INTRODUCTION [> How to Use This Manual — *General Info This supplement contains information for the 1994 Prelude, Refer to following shop manual for service procedures and data not included in this supplement. Special Tools Description Code No. PRELUDE MAINTENANCE, REPAIR and ‘6285000 ‘CONSTRUCTION 92 PRELUDE SUPPLEMENT 93 Specifications 6288020, The first page of each section is marked with a black tab that lines . up with one of the thumb index tabs on this page. You can quickly Maintenance find the first page of each section without looking through a fll to- ble of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Engine [Special Information oF loss of, tes a strong possibility of severe personal injury instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information, CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service oper not included. Please note that this manual contains warnings and cautions against some specif jc service methods which could cause PERSONAL INJURY, damage 2 vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not, commended by HONDA, might be done, or of the possible hazardous consequences of every conceivable way, nor could HONDA investigate all such ways. Anyone using service procedures ‘r tools, whether or not recommended by HONDA, must satisfy him ‘self thoroughly that neither personal safety nor vehicle safety be jeopardized. All information contained in this manual is based on the latest product information aveilable at the time of printing. We reserve the right ‘to make changes at any time without notice. No part of this publica tion may be reproduced, stored in retrieval system, or transmitted, any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tebles ‘marked sections are not included in this manus. [Re sections with * include SRS components; ‘Special precautions are required. when seriing First Edition 11/83 210 pages HONDA MOTOR CO.,LTD. All Rights Reserved Service Publication office |* Heater and Air Conditioning *Electrical (Including | SRS })Outline of Model Changes rem DESCRIPTION 93 MODEL 94 MODEL REFERENCE. ‘SECTION Engine ‘Added +1222 engine ‘Added + H22A1 engine (KO model) + Recommended engine oil SH grade PGM-FI ‘Added + H22A2 engine ‘Added + H22A1 engine (KO model) Changed + Main wire harness u Manual Transmission ‘Added + M2F5 manual tranemission for H22A2 engine ‘Automatic Transmission Modified + Circuit diagram Changed + Reverse idler gear shaft and holder + Main valve body assembly + Secondary shaft assembly + Clutch dises and pistons + Throttle control cable inspection and adjustment Discontinued + Right side cover protector 14 Steering (@WS) Changed + Blinking interval of prablem code indication patterns Deleted + No. 70 (IG1) of problem code Body Changed + Center console + Door construction Added + Rear emblom + Trunk spoiler with high mount brake light (KQ model VTEC) 20 Air Conditioning Changed + Refrigerant: Refrigerant HEC-134a (R-134a) 22rem | DESCRIPTION 93 MODEL 94 MoDeL Electrical ‘Added + H22A2 engine | + Inter lock system (KO modell | + Power door lock actuator (KO model) + SRS type | Changed + Power supply circuit + Dash lights brightness control unit (European model + Intograted control unit (KY model) REFERENCE ‘SECTION ‘Added H22A1 engine (KO model) New indicator light (some models) + CeilingrSpot light (KQ, KY models) | «SRS type mn Changed + Shift lever position indicator (luminescent gauges) * Inter lock system connector (KQ model) + Brake/High mount brake light failure sensors + Turn signal/Hazard flasher system circuits + Dash lights brightness control controller locations (some models) + Power windows driver's switch assembly + Head light adjuster switch location + Seat heater switch location + Power mitror switch location + Headlight washer switch location Adopted +_New main gauge (luminescent gauges! 23General Information Chassis and Engine Numbers ... Identification Number Locations . Warning/Caution Label LocationsChassis and Engine Numbers European Model Vehicle Identification Number TT 89: Prelude/F20A8 passenger's SRS ai srs sesesrten |} system Fixed Code Auxiliary Numbe Factory Code —— C: Ssitama Factory in Japan (Sayama) Mode! Year —— Type of Vehicle — | UHM: HONDA MOTOR CO.., LTD. HONDA Passenger car | Line, Body and Engine Type BB1: Prelude/H22A2 BB2; Prolude/H23A2 1: 1994 (881) 2: 1984 (BB2, BB3) Serial Number 1-2 [- Engine Number F20A4-9300001 225,250 sone Seana Ma | [— Transmission Number M2ES-2000001 Transmission Type ~ ——_ M25: Manual with H22A2 engine M2J4: Manual with F20A4 engine M2K4: Manual with H23A2 engine MP1A: Automatic Serial Number — M2FS: 2000001 ~ Except M2FS: 3000001 ~Except European Model Vehicle Identification Number JHMBA81400C200001 Manufacturer, Mi tetrwezmanoa | | ||| HONDA, Passenger car Line, Body and Engine Type ———~ BAG: Prelude/F22A 1, F22A2 BB1: Prelude/H22A1 | 882: Prolude/H29A1 Body Type and Transmission Type —! 1! 2door Coupe! speed Manusl 2: 2-door Coupe/4-speed Automatic Vehicle Grade (Series) 4:8 (KO), SI (KT. KY) $1 (KO) and SI SPECIAL (KQ) 7: VIER Ka) Fixed Code ‘Auxiliary Number Factory Code —— Ct Seiteme Factory in Japan (Sayama) Model Year ——— 1: 1984 (981) 2: 1994 (@a8, Ba2) | Soria! Number | [— Engine Number F221-9390001 27a Engine Type ————_—_____ F22A1: 2.2 € SOHC Sequential Multi- port Fuel-injected engine with | catalytic converter (KQ) F22A2: 2.2 € SOHC Sequential Mult port Fuel-injected engine without catalytic converter (KTIKY) H22A1: 2.2 € DOHC VTEC Sequential Multi-port Fuelinjected engine with catalytic converter (KQ) 2.3 € DOHC Sequential Multi- Port Fuelinjected engine with catalytic converter (KQ) Serial Number ———_—— F22A1: 9390001 ~ F22A2: 9300001 ~ H22A1: 1900001 ~ H23A1: 3800001 ~ H2aa1 — Transmission Number M2c4-3000001 ‘Transmission Type ————___—! M2C4: Manual with F22A2 engine (KT/KY) M2F5: Manual with H22A1 engine (KQ) M2J4: Manual with F22A1 engine (KQ) M2K4: Manual with H23A1 engine (KQ) MP1A: Automatic Serial Number ——— | ‘M25: 2000001 ~ Excopt M2F5: 3000001 ~ 1-3Identification Number Locations Vehicle Identification ‘Namber (VIN) Built Date an: Vehicle Type (Kal, Plate VIN, Engine Number and Vehicle Type (KT), PlateWarning/Caution Label Locations SRS Airbag System Type Ill: A: CABLE REEL CAUTION A (see page 1-7) : DRIVER MODULE DANGER ®: STEERING WHEEL WARNING WARNING [SAS] ‘© REFER TO THE SHOP MANUAL ‘© SE REPORTER AU MANUEL D’ATELIER. (© WERKSTATT HANDBUCH LESEN. © LEES HET WERKPLAATSHANDBOEK. aS] @ DANGER ReFEh To SERVICE (SHOP) MANUAL FOR DETAILED IN- EXPLOSIVEIFLAMMABLE STRUCTIONS. PoIson REFER TO SHOP MANUAL. POUR LES INSTRUCTIONS DETAILUEES, SE REPORTER AU Dancer MANUEL DE REPARATIONS. EXPLOSIF EY INFLAMMABLE poison BUR, RBS Ht -—KAVHAaTVESBL SE REPORTER AU MANUEL D’ATELIER. Thieey © Gerann ExpLosivenrZuNoBAR AUSF HRLIGHE ANMEISUNGEN SIND DEM ZU ENTINEMEN er WERKSTATTHANDBUCH LESEN. RAAD PLEEG HET WERKPLAATSHANDBOEK VOOR NA Gevaan Dene AANWUZINGEN, EXPLOSIEGEVAAR/BRANDBAAR Girne LEES HET WERKPLAATSHANDBOEK. D: DRIVER MODULE WARNING WARNING [SRE '¢ REFER To THE SHOP MANUAL. ‘© SE REPORTER AU MANUEL D’ATELIER, WERKSTATTHANDBUCH LESEN. LEES HET WERKPLAATSHANDBOEK. (cont'd) 1-5Warning/Caution Label Locations r (cont'd) {soe page 1-7, 8) (see page 1-8) (see page 1-8, 9) (s08 page 770) (See page 1-10), 1-6E: BAM INFLATOR LABEL (European Mode! only) “Morton Intemational, Inc. menutactured infor F: SRS WARNING (HOOD) (4S model) ‘AIR BAG GAS GENERATOR UT11600 MORTON INTERNATIONAL, INC. OGDEN UT. USA HERSTELLUNGSJAHR: 1992 EINFOHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM PT:.0388 DER GASGENERATOR DARF NUR FOR INSASSEN- RUCKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHR- ZEUGE MONTIERT