ACUrj|A
INTEGFIF| Service Manual 1994
INTRODUCTION How to Use This Manual This manualis dividedinto 23 sections.The first pageof each section is markedwith a blacktab that linesup with its corresponding thumb indextab on this page and the back cover. You can quickly tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The svmbolsprintedat the top cornerof each page can also be used as a quick referencesystem. Each section includes: 1. A table of contents.or an explodedview index showing: a Partsdisassemblvsequence. a Bolt toroues and thread sizes. a Pagereferencesto descriptionsin text. proceduresand tools. 2. Disassemblv/assembly 3. InsDection. 4. Testing/troubleshooting. 5. Repair. 6. Adiustments.
Specifications
trtl:{lt'
M a i n te n a n c e
4Pi
Engine
H
I-""
SpecialInformation lnai""tes a strong possibility of sevor€ pelsonal iniury @ 01 loss of life it instructions al€ not tollowed. CAUTION: Indicates a possibility ot personal inlury or oquipmont damage if instructions ale not followed. NOTE: Gives helpful information. CAUTfON: Detaifeddoscriptionsot standad workshop procedures, salety principlosand servicaopelationsare not included Pleasonote that this manual conlains warnings and cautions against somo spocific sgrvice methods which could cause PERSONALINJURY, damage a vehicle or make it unsafe. Pleasounderstandthat those warnings cannot cover all conceivablcwaYs in which service, whetheaor not recommended bv HONDA, might be done, or of the possibla hazardous consequences of svery conceivable way, nor could HONDA investigateall such ways. Anyone using seryice plocedures or toofa, whethor 01 not recomondedby HONDA, ,nust sttisfY himsett thoroughly that neither personal saf€ty nor v€hicle safety will be jaopaldized. All informationcontainedin this manualis basedon the latest product informationavailableat the time of printing.We reservethe right to makechangesat any time without notice.No part of this publication mav be reproduced,storedin retrievalsystem, or transmitted, in any Jorm by any means,electronic,mechanical,photocopying, recording,or otherwise,without the priorwritten permissionof the publisher.This includestest. figures and tables.
Fueland Emissions Za *Transaxle * Ste e ri n g
r-\
* Brakes
o
(lncludins !TEg)
l D l \.t/
HONDA MOTORCO.,LTD, 1448 pages First Edition7/93 Service Publication ottice All Rights Reserved and Canada Apply to U.S.A. Specifications
*Electrical As sections with r includ€ SRS components. special precautions are lequiled when servicing.
(lncludins ISBE)
J--*
, ,
SUPPLEMENTAL RESTRAINT SYSTEM(SRS} The IntegraSRSincludesa driver's airbag,locatedin the steeringwheel hub. ln addition,all mod€lsexcepi tna Rs modelfor canada have a front passenger'sairbsglocatedin the dashboardabovethe glove box, InformaUon necessaryto safely servicethe SRSis includedin this servica Manual.ltems markedwith an sstorisk(r) on thr contents page include,or are locatednear, SRScomponents.Servicing.disassemblingor roplacingthea6 ltems will requirespecialprecautionsand tools, and shouldthoreiore be done by an authorhed Acura dealer. ' To avoid ronderingths sRS inoporativo,which could lard to porronll Injury or darth In thc cvant ot. r.yr. trontal collision, all sRs sorvico work must be pcrformcd by !n ruthorizcd Acu.! daerrr, ' lmpTopor3orvica proceduroa,including inco.roct r.movd r d Installation of tha SRS,could Lld to pc[onc Inlury caussd by unintsntionalactivationot tho airbags. ' All sRs oloctrical wiring harnoa$! aro coverod with yallow In3ulatlon, Rcbtcd componcnts arc bcrtad In tha stoeringGolumn,front console,dsrhboa.d,and darhboardlowor plnol, lnd in thc d$hbolrd abovc tha gaov! bor. Do not uas oloctdcalte$ oquipmonton thaaa citcuhs. NoTE: The originalradiohas a codedthett protectioncircuit. Be sureto get the customer'scode numb6r b€lore * disconnecting the battery. - removingthe No. 32 (7.S A) fuse Jromthe undsr-hood fuse/relaybox. - removingthe radio. After service,reconnectpowerto the radioandturn it on. Whenthe word ,,CODE,,is displayed, enterthe cus_ tomer's 5-digit code to restoreradio oDerauon.
