthe properaddtuves. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF). Usinga non-HondaATF can affect shift quality. *3: Always use GenuineHondaDOT3 B.akeFluid,Usinga non-Hondabrakefluid can causecorrosionand decreasethe life of the system. '4: Always use GenuineHondaPower SteeringFluid-Vor S. Using any other type of power steeringfluid or automatic transmissionfluid can causeincreasev,/earand poor steeringin cold weather.
4-2
{
at at
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* \-_-.-
il/
.
_
NOTE: Lubricateall hinges.latches,and locksonce a year. ln corrosiveareas,more frequent lubricationis necessary. We recommendHondaWhiteLithiumGrease.
4-3 )
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4-7
r a Engine E n g i n eR e m o v a l / l n s t a l l a t i o. .n. . . . . . . . . . .5 - 1 C y l i n d eH r e a d / V a l vTer a i n . . . . . . . . . . . . . 6 . .- 1 E n g i n eB l o c k. . . . . . . . . ........7-1 E n g i n eL u b r i c a t i o n .........8-1 I n t a k eM a n i f o l d / E x h a u S s ty s t e m . . . . . . 9 - 1 . . . . . . .1 0 - 1 Cooling
\-a EngineRemoval/lnstallation Tools.......... ...........5-2 Speciaf ................ EngineRemovaUlnstallation 5-3 Mount/Bracket Torque ....5-17
)
SpecialTools
Rel.No. I
o
Tool Number 07MAC- SL00200
Description BallJoint Remover,28 mm
Oty ,l
I
PageReterence 5 10
L
EngineRemoval/lnstallation 2.
Removethe strut brace.
Make sure iacks and safety stands ate placed plopelly and hoist brackets are attached to the correct positionson the engine{see section 11, Makesurethe car will not rollolt standsand latl while you are wgrking under it.
8 x 1.25mm 24 N.m {2.4 kgf.m, 17 tbf.tt)
CAUTION: . Use fender covers to avoid damaging painted surfaces. Unplugthe wiring connectorscarelullywhile holding the couplerand the connectorportionto avoid d8mage. Mark all wiring and hosesto avoid misconnection. Also. be sure that they do not contact other wiring or hoses,or intedere with other parts. NOTE:Anti-theftradioshavea codedtheft protectioncircuit.Be sureto get the customer'scodenumberbetore - Disconnecting the battery. - R e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox. Removingthe radio After service,reconnectpower to the radio and turn it on. When the word "CODE"is displayed,enterthe cus tomer's5-digitcodeto restoreradiooperation. 1.
Removethe hood (seesection20).
STRUTBRACE
3.
Disconnectthe batterynegativeterminalfirst, then t h e p o s i t i v et e r m i n a l . Disconnectthe batterycablesIrom the under-hood Iuse/relaybox and under hood ABS {use/relaybox.
BAITERY CABLES
6x1.0mm 9.8 N.'4 (1.0 kgf.m, 7.2 rbf.ft)
(cont'dl
5-3
Engine Removal/l nstallation (cont'dl R e m o v et h e i n t a k ea i r d u c t , a i r c l e a n e rh o u s i n g assemblyand the bracket.
7.
Removethe brake boostervacuum hose,evaporative emission(EVAP)controlcanisterhose and tuel returnhose(818C5engine).
6 r 't.0 mm 9.8 N.m (1.0 kgt.m,7.2 lbf.ft)
R e m o v et h e e v a p o r a t i v e m i s s i o n{ E V A P c) o n t r o l c a n i s t ehr o s e( B1 8 B 1B , ' 1 8 Ce1n g ; n e s ) .
Removethe enginewire harnessconnectorson the right side of enginecompartment.
6 x 1.0 mm 9 . 8 N . m l 1 . Ok g l . m ,
\
5-4
EngineRamoval/lnstallation (cont'dl 13. Removethe enginewire harnessconnectors,terminal and clampson the left side ot enginecompanmenr,
6 x 1.0 mm 9.8 N.m 11.0 kgl.m, 7.2 tbt.ttl
1 5 . Removethe enginegroundcableat the body end. to.
l.
Removethe adjustingbolt and mountingbolts,then r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d pump. . Do not disconnectthe P/Shoses.