WERDEN. DIE MONTAGE UND DEMONTAGE DES GASGENERATORS. DARF NUR VON DAFUR GESCHULTEM PERSONAL VOR: CAUTION THE GAS GENERATOR SHOULD ONLY CONTAINS BE INSTALLED IN VEHICLES EQUIPPED FLAMMABLE WITH THE AIRBAG SYSTEM. SOLIDS ‘THE GAS GENERATOR IS TO BE IN. US DOT-£.8214 STALLED AND/OR DISASSEMBLED ‘ONLY BY TRAINED PERSONNEL ATTENTION LE GENERATEUR DE GAZ NE PEUT CONTENT ETRE INSTALLE QUE SUR DES VE DE HICULES EQUIPES D'UN SYSTEME AIR- SOLIDES BAG. LE MONTAGE ET Le FLAMMABLE — DEMONTAGE DU GENERATEUR DE US DOT-£-8214 GAZ NE PEUT ETRE EFFECTUE QUE PAR UN PERSONNEL QUALIFIE. NIPPON KOKI manufactured inflator ‘AIR BAG GAS GENERATOR NKO NIPPON KOKI, SHIRAKAWA JAPAN HERSTELLUNGSJAHR: 1991 EINFUHRER: HONDA DEUTSCHLAND GMBH/OFFENBACH BAM PT1-0378 DER GASGENERATOR DARF NUR FOR INSASSEN. RUCKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHR- ‘ZEUGE MONTIERT WERDEN. DIE MONTAGE UND DEMONTAGE DES GASGENERATORS. DARF NUR VON DAFUR GESCHULTEM PERSONAL VOR- ‘THE GAS GENERATOR SHOULD ONLY BE INSTALLED IN VEHICLES EQUIPPED ‘cauTion ‘CONTAINS FLAMMABLE WITH THE AIRBAG SYSTEM, THE GAS SOLIDS GENERATOR IS TO BE INSTALLED ANDIOR DISASSEMBLED ONLY BY ‘TRAINED PERSONNEL, ATTENTION LE GENERATEUR DE GAZ NE PEUT CONTENT DE ETRE INSTALLE QUE SUR DES VE- SOLIDES "_HICULES EQUIPES D'UN SYSTEME AIR- FLAMMABLES BAG. LE MONTAGE ET LE DEMONTAGE DU GENERATEUR DE GAZ NE PEUT ETRE EFFECTUE QUE PAR UN PERSONNEL QUALIFIE. WARNING ‘THIS VEHICLE IS EQUIPPED WITH AN AIRBAG SYSTEM AS ‘A SUPPLEMENTAL RESTRAINT SYSTEM. (SRS) ‘ALLS.R.S. ELECTRICAL WIRING AND CONNECTORS ARE ‘cotoned vetLow. DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE circurrs, ‘TAMPERING WITH OR DISCONNECTING THE S.R.S. WIR- ING COULD RESULT IN ACCIDENTAL FIRING OF THE IN- FLATOR OR MAKE THE SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY. VARNING [SRS] a DETTA FORDON HAR EN LUFTKUDDE FOR FORARSATET ‘SOM ETT KOMPLETTERANDE SKYDDSSYSTEM (SRSI. SAMTLIGA ELLEDNINGAR OCH KONTAKTER | SRS: ‘SYSTEMET AR GULFARGADE. ANVAND INTE ELEKTRISK PROVUTRUSTNING FOR DESSA KRETSAR. OM DU AN. DRAR ELLER LOSSAR EN SRS-LEDNING KAN DET RESULTERA I EN OAVSIKTLIG UTLOSNING AV TRYCKPUM- PEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA. OA KAN EN ALLVARLIG OLYCKA UPSTA. varorrus [SAS] ‘TASSA AUTOSSA ON YLIMAARAISENA TUKLJARJESTEL- MANA AJAJAN ILMATYYNY. (SRS) KAIKKI SRS-SAHKOJOHOOT JA -LITTIMET OVAT KEL- ‘TAISEr. ALA KAYTA SAHKOKOELAITTEITA NAISSA.VIRTAPL IREISAA, SRS JOHTOJEN TUKKEAMINEN TAl IRROTTAML NEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TAL TEHDA JARJESTELMAN KAYTTOKELVOTTOMAKS! ‘TASTA-TAAS SRATTAA AIHEUTUA VAKAVIA VAURIOITA, (cont'd) 1-7Warning/Caution Label Locations r (cont'd) F: SRS WARNING (HOOD) (Excopt KS model) G: DRIVER INFORMATION (SUNVISOR} (Except KS, KE models) WARNING: [SAS ‘THIS VEHICLE 1S EQUIPPED WITH AN AIRBAG SYSTEM AS, ‘A SUPPLEMENTAL RESTRAINT SYSTEM. (SRS) ‘ALL S.R.S. ELECTRICAL WIRING AND CONNECTORS ARE ‘CotoneD YELLOW. DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE cincurrs. ‘TAMPERING WITH OR DISCONNECTING THE 5.8. WIR- ING COULD RESULT IN ACCIDENTAL FIRING OF THE IN- FLATOR OR MAKE THE SYSTEM INOPERATIVE WHICH MAY RESULT IN SERIOUS INJURY. ATTENTION — [SRS] CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR DU COTE CONDUCTEUR QUI CONSTITUE UN SYSTEME DE RETEUNUE COMPLEMENTAIRE (5.R.S.) TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYS- ‘TEME DE RETENUE COMPLEMENTAIRE (S.A.S.) SONT DE COULEUR JAUNE. N'UTILISEZ PAS UN EQUIPMENT D'ES- SAIS ELECTRIQUES SUR CES CIRCUITS. NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME S.R.S CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHE- MENT ACCIDENTEL DU GONFLEUR OU RENDRE LE SYS. ‘TEMEINOPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES. WARNUNG DIESES FAHRZEUG IST MIT EINEM FAHRER-AIRBAG (SRS) ALS. ZUSATZLICHEM RUCKHALTESYSTEM ‘AUSGEROSTET. ‘ALLE ELEKTRISCHEN KABEL, SOWIE DIE ZUGEHORIGEN 'STECKVERGINDER DES 5.R.5.-SYSTEMS SIND IN GELBER FARGE AUSGEFOHRT. KEINE ELEKTRISCHEN PROFGERATE AN DIE 5.R.S.- \VERKABELUNG ANSCHLIEBEN. VERANDERN ODER UNTERBRECHEN DER S.R.S.- VERKABELUNG KANN UNKONTROLLIERTES ZUNDEN DES GASGENERATORS AUSLOSEN. ODER DAS SYSTEM AU- BER FUNKTION SETZEN WAS ZU ERNSTHAFTEN VERLET. ZUNGEN FOHREN KANN. WAARSCHUWING DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN ‘AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMING (SRS). ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITINGEN VAN DE S.A.S. ZLIN GEEL GEKLEURD, GEBRUIK GEN ELEK TRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS. KNOEIEN MET OF LOSKOPPELEN VAN DE S.A. LEIDIN: GEN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF ‘TOT UITSCHAKELEN VAN HET SYSTEEM DIT KAN TOT ERNSTIGE ONGELUKKEN LEIDEN. [SRS] ALWAYS WEAR VOUR SEAT BELT ‘6 THis CAR IS EQUIPPED WITH A DRIVER AIRBAG AND FRONT SEAT PASSENGER AIRBAG AS A SUP- PLEMENTAL RESTRAINT SYSTEM (S.R.S.) @ ITS DESIGNED TO SUPPLEMENT THE SEAT BELT. (© IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING ‘SEE YOUR AUTHORIZED HONDA DEALER SRS] _ATTACHEZ TOUJOURS VOTRE CEINTURE | fe VEHICULE EST EQUIPE D'UN COUSSIN D’AIR | POUR LE PASSAGER AVANT, QUI CONSTITUENT UN | ‘SYSTEME DE RETENUE COMPLEMENTAIRE (S.R.S.) | (© CE COUSSIN D’AIR COMPLETE LA FONCTION DE LA | CEINTURE DE CECURITE. \ ‘© SILE TEMOIN SRS S’ALLUME PENDANT LA CON- DUITE, ADRESSEZ-VOUS A VOTRE CONCESSION. NAIRE HONDA OFFICIEL. [SRS] SICHERHEITSGURTE BEI JEDER FAHRT ANLEGEN (© DIESES FAHRZEUG BESITZT JE EINEN AIRBAG FOR FAHRER UND BEIFAMRER ALS ZUSATZLICHES. ROCKHALTESYSTEM (S.R.5.). ¢ DAS ROCKHALTESYSTEM IST EINE ERGANZUNG ZUM SICHERHEITSGURT.. © SOLLTE WAHREND DER FAHRT DIE ‘SRS-KONTROLLEUCHTE AUFLEUCHTEN SUCHEN SIE BITTE UMGEHEND EINEN HONDA-HANDLER SUF. SRS] DRAAG ALTIJD UW VEILIGHEIDSGORDEL DIT VOERTUNG IS UITGERUST MET AIRBAG (SRS) ‘AAN BESTUURDERSZUDE EN PASSAGIERSZLIDE | ‘VOOR EXTRA VEILIGHEDD. | (© ONTWORPEN ALS EXTRA BESCHERMING NAAST DE | VEILIGHEIDSGORDELS. © ALS HET SRS. WAARSCHUWINGSLAMPJE GAAT BRANDEN ONDER HET RLJDEN, NEEM DAN KON- ‘TAKT OP MET EEN HONDA DEALER 1-8(KE model) H: BAM INFLATOR LABEL [SES] ALWAYS WEAR VoUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN- ‘TAL RESTRAINT SYSTEM (S.R.5.). ‘© TIS DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER. (KS model) [ERS] ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AND FRONT SEAT PASSENGER AIRBAG AS A SUPPLEMEN: TAL RESTRAINT SYSTEM (S.R.5.). © IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. ‘3 IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE ‘YOUR AUTHORIZED HONDA DEALER. SRS) ANVAND ALLTIO BILEALTET ‘© DETTA FORDON AR FORSETT MED EN LUFTKUODDE FOR FORARSATET OCH EN LUFTKUDDE FOR PAS: ‘SAGERSATET FRAM SOM ETT KOMPLEMENTERANDE SKYDDSSYSTEM (5.F.S.) © DET AR AMNAT ATT KOMPLEMENTERA BILBALTET. ‘© OM SRS.INDIKATORN TANDS UNDER KORNING SKALL DU_KONTAKTA EN AUKTORISERAD HONDA. [ATERFORSALIARE. [SRS] KAYTA ana TuRVAVOITA ‘© TAMA AUTO ON VARUSTETTU AJAJAN ILMATYYNYL- LA JA ETUMATKUSTAJAN ILMATYYNYLLA. JOTKA TOIMIVAT YLMAARAISENA TUKVARJESTELMANA (srs. @ SE"ON SUUNNITELTU TAYDENTAMAAN TUR: VavYOTA. (© JOS SRS-MERKKIVALO SYTTYY AJON AIKANA. OTTAKAA YHTEYS VALTUUTETTUUN HONDA- MYYJAAN. ‘IRBAG GASGENERATOR UT11873 MORTON INTERNATIONAL. INC. OGDEN, USA HERSTELLUNGS: (JAHR) EINFUHRER: HONDA DEUTSCHLAND GMBH 6050 OFFENBACH BAM PT:-0437 DER GASGENERATOR DARF NUR FOR INSASSEN- ROCKHALTESYSTEME MIT LUFTSACK IN KRAFTFAHR: ZEUGE MONTIERT WERDEN. DIE MONTAGE UND DEMONTAGE DES GASGENERATORS DARF NUR VON DAFUR GESCHULTEM PERSONAL VOR- GENOMMEN WERDEN. CAUTION THE GAS GENERATOR SHOULD ONLY CONTAINS BE INSTALLED IN VEHICLES EQUIPPED FLAMMABLE WITH THE AIRBAG SYSTEM. ‘SOLIDS ‘THE GAS GENERATOR IS TO BE IN- STALLED AND/OR DISASSEMBLED ONLY BY TRAINED