GeneralInformation Chassisand PaintCodes ldentificationNumberLocations Warning/CautionLabelLocations Lift and SupportPoints Lift FloorJack Safety Stands Towing
1-2 1-4 1-5 1-9 1-10 1 - 11 1-12
I
Chassisand PaintCodes U.S.Model
VehicleldentificationNumber
EngineNumber
JH4DB754*RSOOOOO 1
8 l 8 B r ------T----r300@l
Manutactulol, Make and Typ€ of Vshicle J H 4 : H O N D AM O T O RC O . ,L T D . ACURAPsssenger car Line, Body and EnginoType
Engine Typ6
DB7:INTEGRA 4-door/B1 881 DB8:INTEGRA 4-door/81 8Cl DC2:INTEGRA 3-door/B18C 1 DC4:INTEGRA 3-door/B1 8Bj BodyType and Trsnsmission Type 3: 2-doorHatchbackS-speedManual 4: 2-doot Hatchback4-speed Automatic 5; 4-doorSedans-speedManual 6: 4-doorSedan4-speedAutomatic
Se al Numbel
81881: 1.8 f DOHCSequentiat Muhi-pori Fuel-injectedengine B l8Cl : 1.8 | DOHCVTECSequ€nrial Multi-port Fu€l-iniected€ngin€
Transmission Numbsr Y80- 1000@ I
Transmission Type Y80: Manual MPTA:Automatic
Vehicle Glado (Seriesl 4: RS 5: LS 8; GS-R
Serial Numbel
Check Digit Model Yaal R: 1994 Factory Code S: SuzukaFactoryin Japan
Paint Code
COLOR BG.33P
Serial Numb€l
Vehicleld€ntification Numberand FederalMotor VehicleSafety StandardCertification 3DOOR
1-2
4DOOR
PaintCode PaintCode BG.33P G-71P NH-5O3P NH-538 NH-575M R-72P R-81 RP.24P YR.5O3M
Color ParadiseBlue-g.€enPeErl LausanneGr6enPead GrsnadaBlack Pea.l Frost White ThunderGrav Metallic Torino Red Pearl MilanoRed Stealth Gray Pearl RosewoodBrown M€tallic
CanadaModel EngineNumber
VehicleldentificationNumbel
8 1 8 8 1 - 17 0 0 0 0 1
JH4DB753.RS800001
Engin€Type Multi-port 81881: 1.8 I DOHCSequential Fuel-injectedengine B 1 8 C 1 :1 . 8 I D O H CV T E CS e q u e n t i a l engrne Multi-DortFuel-iniected
Manutacturer,Makeand Type of v€hicle JH4: HONDAMOTORCO., LTD. car ACURAPassenger Lino. Body and EngineTYPo 4-doot/Bl881 D87: INTEGRA DC2:INTEGRA3-dootBl 8C1 3-dooriB18B1 DC4:INTEGRA Body Type and TransmissionTYPo 3: 2-doorHatchback5-speedManual 4'. 2-doorHatchback4-speed Automatic 5: 4-doorSedans-speedManual 6: 4-doorSedan4-speedAutomatic VehicleGrade{Sedes} SRSairbag 3: RS without passenger 4: RS with passengetSRSaitbag
SerialNumber
Number Transmission Y80-1000001
Type Transmission Y80: Manual MPTA:Automatic SerialNumbel
8: GS-R Check Digit Model Yeat R: 1994 FactoryCode S: SuzukaFactoryin Japan
Paint Code
COLOR BG.33P
Serial Numbel
Numberand Vehicleldentification CanadianMotor Vehicle Safety Standard Certification 3DOOR
4DOOR
Paint Code PaintCode BG.33P G-71P NH-5O3P NH-538 NH-575M R-72P R-81 RP-24P YR-503M
Color Pearl ParadiseBlue-green LausanneGreenPearl GranadaElackPearl Frost White ThunderGrayMetallic TorinoRedPearl MilanoRed StealthGrayPearl RosewoodBrown Metallic
1-3
II I
ldentificationNumberLocations
Vehicle ldontification NumberlvlNl
v.hiclo ldontificalion Numb€rlVlNl
S
Transmbsion Numbor lAuromatic)
Transmissioh l\lumbor lManuall
1-4
LabelLocations Warning/Caution
A: CABLEREALCAUTIONA MANUALFORDETAII'fDINSTRUCTION SERVICE BEFERTO-
B: CABLEBEALCAUTIONB REFERTOSERVICEMAI{UAL FOROETAILEDINSTRUCTION WHEEL OTICE C: STEERII{G
]{OT|CE ORINSTALLATION WIIEELREMOVAL STEERII{G IMPROPEB DAMAGESRSCOMPONENT. CAREFULLY. MANUALINSTRUCTION FOLLOWSERVICE D: DRIVERINFLATORWAR[{|NGTAG WARNII{G AND POSSIBLE D€PLOYMENT TO PflEVE T ACCIDE]TTAL
INJURY: SHORTCOI{NECTOR ALWAYSII{STALLTHEPNOTECTIVE IS WHENTHEHARNESS COI{I{ECTOR O THEINFLATOR DISCONNECTED.