I I
MOUNTING BOLTS I x 1.25mm 24 N.m 12.4 kgt'm, 17 lbl.ft)
14. Removethe cruisecontrolactuator.
't7. Loosen the
idler pulley bolt and adjusting bolt, then remove the air conditioning (Ay'C)compressor belt.
I x 1.25mm 24 N.m 12.4 kgt.m, 17 tbt.ft)
IDLERPULLEYBOLT 10 x 1.25mm /14 N'm 14.5 kgf.m, 33 lbt'frl
A/C COMPRESSOREELT
\
5-6
EngineRemoval/lnstallation (cont'd) 26. Removethe upperand lower radiatorhosesand the heaterhoses.
27. lAutomatic transmission)Removethe ATF cooler hoses.
81881,B18C5engines: UPPERRADIATOR
..f.
c
,1 i r
HOSES
LOWCRRADIATOR HOSE
24. Removethe radiatorassembly(seepage10-5). HEATER HOSE
29. Removethe A,/Ccompressor. . Do not disconnectAy'Choses.
HEATER HOSE LOWERRADIATOR HOSE ,
5-8
UPPER RADIAToR HOSE
8 x 1.25mm 24 N.rn 12.4 kgl.m, 17 lbf.ft)
t
7
30. D i s c o n n e ctth e p r i m a r yh e a t e do x y g e n s e n s o r ( P r i m a r yH O 2 S )c o n n e c t o rt,h e n r e m o v ee x h a u s t pipeA.
31. Remove the shift rod and extension rod {Mff).
PRIMARY HO2S
818C1engine:
8 x 1.25mm 22 N'm 12.2 kgl.m, '16 lbt.ttl
SHIFTROD
8 x 1.25mm 24 N.m 12.4 kgl.m. t7 rbt.ftt Replace.
GASKET Replace.
RETAINER
Replace.
SELF-LOCKING I{UT 8 r 1.25mm 1 6 N . m ( 1. 6 k g f. m , 12 tbt.frt Beplace.
EXHAUST PIPEA NUT 10 x 1.25mm 54 N.m {5.5 kgt'.n, tlo lbt.ft} Replace.
32. Remove the shift cable (A,/T).
I x 1.25mm 22 N-l'. 12.2 kgl.m, 16 lbf.frl
81881,818C5engines:
SHIFT CABLE
PRIMARY HO25 CONNECTOF 8 x 1.25mm 24 N.m (2.4 kgt.m, 17 lbf.frl Replace.
GASKET Replace.
CONTROL LEVER
GASKET Replace. NUT Sâ&#x201A;¬LF.LOCKING 8 x 1.25mm 16 N.m (1.6kgf'm, 12 tbt.fr) Replace.
f{UT 10 x 1.25 mm 54 N.m {5.5 kgf'm, 40 lbf.ftl Replace.
SHIFT CABLE COVER LOCK WASHER
6 x 'l.O mm 14 N.m {1.4 kgf.m, 10 lbt.ft}
{cont'd)
5-9
EngineRemoval/lnstallation (cont'dl Removethe damper{ork. 34. D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s '18 u s i n gt h e s p e c i a tl o o l . R e f e rt o s e c t i o n f o r t h e properprocedure. N O T E :A d j u s tt h e t o o l s o t h e j a w s a r e p a r a l l etl o eachother.
35. Removethe driveshafts. CAUTION: . Do not pull on the driveshaft,the CV joint may come aoart. . Use care when prying out the assembly. Pull it straight to avoid damaging the differential oil seal or intermediate shaft dust seal. N O T E :C o a t a l l p r e c i s i o nI i n i s h e ds u r f a c e sw i t h c l e a ne n o i n eo i l .
DRIVESHAFT
/.-:
/
,{:
12 x 1.25mm
\
5-jl0
EngineRemoval/lnstallation (cont'dl Enginelnstallation Installtheenginein the reverseorderof removal R e i n s t a l lt h e m o u n t b o l t s / n u t si n t h e f o l l o w i n g sequence.Failureto follow theseproceduresmay cause excessivenoiseand vibration,and reducebushinglife
2.
I n s t a l tl h e e n g i n es i d e m o u n t , t h e n t i g h t e n t h e bolvnutson the engtneside.Leavethe mount bolt toose. 1 0 x 1 . 2 5m m 52 N.m 15.3 kgf.m, 38 tbf.ft, Replace.