PERSONNEL. ATTENTION LE GENERATEUR DE GAZ NE PEUT CONTENT —_ETRE INSTALLE QUE SUR DES VE. be HICULES EQUIPES D'UN SYSTEME AIR. SOUIDES BAG. LE MONTAGE ET LE FLAMMABLE DEMONTAGE DU GENERATEUR DE GAZ NE PEUT ETRE EFFECTUE QUE PAR UN PERSONNEL QUALIFIE (cont'd) 1-9Warning/Caution Label Locations (cont'd) | FRONT SEAT PASSENGER AIRBAG MODULE DANGER K: SRS MONITOR NOTICE ‘© DANGER Sh] EXPLOSIVE/FLAMMABLE POISON (© WARNING REFER TO SHOP MANUAL. © DANGER EXPLOSIF ET INFLAMMABLE POISON © ATTENTION SE REPORTER AU MANUEL D’ATELIER, © GeFAHR EXPLOSIVIENTZUNDBAR Grr © WaRNuNG WERKSTATTHANDBUCH LESEN. © GEVAAR. EXPLOSIEGEVAAR/BRANDBAAR GrTic. © WaARScHUWING LEES HET WERKPLAATSHANDBOEK. NOTICE [sas] © NO SERVICEABLE PARTS INSIDE. (© REFER TO SERVICE (SHOP) MANUAL FOR DETAILED INSTRUCTIONS, LTRS ORR PRA LS— s REMARGUE ‘© AUCUNE PIECE REPARABLE A L'INTERIEUR, © POUR LES INSTRUCTIONS DETAILL'EES, SE REPORTER AU MANUEL DE REPARATIONS. TET uPt ‘© GEN ONDERDELEN BINNEN DEZE UNIT WAARAAN WERKZAAMHEDEN KUNNEN WORDEN VERRICHT. (© RAADPLEEG HET WERKPLAATSHANDBOEX VOOR, NADERE AANWLJZINGEN. J: STEERING COLUMN NOTICE NOTICE ‘TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL ‘BEFORE REMOVING STEERING SHAFT CONNECTING BOLT. REMARQUE POUR EVITER TOUT DOMMAGE DU SRS, RETIRER LE VOLANT AVANT DE RETIRER LE BOULON DE RECCORD- “ACHTUNG DIE INNENTILE BEDORFEN KEINER WARTUNG. (© AUSFUHRLICHE ANWEISUNGEN SIND DEM WERK. STATTHANDBUCH ZU ENTNEHMEN. MENT DE. LABEL [AIRBAG] 1-10SRS Airbag System Type A: MAINTENANCE LID CAUTION 2 page 1-13), F (RHO) (eee page 1-12), (See page T1 B: MONITOR NOTICE (SRS) year RAYKE ae SRSA4 2 FFL AIL 47: MotHHTIL. cauTion BEFORE MAINTENANCE, SWITCH OFF THE IGNITION. ATTENTION AVANT TOUT ENTRETIEN, COUPER LE CONTACT. ACHTUNG VOR WARTUNG ZUNDUNG AUSSCHALTEN. Ler oP ZET HET KONTAKTSLOT AF ALVORENS MET HET ON- DERHOUO TE BEGINNEN. NOTICE [SAS] ‘© REFER TO SERVICE (SHOP) MANUAL FOR DETAILED N- 'STRUCTIONS. REMARQUE, ‘© POUR LES INSTRUCTIONS DETAILUEES, SE REPORT ER AU MANUEL DE REPARATIONS Ler Up ‘¢ RAADPLEEG HET WERKPLAATSHANDBOEK VOOR NA- DERE AANWLIZINGEN. ACHTUNG ‘@ AUSFOMRLICHE ANWEISUNGEN SIND DEM WERK- ‘STATTHANDBUCH 2U ENTNEHMEN. (cont'd 1-11Warning/Caution Label Locations (cont'd) ©: BODY COVER CAUTION (KS model TEg CAUTION ACHTUNG: — [SRS] OSRS AY FH YAMIEY ER TA AT LESH Fork. (© REFER TO THE SHOP MANUAL ‘SE REPORTER AU MANUEL D’ATELER. WERKSTATTHANDBUCH LESEN © LEES HET WERKPLAATSHANDBOEK. D: DRIVER INFORMATION (SUNVISOR) (Except KE, KO, KS modols) [SRS] __ ALWAYS WEAR VOUR SEAT BELT HIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (S.R.S.). © IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING, SEE YOUR AUTHORIZED HONDA DEALER. [SRS] _ ATTACHEZ TOUJOURS VOTRE CEINTURE '@ CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR POUR LE CONDUGTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE (5..5.) (© CE COUSSIN D'AIR COMPLETE LA FONCTION DE LA CCEINTURE DE SECURITE. © SILE TEMOIN SRS §’ALLUME PENDANT LA CONDUITE, ADRESSEZ-VOUS A VOTRE CONCESSIONNAIRE HONDA OFFICIEL, [SRS] SICHERHEITSGURTE BEI JEDER FAHRT ANLEGEN (© DIESES FAHRZEUG BESITZT EINEN FAHRER-AIRBAG [ALS ZUSATZUCHES RUCKHALTESYSTEM (S.R.5.) ‘© ES IST EINE ERGANZUNG ZUM SICHERHEITGURT. (© WENN QUE SRS-KONTROLLEUGHTE WAHREND DER FAHRT AUFLEUCHTET, UMGEHEND FINEN HONDA HANDLER AUFSUCHEN. [BRS] DRAAG ALTIJD UW VEILIGHEIDSGORDEL "© Dit VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN ‘AAN DE BESTUURDERSKANT ALTS EXTRA BESCHERM. ING 18.88). © DITIS ONTWORPEN ALS EXTRA BESCHERMING BLJ DE VEILIGHEIDSGORDEL, © ALS HEL SRS-WAARSCHUWINGSLAMPJE GAAT BRANDEN ONDER HET RLIDEN. NEEM DAN KONTAKT (OP MET EEN HONDA DEALER. (KE, KQ models) AS] ALWAYS WEAR VOUR SEAT BELT ‘THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (S.A... 12 ITs DESIGNED To SUPPLEMENT THE SEAT BELT. 3 Ir Your shs inpicaTon LicHs WHILE DRIVING See YOUR AUTHORIZED HONDA DEALER. [SRS] _ ALWAYS WEAR YOUR SEAT GELT ‘@ THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A ‘SUPPLEMENTAL RESTRAINT SYSTEM (5.F.5.) © IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF YOUR SAS INDICATOR LIGHTS WHILE DRIVING SEE ‘YOUR AUTHORIZED HONDA DEALER, ANVAND ALLTIO BILBALTET "© DETTA FORDON HAR EN LUFTKUODDE FOR FORAR- SATET SOM ETT KOMPLEMENTERANDE SKYDDS- SYSTEM (5.R.S.) © DET AR AMNAT ATT KOMPLEMENTERA BILBALTET. ‘© OM SRS.INDIKATORN TANDS UNDER KORNING SKALL DU KONTAKTA EN AUKTORISERAD HONDA. ATERFORSALJARE. (SRS) KAYTA AINA TURVAVOITA ‘© TAMA AUTO ON VARUSTETTU AJAJAN LMATYYNYL: UA JOKA ON. YLMAARAINEN” TUKIJARJESTELMA GAS. © SE ON SUUNNITELTU TAYDENTAMAAN TUR. VavyOrk. (© JOS SRS-MERKKIVALO SYTTYY AJON AIKANA. OTTAKAA YHTEYS VALTUUTETTUUN HONDA- MYYJAAN. E:Lape [AIRBAG] 1-12F: SRS WARNING (HOOD) (Except KS modell WARNING: [SRS] THIS VEHICLE IS EQUIPPED WITH A DRIVER AIRBAG AS. A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). ‘ALLS.R.S. ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE. cincurts. ‘TAMPERING WITH OR DISCONNECTING THE S.R.S. WIR ING COULD RESULT IN ACCIDENTAL FIRING OF THE IN. FLATOR OR MAKE THE SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY. ATTENTION _ [SRS CE VEHICULE EST EQUIPE D’UN COUSSIN 0’AIR DU COTE. CONOUCTEUR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMENTAIRE (S.R.5.) ‘TOUS LES FILS ET CONNECTEURS ELECTRIQUES DU SYS- ‘TEME DE RETENUE COMPLEMENTAIRE (S.R.S.) SONT DE ‘COULEUR JAUNE. N'UTILISEZ PAS UN EQUIPEMENT D'ES. ‘SAIS ELECTRIQUES SUR CES CIRCUITS. NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU SYSTEME S.R.S. CAR CECI POURRAIT DE TRADUIRE PAR LE DECLENCHE- MENT ACCIDENTEL DU GONFLEUR OU RENDRE LE SYS. ‘TEMEINOPERANT ET VOUS EXPOSER AINSIA DE GRAVES, BLESSURES. WARNUNG DIESES FAHRZEUG IST MIT EINEM FAHRER AIRBAG (SRS) ALS ZUSATZLICHEM RUCKHALTESYSTEM AUS: GerosTeT. ALLE ELEKTRISCHEN KABEL, SOWIE DIE ZUGEHORIGEN ‘STECKVERBINDER DES 5.R.S. SYSTEMS SIND IN GELBER FARBE AUSGEFOHRT. KEINE ELEKTRISCHEN PROGERATE AN DIE SRS. VERKABELUNG ANSCHLIEBEN. VERANDERN ODER UNTERBRECHEN DER S.R.S \VERKABELUNG KANN UNKONTROLLIERTES ZUNDEN DES, GASGENERATORS AUSLOSEN. ODER OAS SYSTEM AU. BER FUNKTION SETZEN, WAS ZU ERNSTHAFTEN VERLET- ZUNGEN FUHREN KANN. WAARSCHUWING [SRS] DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN ‘AAN DE BESTUURDERSKANT ALS EXTRA BESCHERMING (SRS), ‘ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITIGEN VAN DE S.R.S. ZUN GEEL GEKLEURD. GEBRUIK GEEN ELEKTRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS. KNOEIEN MET OF LOSKOPPELEN VAN DE S.R.S, LEIDINGEN KAN LEIDEN ‘TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKE- LEN VAN HET SYSTEM DIT KAN TOT ERNSTIGE ON. GELUKKEN LEIDEN. (KS model WARNING [SRS THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS. ‘A SUPPLEMENTAL RESTRAINT SYSTEM. (SRS) ‘ALL S.R.S. ELECTRICAL WIRING AND CONNECTORS ARE ‘COLORED YELLOW. 00 NOT USE ELECTRICAL TEST EQUIPMENT ON THESE cIRCUITS. ‘TAMPERING WITH OR DISCONNECTING THE 5.8.5. WiR- ING COULD RESULT IN ACCIDENTAL FIRING OF THE IN FLATOR OR MAKE THE SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY, VARNING [SRS] DETTA FORDON HAR EN LUFTKUDDE FOR FORARSATET ‘SOM ETT KOMPLETTERANDE SKYDDSSYSTEM (SRS). SAMTLIGA ELLEDNINGAR OCH KONTAKTER | SRS- ‘SYSTEMET AR GULFARGADE. ANVAND INTE ELEKTRISK PROVUTRUSTNING FOR DESSA KRETSAR. OM DU AN: DRAR ELLER LOSSAR EN SRS-LEDNING KAN DET RESULTERA IEN OAVSIKTLIG UTLOSNING AV TRYCKPUM: PEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA, DA KAN EN ALLVARLIG OLYCKA UPPSTA. varorrus [SRE] ‘TASSA AUTOSSA ON VLIMAARAISENA TUKIJARJESTEL- MANA AJAJAN ILMATYYNY. (SRS) KAIKKI SRS-SAHKOJOHDOT JA -LIITTIMET OVAT KEL: TAISET. ALA KAYTA SAHKOKOELAITTEITA NAISSA_VIRTAPI IREISAK, SRS-JOHTOJEN TUKKEAMINEN TAIIRROTTAM NEN SAATTAA SYTYTTAA VAHINGOSSA PUMPUN TAL TEHDA JARJESTELMAN KAYTTOKELVOTTOMAKG TASTA-TAAS SAATTAA AMEUTUA VAKAVIA VAURIOITA, 1-13Special Tools Individual tool lists are located at the front of each sectionSpecifications Standards and Service Limits ... Design Specifications .. Body Specifications . 