MODULEDANG€R E: DRIVER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITHACID,WATERORHEAVYMETALSSUCH HARM. MAY PRODUCE LEADOR MERCURY AS COPPER, FUL AND IRFITATINGGASES OR EXPLOSIVECOM. POUNDS. MUST NOT EXCEED2OOOF STORAGET€MPERATURES (1OOOCI. HANDLING.STORAGEAND DISFORPROPER TO THE SERVICEMANUAL, REFER POSALPROCEDURES SRSSUPPLEMEf{T. POTSON SODIUMAZIDEANDPOTASSIUM POISONOUS CONTAINS I{ITRATE. FIRSTAID IF CONTENTSARESWALLOWED,INDUCEVOMITING. FOR EYE CONTACT, FLUSH EYES WITH U'ATER 15 MINUTES.IF GASESIFROMACIDORWATERCONTACT} ARE INHALED.SEEKFRESHAIR. IN EVERYCASE, GET PROMPTMEDICALATTENTION. KEEPOUT OF REACHOF CHILDREN F: DRIVERMODULEWARNING A, WABNING AND' IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE I{URTOR KILLYOU. TALLYDEPIOYED,CAN SERIOUSLY ORPROBTESTEOUIPMEI'IT . DO NOTUSEELECTRICAL ING DEVICES. OEPLOYMENT. THEYCAN CAUSEACCIOENTAL PARTS INSIOE,DO NOT DISAS. . NO SERVICEABLE SEMALE. . PLACEAIRBAGUPRIGXTWHENREMOVED' . FOLLOW SERVICEMANUAL II{STRUCTIONS CAREFULLY.
(cont'd)
1-5
Warning/CautionLabel Locations (cont'd)
G: DBIVEBTNFORMATTON {SUNV|SORt
G: DBIVEBINFORMATTON {SUNvtSORt. ALWAYS WEARYOUNSCIT EELT C.Ai IS EOUIPPEDWITH A DRIVERAIRBAG ANO A_FRo_NTSEAT pASSENGERnrnslc nNo e raoNi SEATPASSENGER AIRBAGAS A SUPPIEMENTALBES. TRAINT SYSTEM {SBSI
ro suppLEMENr rHEsEArBEt-r. Lr_ll^gls_lglls .: BEFoRE oRrvrNG, ReeoL.qsetmsiDrrxE GLovEBox.
1-6
rThis vo.3ion ot tho lsb€l i! us6d in csrs wtth a,ront soat paas€ngor'sairbag.
J: GLOVEBOX INFORMATIOf{ AIBBAGINFORMANO RESTiAINTSYSTEM(SRS) SUPPLEMENTAL TEN YEARSAFTERIT . THE SRSMUST BE INSPECTED IS SHOWN TI{EDATEOFINSTALLATION IS INSTALLED. PLATE,LOCATEDON THE ON THE CERTTFICATION DOORJAMB. DRIVER'S OF SNS . DIAGNOSTICCHECKSAND REPLACEMENT MUST BE DONEBY AN AUTHORIZED COMPONENTS DEALER . SEEYOUROWNER'SMANUALFORAODITIONALSRS INFORMATION. INFLATORWARNINGTAG K: FRONTSEATPASSENGER A WARNING CAN SERIOUSLY ACCIDENTALAIRBAG DEPLOYMENT HURTOR KILLYOU. WHENTHE INCONNECTOR INSTALLTHE REDSERVICE FLATORHARNESSIS DISCONNECTED MODULEDANGER L: FRONTSEATPASSENGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITHACID,WATERORHEAVYMETALSSUCH HARM' MAY PRODUCE LEADOR MERCURY AS COPPER. FUL AND IRRITATINGGASES OR EXPLOSIVECOM. POUNDS. MUST NOT EXCEED2OOOF STORGETEMPERATURES AND DISSTORAG€ HANDLIING, tlOO"CI.FOBPROPER MANUAL, REF€BTO THESERVICE POSALPROCEDURES SBS SUPPLEMENT. POTSON SODIUMAZIOEAND POTASSIUM CONTAI'\'SPOISONOUS NITRATE. FIRSTAID INDUCEVOMITING. IF CONTENTSARESWALLOWED, FOREYECONTACT,FLUSHEYESWITH WATERFOR15 MINUTES. IF GASES(FROMACID OR WATERCONTACT)ARE IN. HALED,SEEKFRESHAIR. IN EVERYCASE.GETPROMPT ATTENTION. MEDICAL KEEPOUT OF REACI.IOF CHILDREN.
M: AIRBAGLABEL AIRBAG HOODI N: SRSWARNINGIENGINE SYSTEM(SBSI RESTRAINT SUPPLEMENTAL WITH DRIVERSIDEAIRBAG. THISVEHICLEIS EOUIPPED ARE WIRINGAND CONNECTORS ALL SRS ELECTRICAL YELLOW. COLORED ORUSINGELECTRIWITH,DISCONNECTING TAMPERING ON TI{E SRSWIRINGCAN MAKE CAL TESTEOUIPMENT FIR' OB CAUSEACCIOENTAL THESYSTEMINOPERATIVE ING OF THE INFLATOR. A. WANING AND, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE HURTYOU' CAf{ SERIOUSLY TALLY DEPLOYED, CAREFULLY. MANUALINSTRUCTIONS FOLLOWSERVICE HOODIi N: SRSWARNINGIENGINE SYSTEM{SRSI RESTRAINT SUPPLEMENTAL WITH DRIVERANO FRONT THIS VEI{ICLEIS EOUIPPED AIRBAGS. SEATPASSENGER ARE WIRINGAND CONNECTORS ALL SRS ELECTRICAL YELLOW. COLORED ORUSI G ELECTRI' WITI{, DISCONNECTING TAMPENING ON THESRSWIRINGCAN MAKE CAL TESTEOUIPMENT FIB' ORCAUSEACCIDENTAL THESYSTEMINOPERATIVE ING OF THE INFLATOB. A WABNING AI{O, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE HURTYOU' CAN SEBIOUSLY TALI-YDEPLOYED, CAREFULLY. MANUALINSTRUCTIONS FOLLOWSERVTCE 'This vorsionol tho labolis u36din cs.t with a front soat passonger'sairbag.