1 . I n s t a l lt h e t r a n s m i s s i o nm o u n t , t h e n t i g h t e n t h e bolvnutson the tfansmlssionside.Leavethe mount bolt loose. AIT: ' 1 2x 1 . 2 5 m m g N.m (6.5 kgl'm. 47 thl.ftl
o
/
llf
3,
Tightenthe mount bolt on the transmissionmount.
AIf l MOUNT EOLT
L 1 2 x 1 . 2 5m m 64 N.m {6.5 kgf.m, 47 lbf.fr|
12 x 1.25mm 74 N.m 17.5 kgl.m, 54 rbf.ftl
M/T:
I
1 2 x 1 . 2 5m m 74 N.m (7.5 kgl.m, 54 rbf.ftl
I
5- 1 4
\
{
EngineRemoval/lnstallation {cont'dl 7.
Installthe left front mount,then tightenthe bolts in the numberedsequenceshown (O - @).
.
C h e c kt h a t t h e s p r i n g c l i p o n t h e e n d o f e a c h driveshaftclicksinto place.
CAUTION: Use new spring clips. . ' 1 . 2 5m m O t2 x 83 N.m 18.5kgt.m,61 lbl.ft) Fleplace.
. . . .
@ 12 x 1.25mm 59 N.m 16.0 kgf.m, 43 lbf.frl Replace.
O 1 0 x 1 . 2 5m m
il4 N.m 14.5 kgt'm,33 lbt.ft)
,5-16
!
Bleed air {rom the cooling system at the heater valveopen (seepage10-6). Adjustthe throttlecable(seesection11). Checkthe clutchpedalfreeplay (seesection12). C h e c kt h a t t h e t r a n s m i s s i o ns h i f t s i n t o g e a r smoothlY. Adjust the tension of the following drive belts. Alternatorbelt {seesection23). P/Spump belt (seesection171. A/CcomDressor belt (seesection22). Inspectfor tuel leakage(seesection1ll. . After assemblingfuel line parts,turn on the ignitionswitch (do not operatethe staner)so that the fuel pump operatesfor approximately t w o s e c o n d sa n d t h e f u e l l i n e p r e s s u r i z e s . Repeatthis operationtwo or three times and checkfor tuel leakageat any point in the {uel line.
I Mount/BracketTorque (cont'dl ( 818C5engine: ALTERNATORBRACKET
REARSTIFFENER
1 0 r 1 . 2 5m m
--q;;/44N'mtr.5kst'm'
v=ahp /
12 x 1.25mm 57 N.m {5.8 kgf.m, 42 tbt'trt
w# q7 24 N.m 12.4 kgl.m, 17 rbf'ftt
t: ltri rH {ir \
I
10 x 1.25mm 54 N.m 15.5 kgf.m. 40 rbt.frl
P/S PUMP BRACKET 10x 1.25mm
;
/r/rN.m {4.5 kgf.m, 33 lbtftl
FRONTSTIFFENER A/C COMPRESSORBRACKET
HEAr
6\---
d'1N
^rNsuLAroR
I "--H Gh\ \
sxrlomm
*o-r$l/ v
12 N.m 11.2kgf.m. 8.7 tbf.ftt I x'1.25mm 24 N.m (2.4 kgf'm, 17 rbf.ft)
12 x 1.25mm 57 N.m 15.8kgt.m, 42 lbf.ftt
ValveClearance Adjustment
r.lJ
NOTE: . V a l v e ss h o u l db e a d j u s t e dc o l d ; a t a c y l i n d e rh e a d temperatureof lessthan 100'F(38"C). Adjustmentis the same for both intakeand exhaust valves. . After adjusting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgf.m,130lbf'ft).
2.
1.
Number1 pistonat TDC:
Removecylinderheadcover.
Set the No. 1 piston at top dead center(TDC)(see p a g e6 - 1 2 ) ". U P " m a r k o n t h e p u l l e ys h o u l db e a t the top, and the TDC grooveson the pulley should align with the TDCgroove on timing belt back cover.TDC mark (paintedwhite) on the crankshaft pulley should align with pointeron the timing belt lower cover.
ADJUSTINGSCREWLOCATIONS:
"UP" MARKS
TDCGBOOVES
( EXHAUST
POINTERON LOWER
TDC MAFK (P.inted whh.l
(cont'd)
6-3
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