3-15 3-20Standards and Service Limits [~ Cylinder Head/Valve Train (F20A4, F22A1, F22A2 engines) — Sections 6 MEASUREMENT STANDARD (NEW) SERVICE UMIT Compression | 250 min" (rpm) and Nominal 1,250 (12.6, 178) Wide open throttle Minimum 950 (8.5, 136), kPa tkg/em?, psi) Maximum variation 200 12.0, 281 Grinder head | Warnoge = 0.08 (0.002) Height 99.95-100.05 (3.935-3.939) S Camahait End play '0.08-0,15 (0.002-0.006) 0.80 10.03) Camshett-to-holder oil clearance (0.050.0.089 10.002-0.004) 0.15 (0.006), Funout 0.03 (0.001) max 0.04 (0.002), Cam lobe Height ——-F20A4, F22A2 engines IN | 38.741 (1.5262) ex | 38.972 (1.5343) = F22A1 engine Iw } 38.526 (1.5167) - ex | 38.778 (1.5266) Valve Valve clearance IN | 0.23-0.28 (0.009.001) = &x | 0.27-0.32 (0.011-0.013) = Valve stem 0.0. IN | 5.485-5.495 (0.2159.0.2163) 5.465 (0.2148) x | 5.450-5.480 (0.2146-0.2160) 5.420 (0.2134) | ‘Stom-to-guide clearance IN | 0.020.0.045 (0.0008.0:0018) 0.08 (0.003) | _ Ex | 0.088.0.080 (0.0021-0,0031) 0.12 (0.005) Valve seat Wath Iw] 1.25-1.88 (0.049.0.061) 2.0 10.079), £x | 1.25.1.88 (0.049.0.061) 2.0 (0.079) ‘Stem installed height WW | 48.245-48,716 (1.9994-1.9179) | — LL I &x | 50.315.60.785 (1:9809-1.9994) | — Valve spring | Fro length F204, F22A2 engines IN | 63.16 (2.0929/"1 = 53.15 (2.0925)-2 = © | 55.80 (2.196a)*1 = 55.78 (2.1960)"2 = F201 engine w | 5431 2.1578) “1 = | 54.82 (2.1882) °2 = ex | 86.26 (2.2150) +3 = 56.28 (2.2157) +2 = Valve guide| 1b. W | 5.815:6.630 (0.2171 0.217) 5.55 (0.219) x | 5,515:8.530 10.2171.0.2177), 5.58 (0.219), Installed height Iw | 23.75-24.25 (0.925-0.955) &x | 15.05-15.55 (0.593.0.612) = Rock ‘Armito-shalt clearance WW | 0.017-0.050 (0.0007-0.0020) (0.08 10.003) © | _0.018:0.084 10.0007-0,0021) 0.08 (0.003) 11; CHU HATSUJO manufactured valve spring +2: NIHON HATSUJO manufactured valve spring— Cylinder Head/Valve Train (H23A1, H23A2 engine) — Sections 6 —— Unit of length: mm tnd MEASUREMENT STANDARD (NEW) SERVICE LIMIT ‘Compression | 250 min=' (rpm) and Nominal 1,250 (12.5, 178) ‘wide ‘open throttle Minimars 950 (9.5, 136) kPa ikgrem®, pail, Maximum variation | 200 (2.0, 28) Cylinder heed | Warpoge = 0.08 (0.008) Height 121.95-192.05 16.195-5.199) Camahatt End play 10.05.0.18 (0.002-0.008) 0.5 (0.02) Camshaft to-holder oil (0.080-0.088 (0.0020-0.0035)" | 0:15 (0.006)*? (0.100-0.139 (0.0039-0.0055)"2 | 0.20 (0.008)"2 Total runout 0,03 (0.001) max. 0.04 (0.002), Cem lobe height in | 33.681 (1.3252) - ex _| 33.725 (1.3278) = Vaive Valve clearance: ww | 0.07.0.11 (0.003-0.004°> = Ex | 0.15.0:19 10.006.0.007)"3 = Valve stem 0.0 In. | 8.580:6.590 (0.2591-0.2594) | 6.55 10.258) Ex | 6.850-6.560 (0.2579.0.2583) | 6.52 (0.257) Stom-to-guide clearence In. | 0.02-0.05 10.001.0.002) 0.08 (0.003) EX_| _0.05-0.08 (0.020.003) 0.11 (0.008) Wwiath in| 1.25-1.65 10.049-0.061) 2.0 (0.08) &x | 1:25-1155 10.049-0.061), 2°0 10.08) ‘Stor installed height in | 39.366-39.835 (1.5498-1.5683) | 40.085 (1.5781) Ex_| 39.165-29.635 (1/6619.1.8608) | 39,885 (1.5703) Valve spring | Froe length in| 47.14 (1.886) ex_| 47:16 (1.856) Vawe guide| 1D, IN| 6.61-6.63 (0.260-0.261) 6.70 0.268) ex | 6.61-8.63 (0.260-0.261) 6.70 (0.268) Installed height In | 13:26-13.75 (0.522-0.541) = L ex _|_13:75-18:25 10.541-0.561) = Fr Exhaust No, 6 journal +2: Except exhaust No. 5 journal +5: Measuring point Between camshaft and rocker arm (cont’a 3-3Standards and Service Limits [~ Cylinder Head/Valve Train (H22A1, H22A2 engines) — Section 6 — (MEASUREMENT STANDARD (NEW) SERVICE LiMiT ‘Compression | 250 min om) ona Nominal 1,300 113.0, 185) ‘wide open throttle Minimum 950 (9.5, 135) { kPa tkglom?, sil Maximum varistion__|_200 (2.0, 28) Cylinder head | Warpage = ‘0.08 10.002) Height 146.95-147.05 (5.785-5.789) Camahort End play 10.08-0.18 (0.002-0.006) 08 0.02) Camshattto-holder oll clearance 0.080.0.089 10.0020-0.003) | 0:18 10.008) Total runout 0.03 (0.001) max. 0.04 10.002) Cam lobe height IN Primary 34.041 (1.3402) = Mig 36.856 (1.8510) 7 Secondary | 34.971 (113768) = —X Primary 33.745 (1.3265) = Mid 36.325 (1.4300), 7 7 _ Secondary | 34°83 (1:3685), = Valve Valve slearance I | 0.15.0.19 (0.006-0,007/ = £X | 0.17.0.21 (0.007-0.008)"8 — Valve stem 0.0. IN | 5.475-5.485 (0.2156-0.2159) | 6.445 (0.2144) EX | 6.475.5.486 (0.2156-0.2159) | 5.448 (0.2144), ‘Stemto-guide clearance IN | 01026-0.085 (0.0010-0.0022) | 0108 10.00%) Ex_|_0.050.0.080 10.0020-0:00311_|_ 0.11 10.008 Valve seat wath IN _ | 1-30-1.50 10.051-0.089) 2.0 0.073) &x | 128-1:55 (0.049-0.061) 2.0 10.079) Stem installed height IN | 37.485-37.935 (1.4750-1.4935) | 38.186 (1.5033) ____&_|_37:185.37-635 (114632.1.4817) | 37.885 (1.4918) Valve saring IW Outer 45.16 (1.778) *7 - 45.76 (1.802) « 5 Inner 41.78 (1.645) *1 = 41.75 (1-644) +2 = —X Outer 46.72 (1.839) *1 = 48.74 (1.840) *? = Inner 39.32 (1.548) + = zo 39.28 (1.546) +2 Vaive guide 11.0, WW | 5.5108.530 0.2168.0.2177 | 5.88 0.210) ex | 5.835-5.555 (0.2179.0.2187) | 5.60 (0.220) Installed height IN | 14.55-16.08 (0.573-0.593) S EX_| 14:95-18.45 10.589.0.608) = Rooker arm | Anm-to-shaft clearance Ww | 9.025-0.082 10.0010-0.0020) | 0.08 10.003) £x_| 01026.0.082 (0.0010-0.0020) __| 0.08 (0.003), 11: CHUO HATSUJO manufactured valve spring 12: NIHON HATSUJO manufactured valve spring "8: Measuring point between camahett and rocker arm 3-4[— Engine Block — Section 7 Unit of length: mm tin) MEASUREMENT | STANDARD (NEW) SERVICE LIMIT Cylinder Bock | Wapage of dock wrfoce (0.07 (0.009) max 0.10 0.004) Bore diameter F20A8, F22A1, £2242 engines ‘8 | 85.0108 020 (3.9468.9.672) Nera 8 | Ss.coo-88.0%0 3 3468-3.2868) M231, H23A2, H22A1, H22A2 engings A | 87/010 87.020 |3.4296.3.4260) } 27.07 42a 8 | 7.00087 010 (2.4282.3.4286) Reboraing limit £2088, £2281, £2282 engines = 0.80 (0.020) HZ3A%,H29K3.H2201, HDA? engines | — _ 0:28 (0.010) Paton BER O77 F2088, F22A1, F2282 engines No totter is) | 84.980-88.990 (3 3457-3.9460) 24.970 19.2489) Ueto 8) 4.970.84.980 (3 3483.3.38571 84 960 19.2480), H2ans, H29K2, H22A1, H2AD engine No Letter (&) | 86,990.87 003 (3.4248-3.4253), 88.080 (3.4240) eter i 86,960-86,003 (3.240-3.4249) 86.970 (3.4240) Clearance in evinder F20K4, F241, £2243 engines 0.020 0040 0.0008-0.006) 8.08 (0.002) W281, H29K2, H2DAT, HE2AZ engines | 0.007-0,090 (0,0008-2.0012) 8.08 (01002) ae "Top 1.22041.230 0.0480-0.0008) 1.28 10.040) Second 3'320.1-230 (0.0480-0.0408) 135 18.088) or 21805.2.628 (0.1108-0.11 12) 298 (0.112) 2941, H29A2, H22A1, HBA? engines “Top 1.230-1.248 (0.0494.0.0490) 1.268 (0.0496) Secon 1230-1 2as (0.0402-0 0490) 1268 (0.0098), ot 21808-21620 (0.11000.1110) Bastonta Top 0.035:0.060 0.0014-0.0028) 0.19 10.0081 Second 6.030.008 (0.0012.0.0022) 6310008) Ting ond gan” FROA4, FZ2A1, FZ2A2 enaines ‘Top 0,200.35 (0.008.001) 0.60 10.024) Seeone 0.40085 (o.0v60.0221 6.70 10.028) on 0200.70 (0.008-0.026), 8.80 (0.031 ee 0250.5 @or00014) 0.60 (0.024 Secone 0.60.0.78 (0022-0.030), 0.80 (0.038) on 8.20.09 10.008.0.020)~2 9.60 0.024)-2 Paton ia OD 1 21.984-22.000 10.8669-0.88811 a 6.612-0.028 (0.0008 0.0009) 61012-0026 (0.0008-0.0010) Uitge end bore aiamater ] 0.013.0.039 (0.0008-0.0015) 34'3¢0-21.981 (0.8640.0.0054) Nominal Except F20A4 engine | 1.0 12.001 F2oné engine | 8.0 189) = End play instalod on cranks | 078.0:20 10.006-0.0121 0.40 10.016) Crankahatt ‘Main journal diameter (No. T Journal Excopt H22A1, H22A2 engines | 49.984-60,008 (1.9679-1.9688) - H22R1, H22A2 engines 48.376-50,000 (1 9676-1 9635) 5 No.2 journat 48.976-50.000 {1 