A' WARNING AND. IF ACCIDENIS EXPLOSIVE THEAIRBAGINFLATOR HURTOR KILLYOU. CAN SERIOUSLY TALLYDEPLOYEO, ORPROB. TESTEOUIPMENT . DO NOTUSEELECTRICAL INGDEVICES. DEPLOYMENT. THEYCAN CAUSEACCIOENTAL . NO SERVICEAALE PABTS INSIDE.OO NOT OISASSEMBLE. . PLACEAIRBAGUPFIGHTWHENREMOVED. . F O L L O W S E R V I C EM A N U A L I N S T R U C T I O N S CAREFULLY.
{cont'd)
1-7 fi{lHfiFe*%
_
Warning/Caution LabelLocations (cont'd)
SERVICEINFORMATION
C) SPARKPtUG II{FORMATION
BATTERY CAUTION
AIR CLEAI{€R, RECOMMENDEO OILand FILTER SERVICE RADIATORCAP CAUTIOI{
TIREINFORMATION {300()R)
1-8
TIREINFORMATIOII t4DOOR)
Lift and SupportPoints Lift plac6 Wh€n heavy16arcompon€ntssuch aa susponsion,luel tank, spale tile and hatch ale to b€ removod, in the tuggageareabsforehoisting.Whensubstantialwoightis lemovedfrom ths l€ar ol th€ car, ths il]iii6iliieigltt cantor of gravity may chango and can cause the cal to tip folward on the hoist'
can assist NOTE: Sinceeachtire/wheelassemblyweighsapproximately14 kg (30 lbs),placingthe front wheelsin trunk with the weight distribution.
1. Placethe lift blocksas shown and rock the car to be sure it is firmly supported. 2. Raisethe hoista lew inches(centimeters) 3. Raisethe hoistto full heightand inspectlift pointsfor solidsupport.
POINT FRONTSUPPORT
LIFTBLOCKS
POINT BEARSUPPORT
1-9
Lift and Support Points FIoor Jack 1 . Set the parkingbrakeandblockthe wheelsthat are
not beinglifted.
2 . When when lifting tritrngthe rear o off the car, put the gearshift lever in reverse(Automatictransmissionin
sition).
a
@ po-
3 . Raisethe car highenoughto insenthe safetystands. 4 . Adjustandplacethe safetystandsas shownon page 1-11 so the car will be approximately level,then lower the car onto them. Front
Centerthe jsck bracketin the middle ot the jack lift platform.
JACK LIFTPLATFORM
Rear
JACK LIFTPLATFORM
1-10
Centerthe jack bracketin the middle of the jack Iift platform.
Always uss satety standswhen working oo 01under any vehiclethat is supponedby only a jack. Naverattompt to use a bumporiack fo. lifting or supporting tho car,
Safety Stands
ATTACHMENTS RUBBER
t$ \F
FROI{TSUPFORTPOII{T
SAFETYSTANDS
POINT REARSUPPORT
1-11
Towing It the car needsto be towed, call a professionaltowing service.Nevertow the car behindanothercar with just a rope or chain. lt is very dange.ous.
Front:
Emergency Towing There are three popularmethodsof towing a car: Flat-bedEquipmont-The operatorloadsthe car on the back of a truck. This is the best way of transportingthe car. Whsol Lift Equipment-The tow truck uses two oivoting arms that go under the tires (front or rear)and lifts them otf the ground. The other two wheels remainon the ground.
rl
Sling-type Equipmont-The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspensionand the cableslift that end of the car off the ground.The car's suspensionand bodv can be seriouslydamagedif this methodof towing is attempted. It the car cannotbe transponedby flat-bed,it shouldbe towed with the tfont wheels oft the ground. lf due to damage.the car must be towed with the front wheels on the ground, do the tollowing: ManualTransmission a Releasethe parkingbrake, a Shift the transmissionto Neutral. Automatic Transmission a Releasethe parkingbrake. a Start the engine. a Shift to @ oosition,then to S position. a Turn off the engine. NOTICE:lmpropertowing preparationwill damagethe transmission. Followthe aboveprocedureexactly.lf you cannot shift the transmissionor stan the engine(automatic transmission), your car must be transDortedon a flat-bed. a lt is best to tow the car no tartherthan SOmileslgo km). and keep the speedbelow 3b mph (bE km/h). NOTICE:Trying to litt or tow your car by the bumpers will causeseriousdamage.The bumpersare not designed to supportthe car's weight.