9676-1.9685) No, 3 foswnal 49.972.49,996 (1 9674.1.9683) = No & joa 448.964 50,008 (1'9679-1.9698) = No. 5 joural | 89,980-50.012 (1-9680-1.2690) Rod jou dametet” Except F20R4 engine 447'976-88.000 1 888-1889) FROM engine 44.976 48,000 11.7907.1.97971 = ‘Teper 0.008 10.0002) max 2.006 (0.00021 Out atone Exeapt H221, 42242 engines | 8.008 (0.0002) mex 8.008 (0.00021 HZ2A1, 222 engines 8.006 (0.0002) max 8.006 (0.00021 End pay 8,100.38 100080 014, Sas (o01s) ‘ota! ronout 8.03 10.001) max 8.08 (0.002) Bearings Main bearing ojounal 6 dearance T No: Vowel "Exeept H22A1, W22A2 engines | 0.013-0.037 0.0005-0.0015) 0.050 (0.0020) HaZA1, H22A2 engines ©.021-0.04s (0.0008.0.0018) 8.080 10.0020) No. 2 journal 8.021-0.04s (0.0008-0.0018) 8.080 10.0020) No 3 journal 8.9250.049 (0.0010-0.0018) S.ase (0.00221 No. journal 8.913.007 (o.008-0.0018) 8.080 10.0020) No 5 journal 8.008 0033 10.0008-0.0013) S080 (0.0038) od baving 0 ural ol lerance F20A engine 0.010.049 0.0006-0.0017) 0.050 (0.00201 H22a1, H22A2 engines 61027-01088 (o.00"1-0.0022) 8.080 (0.0028) Excopt F208, H22A1 H22A2 engines _| 0.021.0.048 (0.0008 0.0079), 0.088 (0.0022) "1: Measured at 21.0 mm (0.83 in) on F20A4, F22A1, F22A2 engines and 15.0 mm (0.59 in) on H23A1, H29A2, H22A1, H22A2 engines both from bottom of skirt. 12: TEIKOKU PISTON RING manufactured piston ring +3: RIKEN manufactured piston ring. 3-5Standards and Service Limits [/ Engine Block — Section 7 (eomt’ dy), zi $m MEASUREMENT STANDARD (NEW) SERVICE LinttT No. 1 journal (front) 42.722-42.734 (1.6870-1.6824) | 42,77 (1.689) No. 1 journal ireer) | 20.938-20.950 (0.8243-0.8248) | 20.92 (0.824), No. 2 journats (front roar) | 38.712-38.724 (1.5241-1.5246) | 38.70 (1.828) No, 3 journals (ont, rear) | 34.722-34.794 (1.3670.1.3675) | 34.71 (1.367) ournst taper 10.005 10.0002) = End play, Front | 0:10-0.38 10.00¢-0.014) = Rear | 0.06-0.18 (0.002.0.007} 5 Total runout 0.02 (0.001) 0.03 (0.001) Ol clearance No. 1 journal (roar) 0.060:0.075 (0.0020-0.00301 0.09 (0.00) No. 1 journal (front) and No. 3 journals (front, rear) | 0.066-0.098 (0.0026.0.0039) | 0.12 (0.005) No. 2 journals (ront, ear) | 0.076-0.108 (0.0030.0.0043) _| 0.13 (0.008), Balancer shaft) 10. No. 1 journal (front) “42.800-42.820 (1.6850-1.6956) | 42.83 (1.686) bearing No. 1 journo! (rear) 21.000-21.013 (0.8268-0.8273} | 21.02 (0.828) No. 2 journals (ront and rear) | 38.800-38.820 (1.5276-1.5263) | 38.83 (1.829) No. 3 journals tfront end rear) | 34:800-34.820 (1.3701-1.3709) | 34.83 (1.371) F-_Engine Lubrication — Section 8—~-HJ£ MEASUREMENT ‘STANDARD (NEW) SERVICE Lint Engine oi! Capocity ¢ F20A4, F22A1, F22A2 engines | 4.9 (6.2, 4.3) for engine overhaul (WS-at. Imp at) 3.8 (4.0, 3.3) for ofl change, including titer 3.5 (8.7, 3.1) for oll change without fitor H23A1, H29A2 engines 5.4 (5.7, 4.8) for engine overhaul 4.3 (4.5, 3.8) for oll change, Including fiter 4.0 (4.2, 3°5} for oll change without fiter H22A1, H22A2 engines 5.9 (6.2, 6.21 for engine overhaul 4.8 (5.1, 4.2} for oll change including fitor 4:5 (8.8, 4.0) for oll change without titer ‘Oil pum Inner to-cuter rotor radial clearance °0.02-0.16 (0.001-0.008) 0.20 (0.008) Pump hausing-to-outer rotor radial clearance 0.10-0.18 (0.004-0.007) 0.21 (0.008) Bump housing t0-r0t0r axial clearance 0.02-0.07 (0.001-0.003) 0:12 (0.005) Faliat valve Pressure setting atoll tomperature 80°C [1 76°F) kPa tkgfem?, ps idle 70 (0.7, 10) min, St 3,000 min-* tem) _| 380 (3.5, 80) min. p> Gooling — Section 9 aia MEASUREMENT STANDARD (NEW! Radiator Engine coolant capacity F20A4, F22A1, F22A2 | MIT: 7.1 (7.5, 6.2) for overhaul including engine, | engines 3.5 (3:7, 3.1) for coolant change heater. cooling AMT: 7.0 (7.4, 6.2) for overhaul ling and reservoir 3.4 (3.6, 3.0) for coolant change 1US at Imp at H29A1, H23A2 engines | M/T: 7°6 18.0, 6.7) for overhaul 4.0 14.2, 3.5) for coolant change AIT: 7.3 (7-7, 6.4) for overhaul 3.7 (3.9, 3'3) for coolant change H22A1, H22A2 engines | MIT: 7.8 (8.2, 6.9) for overhaul | 42 (6.4, 3.7) tor coolant change Reservoir capacity €1US at, Imp at) 0.6 (0.6, 0.5) | Radiator cap ‘Opening pressure KPa (kg/cm? pei) 95.425 (0.95-1.25, 14.18) Thermostat Start to open 26 (er) | 76-80 (169-176) Fully open °6 vr) | 90 1194), Valve it at fully open 8.0 (0.31) min. Radiator fan} Coolant temperatura ewitch A “ON” °C (°F) Except H22A1, H22A2 engines | 90-96 (194-208) H22A1, H22A2 engines 92.98 1198-208) Coolant temperature switch A “OFF” 8 (°F) Subtract 2-7 (4-13) from actual “ON” temperature Coolant tomperature switch B "ON" °C (°F) 103-109 1217-228) Coolant temperature switch 8 “OFF” °C (°F) Subtract 4-9 (7-16) from actusl “ON temperatureUnit of length: mm finn MeAsUnEMNT STANDARD (NEW! Fost Pump | Reet valve opening pressure KPa gin, px | #80800 1a 660, 6a 085.) Tranny | Slacamested Kb nate bal Be sie esse sons | F20A4, F22A2, H22A1, H22A2 engines: Heres Gaszan see Fut tank | Capacity 105 ga np aa corres. 13 — Tle sped min-" tor FIOAG,FEZAT angen | Wit 770 © 5 with headlights ond AMT: 770 + 80 (N] or [P] position) AIT: 700 + 50((N] or [P} position) M2342 engine ir: 709 5 0 Mit 789 © £8. or postion 112241 enine tir: 00 2 $0 N3Ad ening it 790 3 8 (ae 60% ‘With CATA: 0.19 max. Without CATA: 1.0 = 1.0% [- Clutch — Section 12 MEASUREMENT STANDARD (NEW) SERVICE LMT Cinch pads! | Pedal height to foor | LHD 190 7-48) (- BHD: 206 (0.11 = stoke 198148 (531-8.70) 7 Free ley 3:15 (0280.50 = Pedal ploy %:0.70 10,040.20) = Disengagement haght to floor | LHD: $9 (2.66) mn = : HD: 108 (8.28) min = Fivaest Chick srface runout 0.05 (0,002) max 0.15 10.008) Chtch die] Rivet head denth 1.3 (0.05) min 02 (0.01) Shicknass 8.4.01 (0,930.20 810.24) Pressure plate | Warpage 0.03 (0,001) max 0.15 (0.06) Diaphragm soring gers signment 8.8 1.62) man 0.8 19.09) (-— Manual Transmission — Section 13 MEASUREMENT STANDARD (NEW) SeRVice UMiT Transmission ol| Capacity C15 at imp ah 1.9 (20, 1.7) fori change 2012.5, 18) for ovemout Wine End pay 0.10-0.16 0.0039-0.0069) ‘aust Biomater of bt bearing contact ora 27977-37'990 10181-1020) | 27°84 (1.100) Diameter of re gear contact sre 37/980-30.000 (1a80e1.2061) | 37.03 1.4931 Diomatr of ball Bearing contect sea 27.987-20.000 (11018.1.3024) | 27.84 1.100) funour 6162110.0008) mai 68 10.002) Wanshat 3d 10 39,009-42.025 (1,69837,688 | 43.080 (1.6981) ana ith gears | End ploy 0.68:0.21 (0,.0024-0,0088) 0:30 (0.012) Thickness Srd oar M24, Macé, MaKA 9282-39-47 (0276-1 278) $230.27 mars 3492.34.97 11 375-1.977 3880.30 sen goar M28, Mace, MaKA $0192.20 97 11247-1.210) 3080.2 | mars 31:82.39.47 (1.237-1.299) 313123 Wainahate 8. 43,009-49.025 1.6939-1 693%] 48.080 (1.6961) Sth oe End play 0:60:0.24 (0.0024-0.0085) 0:30 (0.012) ‘hcknoes $0.9230.97 11247-1219) $08 1.213) Counterha | Diomatr of needle bearing contact area 38,000:38,015 (1.4961-1.4967) | 87.98 (1.494 Girt of el bearing and needle boarng comact | 24967 26.000 (assroess) | ange woven Biomater of tet gear contact area 39,986:40,000 1.5742-1.5748) | 29.99.1.572 nowt 8:02:0,0008 mas dos.0o7 | Coanterhaie 10, 46,009.46.025 (1.81147.8120) | 6.08 1.814) Sstgear | End play 0:0%0.10 10.0020.008) | Rest Countorshatt | 10. 