TOWING HOOKS
Real:
SpecialTools lndividual tool lists are located at the front of each section
Specifications 3-2 Standardsand ServiceLimits .'-.'.'."-'-' 3-17 ....'.'.'...."....."...... DesignSpecifications 3-20 '.....'.'. BodySpecifications
Standardsand ServiceLimits CylinderHead/Valve Train(B188tenginel- Secti Declron 6 Compression
Cylinderh.ad
Camshaft
MEASUREMENT STANDARD {NEWI 250rpmandwideopenth.ottl€ Nominal 1,370(14.0,199) (kgflcm?, psi) kPa Minimum 930(9.5,140) Maximumvariation 200t2.0,2a) W6rpage Height
r 3 1 . 9 5 -1 3 2 . 0(55 . 1 9-5 5 . 1 9 9 )
Endplay Camshaft-to-holder oil clearance Totalrunout Camlobeheight
tN EX lN EX tN EX lN EX
(Cold)* Valveclearance ValvestemO.D. Stem-to-guide clearance
width
tN EX tN EX
Steminstslled height Valvespring
Valv6guide
Freelength{Reference}
NH CH
Lu.
lN
Installed height
EX lN
*: Measuredbetweenthe camshaftand rockerarm. NH:NIHONHATSUJO manufactur€d valvespring CH:CHUOHATSUJO manufacturod valvesDrino
3-2
lN EX
- 0.0061 0.05- 0.15(0.002 - 0.0027) 0.030- 0.06910.0012 0.03(0.001) max. 33.71611.327 1l (1.3200) 33.528 - 0.005) 0.08- 0.12{0.003 0.'r6 - 0.20(0.006- 0.008) - 0.2594) 6.580- 6.590(0.2591 - 0.2583) 6.550- 6.s60(0.2579 0.02- 0.0s(0.001- 0.002) 0.05- 0.08(0.002- 0.003) - 0.061) r.25- 1.55(0.049 - 0.061) 1.25- 1.55{0.049 - 41.235 - 1.6234) (1.6049 40.765 - 1.7022) 12.763- 43.235t1,6a37 42.36(1.668) 47.09{1.854} 47.08(1.854) - 0.261) 6.61- 6.63(0.260 6.61- 6.6s(0.260-0.261) - 14.25 - 0.561} 13.75 {0.541 - 0.640) r5.75- 16.2510.620
'
SERVICE LIMIT
0.05(0.002)
0.5(0.02) 0.1s{0.006) 0.04(0.002)
6.s5(0.258) 6.52(0.257) 0.0810.003) 0.11(0.004) 2.0t0.08) 2.0(0.08) (1.6333) 41.485 (1.7120) 43.485 41.s6{1.636) 46.27tl.A22l 46.21l1.a22l 6.65(0.262) 6.6510.2621
Unitof length:mm {in}
s cti 7 k (81881 EngineBlock {Bl6E1 englnel- sectlon (NEWI STANDARD 0.0710.003)max. - 3.190) 81.00- 81.02{3.189
MEASUNEMENT Cylinderblock
Piston
Warpageot decksLrrface Borediameter BoretaPer Reboringlimit SkirtO.D.at 15 mm (0.6in)Irom bottom of skirt in cylinder Clearance Top Groovewidth (Forring) Second --
Pistonring
clearance Ringto-groove
oil top
Second '....=-
Ringendgap
lop
rod Connecting
Crankshaft
Bearing
o.D.