47.008-47.025 (,8607.7.8814) | 47.08 1.850) Sedgeor | End ploy 0.0%0.10 (0.002-0.008) Rajot | Fhickneee 2892-26-97 10.1391-181) 2801.19 3-7Standards and Service Limits [~ Manual Transmission — Section 13 (cont'd) MEASUREMENT STANDARD (NEW! SERVICE Lirr 3649.26.49 (7.4982-1 4368) | 96.60 11.497) 41'989-42,000'1,6831-1.6838) | 1'98 (1652) & | 2202200013251 3403" | [- 8 | 28.07-28.08 11.144:1.148) = ‘Spacer cover 3}-002-31.0%2 (1,2206-1.2208) | 31.08 [1 22a) (Mainshat teh 37.989-38,000 (1.4966-1.4861) | 37°98 (1.494) and &ih geen) a | 56.45-56.55 (2.232-2-226) = 8 | 26.03.26.08 (1.0288-1.0268 | 76.01 11.024) Reverse lor oar 20.016:20.043 (0.7880.0.78817 | 20.09 (0.79091 0.026:0.088 (0.00140.0033) | 6.180 10.0008), Sync ving Fing geo learance (ipo Pushed east | 9.1.10 o,094-0.0498) ean ‘Dual cone | Clearance ting pushed against goa) - synchro Outer syncivoringto-eynehio cone 2.5-1,0 10.02.04) 2.3 10.01) Synchro cone-to- gear 85.1.0 10.02.0.04) 03 (001 Outer synetve ring 0-gear _| 0.86-.68,0.037-0.068 __|_ 0.8 10.024) Shit Fork Finger thickness M2J4.M2CE,M2K4 | 6.2.6.4 (0.244-0.252) = Mars 7.4.7.6 10.281-0.298) : Forkto-synaivo sleeve clearance 0136-0.05 10.014-0.028) __|_1.0 (0.099) Reverse shit fom) Paw! oroowe width 18.0-18.3 (0.81.0.52) = For-torevers ile georclerance A 0.5.1.1 0.02.0.43) +8 (007 Groowe wit aa | 7.05-7.28 10.276 0.2664 (gp) 22 | 7771029090) - Forko-fitny HA | 0080.38 (0.002.014) 88 10.02) feverse anit 8 a8 | 04081002000) 18 10.08) shat slearance Shik arm 10. 15.978-16,000 10.6280-0 6295) | — Shit am-to-shat clearence 0.008,0.088 1.00020.00231 | — Shift fork iamatr at contct ares 12,9-13.0 10.508-0.512) = Shitarm-t-sift fork shat clewance 0.2.0.8 0.01-0.02) 0610.2) Select ever Pin size of contact area 79-80 (0.311-0.315) = Select lever to shit peice clearance 6.08-0.25 10.002.0.010) 2.5 10.020) Shatt outer diamet Shift arm cover clearance 18.41-15.68 (0,607-0.617) 10.032-0.102 (0:003-0.0040) ‘Shift arm lever OD. 15.941-15.968 (0.6276-0.6287) { ‘Trensmission housing clearance 0.027-0.148 (0.0011-0.0086) | — Tnteriock Bore diemeter 18.00-16.08 (0.630-0.632) = Shift arm lover clearance 0.082-0.108 10.0013-0.0043) _|— Automatic Transmission — Section 14 MEASUREMENT STANDARD (NEW! senvice usar Tranamsion | Copacty €(08 at mp ad 1G. S39) for overhaul tue (25, 211 for td change Hiyécaute | “ie prespare ot 2.060 min pm 800 (80, 114) 750 75, 107 presrure orfE} postion! {Mette fly-closed thottc move than 9/18 Baosarraony ' one aan? ens) 250 (85, 121) three more than 2/16 open kPa tkglem?, “4th clutch pressure at 2,000 min=* (rpm) 530 (5.3, 75) 480 (4.8, 68) a Det postion eet faltne ‘rottefly-losed i 80 Ws, 129) 750 (7's, 107) ttrote ore than 2/18 open | there more than 2136 _ oon id and Bad Guich pressure ot 3000 min] 600 150, 771 450 5, 64) tom ‘rote fay cosas thtte fly-osea (Bal postion i i 850 6.5, 121) 750 (75,107) throttle mote then 218 open | texte more than 3136 open 3a cute pressure at 2.000 min-" tom) | gop.95018.008.8, 114-121) | 78017.8, 107) | Tet end tet hold cut pressure a 31.3.000 min pm 200.890 18.08.5, 114121) | 780178, 107 Exiposiuon) Throttle B pressure Throw tly dored | 0,0) = Throne fly open | 800.980 0.08.6, 114.121 | 750.7.5, 1071 Fiver | “ne prpatare 083,060 mn tpn) 850 (6.5, 120) 300 (8.0, 1141 pressure or [P} position) ‘throttle fully-closed throttle more than 3/16. Plata tmaanz t open ia 200 18.0, 128) - ttrttle more than 2/16 open wre woiem?, | “ag cutch pressure ot 2,000 min“ Wom) | 590 (6.3, 78) 200 8, oa) one bai (Beipoenen, trottlefly-losea futi-losea | i 00 :.0, 126) 00 180, 114) Grete more than 3/18 open | teste more than 3116 open Ged and Bad hich pressure 3,000 maT | 60D 150.71 50 5 G8) iy tet tly-losed ‘rote fly cosed {(D4] position) 200 1.0, 128) 200 180, 114) Shotts more than 2116 open | tote mare than 316 : open Gutch preserve st 2,000 min-* "Pm | g50.900 (8.6-9.0, 121-128) | 800 (8.0. 114) ‘Ist and Tst-hold clutch pressure - 3121000 min pm 880.900 0.59.0, 121-128) | 200180, 114 Eripostion Thottle B prasure” Tho fly closed | 00, 0 = Tiras faly open | 880-900 @.5-0.0, 121-128) | 900.80, 114) Sia apeed min pd FORA 2A 112242 engines] 2,500 7,350-2,680 ‘hock with cor on ove guna) '~°™*Nagatnizons engines | 2.750 2800-2000 3-9Standards and Service Limits [— Automatic Transmission — Section 14 (Cont'd) MEASUREMENT [STANDARD (NEW) SERVICE LIMIT ‘Gluten ‘Clutch initia! clearance Tethold 4st, 2nd 3ed, 408 Clutch return spring free oneth Vet, 2nd, 3d, 4th Guten aise thickness CGuteh plate thickness ist, Isthold 2nd FZ0AA/E22A11/F22A2 engines H23A1/H23A2 engines 3rd, ath 7,00 (0.031-0.0301 0.85 (0.026.0.033), 6 (0.016-0.024), 1.32) 0 10.074-0.079) (0.077.0.081) (0.088.0.093) (0.077-0.081) {0-089-0.093), 31.8 (1.24) Until grooves wom out Discoloration | Discoleration ‘Valve body Clutch end plata thickness ‘Stator shaft needle boaring contact Torque converter side Oil pump side Oil pump gear thrust clearence il pump gearso-body clearance Drive Oil pump driven gear 1.0. Oil pump shaft 0.0. _ ¢ 2. 2 2 2 2. :2.10 (0.081-0.083) 2.20 (0.085-0.087), 2.30 (0.088.0.091), 2.40 (0.093-0.094) 2.60 (0.096-0.098), 2.60 (0.100-0.102), 2.70 10,108-0.106), 2.80 (0.108-0.110} 2.90 (0.112.0.114) 27.000-27.021 (1.0830-1.0638) 29.000.29.013 (1.1417-1.1422) 0.03-0.08 (0.001:0.002 0.210-0.265 (0.0083.0.0104) (0.070-0.125 (0.0028.0.0049) 14.016-14.034 (0.5518-0.5525) 13.980-13.990 (0.5504.0.5508) Discoloration 1 Discoloration Wear oF damage 0.07 (0.003) Wear or damage Wear or damage Shifting device, | Reverse shift fork finger thickness '.90-6.00 (0.282-0.236) 5.40 (0.213) body. parking brake "| Parking brake paw! Wear oF ather defect fand throttio | Parking brake gear = ‘Wear or other defect control system | Throttle cam stopper height 17.0-17.1 10.669:0,673) ‘Servo body | Shift fork sheft bore 1.0. 74.000-14.010 (0.5512.0.5616) | — Shift fork shaft valve bore 1.0. 37,000:37.039 (1.4567-1.4582) | 37.045 (1.4585) Regulator valve] Sealing ring contact 0. '35.000-36.026 (1.3780-1.3789) | 35.05 (1.3799) ‘Accumulator Sealing ring contact 1.0. 32,000-32.015 (1.2588-1.2604) 32.080 (1.2618) ‘Stator shaft 291000.28013 (1,1417-1.1432) 23.050 (1.1437) fa 3-10 ring contact area ‘of stator shaft On countershoft of Tat gear color On countershaft of 4th gear On countershatt of parking gear On countershaft of reverse gear On secondary shaft of Tst gear (On secondary sheft of 2nd gear On roverso dior gear shaft Inside diameter Mainehatt 3rd get Mainshaft ath gear Countersheft 13t geor Countershaft 4th gear Gountershaft reverse gear ‘Countershaft idler gear Secondary shaft 1st 22,984-23.000 (0.9048-0.9055) ‘45.984-46.000 (1.8104-1.8110) $31.984-32.000 (1.2592-1.2598) 40.984-41.000 (1.6135-1.6142) 31.975.31.991 (1.2589-1.2596) '39,984.40,000 (1'5742-1:5748) '36,979.36,000 (1.4165-1.4173) 31.975-31.991 (1.2589-1.2595) 31.975-31.991 (1.2889-1.2595) 13,990.14.000 (0.5508-0.5512) '52,000-52.018 (2.0472-2.0480) '38.005-38.021 (1.4963-1.4969) '47,000-47.016 (1:8508-1.8510) 38,000-98.016 (1.4961-1.4967) 442,000-42.016 (1.6535-1.6542) '48,000-48.016 (1.8898-1.8904) '96,000.36016 (1.4173.1.4179) 37.000 37.016 (1.4567-1.4573), 34 800.14 824 (059827.6.0030) |_w ‘Wear or damage[— Automatic Transmission — Section 14. ————___— MEASUREMENT STANDARD (NEW) SERVICE UNIT “Tronemission | Mainsheft 3rd gear collar length 19,50-19.85 (0.768.0.770) | — (cont'al Mainshaft 4th gear collar length 47.50-47-55 (1.870-1.872) | Wear or damage | Countershart 1st gear collar length 27°80-27.55 (1.083-1.085) | Wear or damage ‘Thrust washer thiekness Countorshaft Tet goar 1.45-1.50 (0.087-0.059) Wear or damage Countershaft idler gear 3.48.3.55 (0.136.0.140) Wear or damage CCountershaft parking gear fongth 25.030-25.048 (0.2854-0.9861) | Wear or damage Secondary shaft Ist gear distance collar length 4.98-6.00 (0.195-0.197), Wear or damage ‘Secondary shaft 2nd gear sping washer “4.02-4.05 (0.158-0.189) = thickness 35. 53 ram 4.07-4.10 (0.160-0.161) = 4.12:4.15 (0.162-0.163) 4:17-4:20 (0.164-0.165) = 4:22-4.25 (0.166-0.167) = 4:27-4:30 (0.168-0.169) = | 4'32-4.35 (0.170-0.171) = | 4.37-4.40 (0.172-0.173) = 4:42-4:45 (0.174-0.178) = STANDARD (NEW) ea 00. Free Length | _ No. of Coils ‘Spring Regulator valve spring A F20ASIF2201/F22A2 engines | 1.8 (0.071) | 14.7 (0.579) | 86.5 (3.406) 165 H23A1/H23A2 engines 180.071) | 14.7 (0:57) | 98.6 3.488) 18.8 Regulator valve spring B 1.810.071) | 9.610.378) | 44.0 11.7321 12.7 Stator reaction spring 450.177) | 26.4*{1.039) | 30.3 (1.183) 1.92 Torque converter check valve spring 1.1 (0.043) | “8.4 (0.331) | 38.2(1'504) 140 Relief valve spring 100.039) | 8.4 0331) | 39.1 11.539) 15.1 Cooler reliet valve spring 11 (0.083) | 8.4 (0.331) | 46.8 (1.843) 170 2nd orifice control valve spring 0.6 (0.024 | 6.610.260) | 58.3 (2.295) 15.8 Orifice control valve spring, 0.8 (0.031) | 6.610.260) | 52'5 (2.087) 33.0 ‘4th exhaust valve spring 0.9 (0.038) | 7.110.280) | 60.8 (2.394) 28.9 Throttle valve B adjusting spring o.a(oost) | 6.210.244) | 30.0 (1.181) 30 Throtte valve B saring 1.4 (0.085) | 8.5 (0.335) | 41.5 (1.634) 10.5 | 1410.05) | 8.5 (0.335) | 41.5 (1.634) 2 1.410.055) | 8.5 (0.335) | 41.6 (1.638) 14 1-2 shitt valve spring 1.010.039) | 8.6 (0.339) | 41:3 (1.626) 169 2.3/5-4 shift valve spring 0.9 (0.038) | 7.6 10-299) | 57.0 (2.244) 26.8 Yethold accumulator spring 4.0 (0.157) | 25.010.984) | 64.7 (2.547) 73 {st accumulator spring 1.810.071) | 16.3 (0.642) | 118.4 (4.543) 188 4th accumulator spring 2910.14) | 22.0 (0.868) | 90.1 (3.547) 103 2nd accumulator spring 3.5 (0.138) | 22.0 (0.866) | 77.1 (3.035) 10.0 5rd accumulator spring 2.8 0.110) | 17:5 10.689) | 94.2 (3.708) 16.1 Lockeup shift valve spring 0.9 0.035 | 7:6 0.229) | 73.7 (2.9021 320 Lock-up timing valve spring 0.810.031) | 6.6 (0.260) | 51.1 2.012) 147 Servo control valve spring, 1.0 (0.039) | 8.1 (0.319) | 62.6 (2.071) 22.4 CPC valve spring 1.410.085) | 9.4 (0.370) | 33.0 (1.299) 108, Modulator valve spring 140.085) | 9.4 (0'370) | 33.0 (1.299) 108, Lock-up control vaive spring 0:7 (0.028) | 6.6 (0.260) | 38.0 (1.436) 14.1 23rd kiek-down spring 110.043) | 7.6 (0:290) | 48.3 11:90) 23.3 3:2 kick-down spring 1.210.047) | _7.1 (0:280) | 46.9 (1.846) 206 3-11Standards and Service Limits [-_ Differential (Manual transmission) — Section 1 | MEASUREMENT ‘STANDARD (NEW) | service unr Differential 9 1.0. 18.000-18.018 (0.7087-0.7094) ‘carer pinion clearance 0.013-0.047 (0,0005-0.0019) 0.10 (0.004) Driveshaft contact area 1.D. 28,005-28.026 (1.1026-1.1033) | — Carcier-to-driveshaft clearance R | 0.025-0.066 10.0010-0.0026), 0.12 10.005) | t_| 0.085-0.091 10.0022-0.0036), 0.16 (0.006), Differential Backlash 0.08-0. 15 (0.002-0.006) ‘Adjust 10. 18.042-18.066 (0.7103-0.7113) | — Pinion gear-to-pinion shatt clearence 0.086-0.095 (0.0022-0.0037)_| 0.18 (0.006) Tapered roller | Starting torque Nem tkg-em, Ibn) 142.6 (14-26, 12-23) ‘Adjust bearing preload (Differential (Automatic transmission) — Section 15 MEASUREMENT | STANDARD (NEW! SERVICE LIMIT Differential Pinion shaft contact area 1.0. 18,000-18.018 (0.7087.0.708) | — carrer Carrierto-pinion clearance 0.017.0.047 (0.0007-0.0018) -_| 0,10 (0.004) Driveshaft contact area .D. 28.005-28.025 {1.1026-1.1033) | — Cartier to-criveshatt clesrance 0,025-0.066 (0.06100.0026) | 0.120.008) _| Differential Backlash 0.08.0.15 (0.002-0.006) ‘Adjust Lo. 18.042-18.086 (0.7103.0.7113) | ~ Binion goar-to-pinion shaft clearance 0.089-0.098 (0.0023-0.0037)_| 0.12 (0.005) Tapered roller | Starting torque New bearings | 2.8-4.0 (28-40, 24-95) ‘Adjust Nem tkg-em,tb-n) Reused bearings 2.5.3.7 (25-37, 22-32) Section V9 MEASUREMENT STANDARD (NEW) Steering whee! | Play at steoring whee! circumference (01.0 (0-04) Starting load at steering wheel crourference N (kg, Ibs) Engine running 30 (3.0, 6.6) When the hydraulic system to the speed sensor is cut off 50 15.0. 11.0) Gearbox ‘Angle of rack-guide-screw loosened from locked | ogy + 8° position 8 7 Pump Pump pressure with shut-off valve closed (epeed: idle. Do not run for more than 5 seconds) KPa kglem?, psi) 7.000-8,000 170-80, 995-1,138), Power steering ftuid Recommended fluid Fluid capacity System AUS at, imp atl Reservoir Honda power eteeringfluic-V 1.71.80, 1.60), 0.5 (0.53, 0.44) Power steering belt* Deflection with 100 N (10 kg, 22 Ibe) Between pulleys 18.6-16.5 (0.53.0,66) with used bolt 915-11.8 (0.37-0.45) with new belt Bolt tonsion W (kg, Ibs) Measured with beit tension gauge ‘350-500 (35-50, 77-110) with used belt 700-900 (70-90, 154-198) with now belt * When using a new belt, adjust deflection or tension to new valves, Run the engine for 5 minutes then tum it off Readjust deflection or tonsion to used belt values, 3-12(— Suspension — Section 18 ——————— MEASUREMENT STANDARD (NEW) Whee! Camber Front O° 00 1° y alignment Ror -08 45 1° rows! Caster Front 2040 21° Total to0 Front 0 + 200 +0.08) Reer IW 2.0 *2.0 (0.08 +0.08) Front wheel turning angle Inward whee! 36° 20" 2° Gutward whee! 29° 40° (reference! Whee! Camber Front 3 oo 21° alignment Rear 08 45° =30" (aws} Caster Front 29.40" 1° Total toe Front 0+ 2000 =0.08) Reor IN 2.0 2.0 (0.08 +0.08) Wheel turning angle Inward wheel Front 36° 20" +2" Re ‘6° 00" 27° Outward wheel Front 29° 40" (roference) Rear 18° 20" ireterencel Whee! Fim runout (Aluminum whoa) ‘Axial 0.0.7 100.03) Radial 0.0.7 10.0.0) Rien runout (Steel wheel) Axial 0.1.0 100.04) 7 Radial 0-1.0 (0-0.08), Wheel bearing | End play Front 10-0.05 (0-0.002) | oer -0.05 (0-0.002) Brakes — Section 99° $$$ fl MEASUREMENT STANDARD (NEW) SERVICE LIMIT Parking brake | Play in strake 200 N (20 kg, 44 tbe) lever force Ta be locked when pulled | — lever 6-10 notch: Foot brake | Pedal height lwith floor mat removed) Mit | LHD: 165 (6.50) = pesst BHD: 180 (7.09), : am | 186 (7.32) = Fro play 1-5 1/16-13/68) = Master cylinder | Piston-to-pushrod clearance Without ABS | 0.0.6 (0-0.02) = With ABS | 0.0.2 (0.0.01) = ise brake | Diso thickness Front 23.0 (0.81) 21.0 10.83) Bear 10.0 10.39), 2.0 (0.31) Dise runout Front 0.10 10.008), Rear 0.10 (0.004) Dise parallel Front and rear 0.018 (0.0006) Pad thickness Front 12.5 (0.48) 158 10.06), 11.0 (0.43) 1.6 10.08)" Rear 9.6 (0.38) 118 10.08), Cheracteristies_[___Vacuum mma Pedal Pressure kg (ibs) | Line Pressure KPa lkgiom, pal 0 20 (44) 7,030 (10.3, 146) min Without Aas: 300 20 (44) 5,690 (56.9, 808) min 800 20 (44) 8,030 (8.03, 1,142) min. ° 20 (4a) 790 (7.9, 112) min with ABS 300 20 (24) 6,320 (63.2, 899) min 500. 20148, 7/880 (78.8, 1,121) min. 7 Gare with H29A2, H22AT and H22A2 engines 3-13Standards and Service Limits r- Air Conditioning — Seetion 22; MEASUREMENT STANDARD (NEW) ‘ir conditioning system Lubricant type: SP-10 (PIN 38899-P13-003) (For refrigerant: HFC-1 34a (R-134a)) Lubricant capacity Condenser | 10 (1/3, 0.4) ‘me if 02, mp oz) Eveporetor | 30 (1. 1.4) Line orhose | 10 (1/3, 0.8) Receiver 1011/3, 0:8), ‘Compressor | Lubricant type: SP-10 (PIN 38898-P13-009) (For ‘etrigerant: HFC-134@ (R-134a)) | [Lubricant espacity mé (f 02, Imp ox) 120-140 (44.213, 4.24.9) Startor coll resistance at 20°C (68°F) & 3.05-3.35 Pulley-to-pressure plate clearence, 0.5 © 0.16 10.02 + 0.006) Compressor | Deflection with 100 N (10 kg, 22 fs) 10.0-12.0 10.39-0.47) with used bet bate" between the pulleys 4.5-7.0 (0.16-0.28) with new belt Bolt tension Nika, (bs) Measured with belt tension gauge ‘Except H22A1, H22A2 engines H22A1, H22A2 engines "450-600 (45-60, 99-132) with used belt 950-1.180 (95-115, 208-254) with new belt 41,000°1,180 (100-118, 220-264) with now belt Elect 77 When using @ ne tension to used \ew belt, adjust dtlection or tension to new values. Run ott valuos the engine for 6 minutes then turn it off. Readjust deilection or 3D Section 23} Am (MEASUREMENT [STANDARD (NEW) Ignition coil Rated voltage V 12 Primary winding resistance 9 at 25°C (77°F) 0.6.0.8 a Secondary winding resistance ka at 28°C (77°F) | 12.9-19.2*2, 14.4-21,6"2 ‘Spark plug Type ‘See section 23 (Base manual code No. 6258000 and this supplement) L Gap 41.0"1.1 (0.039-0.043) [Tanition timing [At iding 15° + 2° (Red) BTOC a ‘Alternator Deflection with 100 N (1.0 kg, 22 Tos) Excopt H22A1, H22A2 engines: 10.0.12.0 10.350.47) bett*' between pulloys ‘with used belt H2281, H22A2 engines: 10.5-12.5 (0.42.0.51) with used belt Excopt H22A1, H22A2 engines: 8.5-11.0 (0.93-0.43) with ew belt H22A1, W22A2 engines: &.0-10.0 (0.52-0.40) with new belt Belt tension N (kg, bal Moacurod with bait tension gouge ‘300-450 (30-46, 66-99) with used belt Except H22A1, H22A2 engines: 500-700 (50-70, 110-154)| ‘with new belt H22A1, H22A2 engines: 550-750 (65-75, 127-165) with naw belt ‘MEASUREMENT ‘STANDARD (NEW! ‘SERVICE LIMIT ‘Output 13.8 V at hot A ‘BO/85**, 80198", 95/1027 (NIPPONDENSO) | Col resistance (rotor) @ 2-28 = Slip fing 0.0. 