;
T
Second oit rrstonrln
R T
clearance Pin-to-piston Pin-to-rodinterference Smallendborediameter Nominal Largeendborediameter on crankshatt Endplayinstalled Mainjournaldiameter N o .1 ,2 , 4 a n d5 j o u r n a l s No.3 iournal Rodiournaldiameter Taper Out-ofround Endplay Runout oil clearance Mainbearing-to-iournal No.1,2, 4 and5 journals No.3 journal oil clearance Rodbearingto-iournal
R T
- 3.189) 80.98- 80.99(3.188 - 0.0016) 0.01- 0.04(0.0004 - r.010(0.04060.0409) 1.030 - 0.0488) - 1.210(0.0484 1.230 2 . 8 0 -5 2 . 8 2 (00 . 1 1 0 40 . 1 1 1 0 ) - 0.0028} 0.045- 0.070{0.0018 - 0.0026) 0.040- 0.065(0.0016 - 0.0028) 0.045- 0.070(0.0018 - 0.014) 0.20- 0.35(0.008 - 0.012) 0.20 0.30(0.008 0.40- 0.5s(0.0r6 - 0.022) - 0.020) 0.20- 0.s0(0.008 - 0.0181 0.20- 0.45(0.008 - 0.8268) - 21.000 (0.8265 20.994 - 0.0009) 0.0r0- 0.022(0.0004 - 0.0013) 0.013- 0.032(0.0005 20.968- 20.981(0.825s- 0.8260) 48.0(1.89) - 0.012) 0.1s- 0.30(0.006
LIMIT SERVICE 0.10(0.004) 81.07(3.192) 0.05(0.002) 0.25(0.010)
80.9713.188) 0.05(0.002) 1.0610.042) 1.26(0.050) 2.8410.112\ 0.13{0.00s) 0.13(0.00s) 0.13(0.005) 0.60{0.024) 0.6010.024) 0.70(0.028) 0.70(0.028) 0.70(0.028)
- 2.1654) 54.976- 55.000(2.1644 - 2.1651) 54.970- 54.994(2.1642 - 1.7717} - 45.000{1.7707 44.S76 max. 0.00510.0002) max. 0.005(0.0002) 0.10- 0.35(0.004- 0.014) max. 0.03(0.001)
0.010(0.0004) 0.010(0.0004) 0.45(0.018) 0.04{0.002)
- 0.0017) 0.024 0.042{0.0009 - 0.0019} 0.030 0.048{0.0012 - 0.0015) 0.020 0.038(0.0008
0.05010.0020) 0.060(0.0024) 0.050(0.0020)
Ri RIKENmanutacture Pistonring pistonring RINGmanufacture PISTON T:TEIKOKU
3-3
Standardsand ServiceLimits Cylander Head/Valve Train(B18Clenginel Section6 MEASUBEMENT Compr€6sion
Cylind6rhoad
C.mshsft
250rpm and wideop€nthrottle Nomin6l kPalkgl/cmr,psi) Minimum Maximumvariation Warpage H6ight Endplay Camshaft-to-holdsr oil clearance Totalrunout Camloboheight lN Primery Mid
EX
Socondary Primary Mid Secondary
Valvoclorrancelcoldl*
lN EX lN EX lN EX tN EX lN EX
ValvestemO.D. Stom-to-guid6 clerrsnco Valvoseat
Width Sr6minstalledh€ight
Valv€Bpring
Fre6length(Roferenca)
lN EX
Valveguido
l.D. Instslledhoight
Rock€rerm
Arm-to-shaft clearance
': M€asuredbetwoonthe camshattand rcc(ersrm. NH:NIHONHATSUJOmanufacture v6lvespring CH:CHUOHATSUJO manufscturo v6lvespring
3-4
STA]TDARD INEWI
Outer Inner
NH CH NH CH
tN EX lN EX lN EX
SERV|C€ UM|T
(19.0, 1,860 270) 930(9.s,140)
200t2.o,2a) 'r41.95 - 1C2.05 (5.s89 - 5.593) 0.05- 0.1s(0.002- 0.006) - 0.0035) 0.050- 0.089(0.0020 0.015(0.0006) max. 33.411{1.3154) 36.377tl.13221 (1.3601) 34.547 33.1110.3036) 35.72011.4063) 34.381 {1.3536) 0.15- 0.19{0.006- 0.007} 0.17- 0.21(0.007- 0.008) - 0.21591 5.475- 5.48s(0.2156 - 0.21s0' 5.450- 5.460(0.2146 - 0.0022} 0.025- 0.055{0.00'10 - 0.0031) 0.050- 0.080(0.0020
- 0.06't) 1.25- 't.5s(0.049 '1.25 - 1.s5{0.049 - 0.061)
- 1.4935) 37.465- 37.935('1.4750 - 1.4817) 37.16s- 37.635t1.4632
41.05(r.6161 36.'16 {1.4241 36.19t1.425) 41.96(1.652) 4 1 . 9 {41 . 6 5 1 ) - 0.218) 5.51- 5.53(0.217 5.5r- 5.53{0.2r7- 0.218) - r3.0s(0.494 - 0.514) 12.55 - 13.05(0.494 - 0.s14t 12.55 - 0.0020) 0.025- 0.0s2{0.0010 - 0.0020) 0.025- 0.0s2(0.0010
0.05{0.002) 0.5(0.02) 0.15{0.006) 0.03(0.001)
5.11510.21441 s.420{0.2134) 0.0810.003) 0.11{0.(x)4) 2.0(0.08) 2.0(0.08) (1.5033) 38.185 (1.491s) 37.885 40.26(1.585) 35.30(1.390) 35.30(1.390) 40.95(1.612) 40.95(1.612) 5.55(0.219) 5.5s{0.219} 0.08(0.003) 0.08(0.003)
Unit of length:mm (in)
(818C1englnel- Section7 BI k (ltluur Engrne]'ocK Cyiinderblock
Piston
MEASUREMENT warpageof decksurlace Borediameter BoretaPer limit Reboring SkinO.D.ar 15mm (0.6in) {rom bottomot skirt in cylinder Clearance ToP Groovewidth (Forring) Socond
oil
Pistonring
Ring-to-pistongrooveclearance Top Second I oP Ringendgap Socond
oil rrstonrtn rod Connecting
crankshatt
Eearing
o.D.
clearance Pin-to-piston Pinto-rodint€rference Smallendborediameter Nominal Largeendborediameter Endplay installedon crankshaft Msinjournaldiameter N o .1 , 2 , 4a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out'olround Endplay Runout oil clearance Mainbsaring-to-journal No.1,2, 4 and5 journals No 3 journal oil clearanc€ Rodbearing-to-journal
(NEWI STANDARD 0.05(0.002)max. - 3.190) 81.00- 81.02{3.189
LIMIT SERVIC€ 0.08(0.003) 81.0713.192) 0.05(0.002) 0.25(0.010)
- 3.189) 80.98- 80.9913.188 - 0.0016} 0.0r- 0.04{0.0004 - 0.0409) 1.030- 1.0,r0{0.0406 - 0.0488) 1.230- 1.240(0.0484 - 0.11101 2.805- 2.820(0.1104 - 0.0028} 0.045- 0.070{0.0018 - 0.0026) 0.010- 0.065(0.0016 0.20- 0.35{0.008- 0.014) - 0.022) 0.40- 0,55(0.016 0.20- 0.s0{0.008- 0.020} - 0.8268) 20.994- 21.000(0.8265 - 0.0009) 0.010- 0.022{0.0004 - 0.0014) 0.017- 0.035(0.0007 20.964- 20.997(0.8254- 0.8267) €.0 (1.89) - 0.012) 0.15- 0.30(0.006
80.97(3.188) 0.05(0.002) 1.060(0.0417) 1.260(0.0496) 2 . 8 4 0( 0 . 1 1 1 8 )
0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.7010.0281
- 2.16541 - 55.000 (2.1644 54.976 54.974- 54.998(2.'|643- 2.1553) -' I.7717) - 45.000 44.976 {1.7707 max. 0.005{0.0002} max. 0.004{0.0002) 0.10- 0.35{0.00{- 0.014) max. 0.020(0.0008)
-t-oou lo.ooort
- 0.0017) 0.024- 0.042(0.0009 - 0.0019) 0.030- 0.048(0.0012 - 0.0020) 0.032- 0.050(0.0013
0.050(0.0020) 0.060{0.0024) 0.060(0.0024)
3-5
Standardsand ServiceLimits - Section EngineLubrication eclton g u _ MEASUREMENT Engineoil
Capacity f (USqt, lmp qt)
STANDARD INEW}
etaet engine 4.6{4.9,4.0}torengineoverhaul 818C1 engine
O i lp u m p
Reliefvalve
SERVICELIMTT
3.8(4.0,3.3)for oil change,inctudin g talter 3.513.7, 3.11for oil change,withouttiher 4.8{5.1,4.2)for engineoverhaul 4.0(4.2,3.5)lor oit change,includin g filter
3.7 i3.9 3 3l fdr ^il .hi
Inner-to-outer rotorclearance Pumphorising-to-outer rotorclearance Pumphousing-to,rotor axialclearance rressuresettingat engineoil temp.176.F{gO.Ct kPalkgtcm,,psi) At idte At 3,000rpm
0.04- 0.16(0.002- 0.006) 0.10- 0.19(0.004_ 0.007) 0.02- 0.07(0.001, 0.003)
0.20(0.008) 0.21(0.008) 0.1s(0.006)
70 (0.7,10)min. 3{0 {3.5,50)min.
Cooling- Sectiont0 Radialor
Radiatorcap Thermostst
MEASUBEMENT Coolant capacity I {USqt, lmpq 0 8 1 8 8 1e n g i n e engine,heater,I I Including I coolinglineandreservoir I Reservoircapacity: 0.61(0.63USqt,0.53tmpqt) 818C1engine
Openingpressure kPa(kgf/cm?,psi) start to open oF(.C) Fullyopen .F (.C) Valvelift at fully open Coolingfan lhermoswitch"ON" temperature .F {oC) "OFF" Thermoswitch temporature "F (.C) ng the coolantin the reservoirandthat remainingin the engine.
3-6
STANDARD INEWI M/T:6.4(6.8,5.6)toroverhaul
4.4(4.6.3.9) f6r s66lsn1gh66q.* A,rf:6.7{7.1,5.9)for overhaul 4.7{5.0,4.1)for coolantchanoe* M/T:6.7 {7.1,5.9}for overhaul 4.7{5.0,4.1)for coolantchanoe*
,3 - 113toss- trs, r3=Jt&
-
1 6 9- 1 7 6{76 80} 194(90, 8.0(0.31) 196- 203(91- 95) Subtract5 - 14 (3 - 8) from actuat-ON', temperature
Unit ot length: mm {in)
Section 11
Fuel and Emissions
sTAt{ItAno(Newl
MEASUREMENT
SERVICEUMIT | 12011.1'1'21 I too (:.1, g.st
F aa3urorggulator
81881engine in l2 V, 10seconds Disolacoment 818C1engins m, (fl oz,lmp oz) Pressurewith regulatorvacuum hose disconnected Bl8Bl engine kPa (kgflcm',psi) Bl8Cl engin€
22217.5,7 -81min. 364(12.3,12.8)min.
tualt6nk
Caprcity , {US gal,lmp gal)
11.01 50(13.2,
En9in6
ldle sDeed with headlight and cooling fan ofi rpm
7501 50 (M/T:neut..ll 750I 50 {A/T:E or E position}
Fast idle rpm
1,600i 2(x'lM/T:nsurr6l) l,eooI 200(A/T:E or E po6itioo)
ldl6 CO
0.1 max.
.u.l pump
Clutch
%
Section 12 STAM'Ad' IiEWI
MEASUREMENT clutch padsl
clutch disc Pr6sur6 plat€
275- 32a 12.8 -3.9,39.6 - 46.9) 329 - 378 (3.35- 3.85,47.6- 5.47)
P6d6lheight Siroke Pedalplay Disengagementheight Clutchsudace runout Riv€t h€ad depth Thickness Warpage Oiaphragmspringlingeralignment
to lloor to floor
SERVICEUMIT
164(6.46) 130- 140(5.12- 5.51) 12 - 21 (0.47- 0.83) 83 (3.27)min.
max, 0.0510.002) 1.3(0.05)min. 8.4- 9.1 (0.3 - 0.36)
mrx. 0.03(0.001) 0-6(0.02)ma*
0.'15(0.006t 0.2(0.011 6.0(0.24) 0.15(0.006) 0.8(0.03)
3-7 {n+
ll Standardsand ServiceLimits ManualTransmission Section 13 MEASUREMENT
STANDARD{NEWI
SERVICEUMIT 2.2{2.3,1.9}loroilchange 2.3(2.4,2.0)lor assembly
Transmission oil
Capacityf {US qt, lmp q0
Mainshaft
End play Diameterot ball bearingcontactarea (clutchhousingside) Diameterof 3rd gear contactarea Diameterof ball besring contactarea (transmission housingside) Runo!t
0.11- 0.18{0,004- 0.007) 27.977- 27s90 l.1.101- 1.1021
Adjust 2 7 . 9 3( 1 . 1 0 )
37.984- 38.000{1.495- 1.495} 27.987- 28.000{r.1018- 1.1024}
37.93{1.493) 21.94 /.1.10!'
0.02 (0.0008)max.
0.05 (0.002)
Mainshafi 3rd and 4lh gears
t.D. Endplay Thickness
, 1.6939) 43.009- 43.02511.6933 0.06- 0.21(0.0024 0.0083) - 31.97 - 1.3768) (1.3748 34.92 - 1.23SOl 31.12- 31.1711.2370
Mainshaft 5th gear
t.D. Endplay Thickness
43.08t 1.696) 0.3(0.012) 34.8(1.370) 31.3 (1.2321 43.08{1.696) 0.3 (0.012) 3 1 . 3( 1 . 2 3 2 )
Countershaft
Diameterof needlebearingconlact area Diameterof ball boaringcontactarea Diameterof 1st gear contactarea
3rd 4th
Bunout Countershaft lst gear
t.D. Endplay
Countershaft 2nd gear
LD. Endplay Thickness
Spacercollar (Countershaft 2nd gear)
t.D. o.D.
Spacercollar {l'rainshaft 4th and sth gears)
t.D. o.D.
81881engino 818C16ngine
Length
B
3-8
Length
B
- 1.6939) 43.009- 43.025(1.6933 0.06- 0.21 (0.0024- 0.0083) 31.42- 31.47t1.237-1.2391 33.000- 33.015(1.299- 1.300) 24.980- 24.993{0.9835- 0.9840) - 1.4567) 36.984- 37.000(1.4561 max. 0.02 10.0008) - 1.6545) 42.009- 42.02511.6539 - 0.0047) 0.04- 0.12(0.0016 - 1.85r4) 47.009- {7.02511.8507 - 0.0047) 0.05- 0.12(0.0020 - 1.3650) 34.62- 34.67(1.3630 - 1.1405) 28.92- 28.97(1.1386 - 1.4366) 36.48- 36.49(1.4352 - 1.6535) 41.989- 42.00011.6531 29.02- 29.04(1.r42s- 1.1433) - 1.1453) 29.07- 29.09(1.1444 - '1.2209) (1.2205 31.002 31.012 - 1.4951) 37.989- 38.000(1.4956 - 2.22641 56.45- 56.5512.2224 - 1.0268) 26.03- 26.08(1.0248
32.95\1.297) 24.94(0.982) 36.93{1.454) 0.05 t0.002) 42.08(1.657) Adjust 47.0811.854) Adjust 3{.5 (1.358) 28.8(1.134) 36.5(1.437) 4 1 . 9 4( 1 . 6 5 1 )
31.06('1.223) 37.94(1.494)
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