13.8 (0.97) 12.8 (0.50) Brush length 10.5 (0.41), | 5810.22) Brush spring tonsion_g (02) 300-260 (10.6-12.7) S 7 ‘Starter moter | Type ‘Spur gear reduction, Permanent magnet (MITSUBA. ‘Mica depth 0.4.0.8 10.016-0.020) (0-18 (0.006) 14 RW) Commutator runout 0.0.02 (0-0.001) (0.05 (0.002) Commutator 0.0. 28.0-28.1 (1.102-1.108) | 27.5 (7.083) Brash length 15.8-16.2 (0162-0.64) 11.0 (0.43) Brush spring tension (new) —N (kg, Ib) 16.0 18.0 (7.60.1.80, 3.533.953) = ‘Starter motor | Type ‘Spur gear reduction, Permanent magnet (miTsuBa, Mice depth 0:4-0.5 (0.016-0.020), 0:18 (0.006) 1.6 KW) Commutator runout 00.02 (0-0.001) (0.05 (0.002) Commutstor 0.0. 28.0-28.1 (1.102-1.106) | 27.5 (7.083) Brush length 15.8.16.2 (0.62.0.64) 11.0 (0.43) | Brush spring tension (new! _N kg, 1b) 16.0 18.0 (1.601.80, 3.58-3.95)| ~ tension to used belt values 3-14 F204, F22A2, H23H2,H22A2 engines F22A1, H23A1, H22A1 engines F20A3, F22A1, F22A2 engines 1: H23A1, H23A2 eng +: H22A1, H22A2 engines When using @ new belt, adjust deflection or tension to new values, Run the engine for § minutes then turn off, Readjust deflection otDesign Specifications | mem METRIC I ENGUSH NoTES DIMENSIONS | Overall Length 4.440 mm 174.8in ‘Overall Wigth 1.765 mm 69.5 in Overall Height 1.290 mm 50.8 in | Wheelbase. 2/550 men 100.4 in | Track Frome 1,526/1,515 mm 60.0159. in | Ground Clearance 145 mm 5.7 In | Seating Capecity Four a weight Soe page 3-18 to 310 ENGINE Type F20A4, F22A1, F22A2 engines cooled, 4-atroke SOHC gasoline engine H23A1, H23A2 engines ‘cooled, 4-stroke DOHC gasoline engine | H22A1, H22A2 engines ‘Water-cooled, 4-stroke DOHC VTEC. ‘gasoline engine Cylinder Arrangement Inline cylinder, transverse Bore and Stroke F20A4 engine 85.0 x 88.0 mm 3.35 ¥ 3.41 in F22A1,F22A2 engines | 85.0% 95.0 mm 3.35 x 3.74 in | H23A1, H23A2 engines | 87.0 x 95.0 mm 3.43 x 3.74 in | H22A1, H22A2 engines | 87.0 x 90.7 mm 3.43 x 3.97 in F20A4 engine 1,997 em? (mt) 122 eurin F22A1, F22A2 engines 2/156 om? (mt) 132 eudin H23A1 engine 2,288 om? (mb) 138 eusin H2342 engine 2,288 em? (mb) 138 cusin H22A1, HB2A2 engines | 2.157 em? (md) 182 cua Compression Ratio F20A$ engine 85:1 F22A1 engine aa:s F222 engine Bart H23A1, H23A2 engines ast 12281, 12282 engines 10.0: 1 Valve Train F20A4, F22A1, F22A2 engines Bolt driven, SOHC 4 valve per cylinder H23A1, H23A2 engines, Bolt driven, DOHC 4 valve per evlinder H22A1, H22A2 engines Bolt driven, DOHC VTEC 4 valve per ovlind Lubsleation System Forced and wet sump, trachois pump il Pump Displacement at 6,000 min~' (rom) F204, F22A1, F22A2 engines 54.3 € (58.7 US at, 47.3 Imp atiiminute Except F20A4, F22A1, F22A2 engines 59.1 £ (62.5 US at, 52.0 Imp qtminute ‘Water Pump Displacement st 6,000 min" pm) F20A4, F22A1, F22A2 engines, 165 £(174 US at, 145 Imp ati/minute H23AT, H23A2 engines 159 ¢ (168 US at, 140 Imp atiminute H22A1, H22A2 engines 163 € (172 US at, 143 Imp qtiminute Rocommanded Gasoline F20A4, H23A1, H29A2, H22A1, Promium UNLEADED grade gasoline with 95 | F22A2 enginos* H22A2 engines Research Octane Number (RON! or higher | UNLEADED grade F22A1 engine UNLEADED grade gasoline with 91 gasoline with 91 Research Octane Number (RON} of higher | RON or higher F22A2 engine! LEADED grade gasoline with 9% ray also be ved Research Octane Number (RON! or higher ‘STARTER | Type ‘Gear reduction Normal Output 14 kW, 1.6 KW. Normal Voltage 12) Hour Rating 0 seconds Direction of Rotation Clockwise as viewed from gear end Weight 37 kg L 3.2 Ihe cuuTCH ‘Clutch Type wr ‘Single plate éry, diaphragm spring AT Torque converter (Clutch Facing Ares wr 203 em? 31 sain (cont’s) 3-15Design Specifications — (cont'd) mem metic | —_eNGUSH Notes TRANSMISSION | Type MT ‘Synchronized 5-speed forward, 1 reverse: - at tlectronealy conolled ‘+epeed automatic, 1 reverse Primary Reduction Ores ti Manual onsmission Fane, | Fada2 | H29Ai, | HOZAt Fazat | engine | H2aa2 | Hazaz engines engines | engines Gear Ratio as 3.307 | 3307 | 3.307 | 3.307 2nd Y903 | Ye09 | i809 | 1.950 ord y2e0 | i230 | 1208 | 11360 a oss | oes | oass | 107 sth over | 0757 | 0787 | 0870 Reverse |_ 3.000 | 3000 | 3.000 | 3.000 Final Reduction Gear type | Single Fecal gear rato 3.266 a.2e6e' | +1: 42201 engine .062"2 | +2: #2202 engine ‘Rotomatie wansmiasion FOOAG, FAA1, HI3AT | __F22A2 enaine H23A2 engines L Gear Ratio is 2.705 2.705 and 1386 Ya38 ara V028 1.028 ath 0750 0731 Reverse | 2087 2087 Fina! Reduction Gear Tyb0 Single helical gear Rao "4288 _ aR Cooling Capacity 14,600 BTU CONDITIONING "Compressor ‘Type/Make- ‘Scroil/SANDEN Novot Gyinder — Cepaciy 85.7 em? (méyrov | 5.23 cwinltev Sheed "10,000 enin~* tom) Lubricant Capacity 120 me 1" ath oz, 4.2 imp oz Lubricant Tybe ‘SP"10 (PIN 98899-P13-003) [Condenser Te Compote in Evaner “Type Cor Motor input 220 wna V Speed Control ‘oped Mase Capacity —_ 400mm "16.247 cu-ten “Temperature Control : imi ee Compressor Chuteh Type Diy, ainleplote, poly-V-beh arive Power Consumption 42 W mon 12 Vat 20°C (08°F) Refrigerant Type HFC-13¢a (R-1340) Qvontity LHD 650.89 22.9.8 o2 HO 700-8 9 24.7.1 oz STEERING | Twos Power assisted, rack and pinion SYSTEM | Overall Ratio. wer 18.80, “ws! 18.1 Flee, Lock to-Lock 2wS: 291. 4WS: 2.77 Staering Whee Biometer | aeomm | 15.0 i \ 3-16| trem MeTRIC ENGLISH NoTes Headlights Inside Outside Fuses In Under-dash Fuse/Relay Box In Under-hood Fuse/Reley Box 12. V—95 A", 12 V-90 A*7, 12 V—80 AP TBA, 108, 18.A, 20, 30.8 TS ANOA, 18A, 20 A, 30 A, 408, 50 A, 60 A, 100 A 12.V—88 Wes, 32 V—65 Wr? 12V—60/85 W*?, 12 v-55 W"!0 Front Turn Signal Lights 12-21 Ww Front Position Lights 12V-5W | Sige Turn Signal Lights 12V-5W oar Turn Signal Lights | 1av-21w ‘rake/Tatlights 12V—21/8 W Back-up Lights | 12v-21W Rear Fog Light"? 12v—31 w License Plate Lights 12v—5 WH, 12 V—8 weld High Mount Brake Light" i2v-24 cP Interior Light i2v-8w Trunk Lights 12V-3.4W Gauge Lights 12 V—1.4 W, 1.7 W, 3.0W Ingieator Lights 12V=1.12W, 1.4 W, 1.7 W, 3.0W, 3.2W Mlumination and Pot Lights 12. V-0.56 W, 0.84 W, 0.91 W, 12 W, 1.4 W, LED | Hoator tlumination Lights A2Vv-1.4W SUSPENSION | Type Front Independent double wishbone, cl spring with ‘stabilizer Roar Independent double wishbone, coil spring with ‘stabilizer Shock Absorbs Front and Rear | __Telescopic, hydraulic nitrogen gas-filed WHEEL Camber Front (0°00 ALIGNMENT Rear 0°45" Caster Front 2°40" Total Toe Front Om on { Rear n2.0 mm __1n 0.08 in BRAKE Type Front Powor assisted self ecjusting ventilated disc SYSTEM Rear Power assisted self-adjusting soli dice Ped Surface Area Front 5B.0.cm? x2 8.99 sein x2 49.4 om? x 2 17.88 sain x 2 Roar 27.9 om? x2 4.32 sgn x 2 Parking Brake Type Mechanical actuating, rear two wheel brakes Tike ~ [Size and Pressure [See tre information label on the driver's door jamb: ELECTRICAL Battery 12. V=88 AH/SHR®', 12 V=62 AH/SHR™? 12.V-8 AH/SHR®® Sterter 12V— Te kWes, 12. V1.4 KWH Altornator ST: H2SA2 (KS medal), H22AT, H22A2 engines 12: H23A2 (except KS modell, F20A4, H23A1 engines 13: F22A1, F22A2 engines ‘$4: Excopt F20A4 (MIT), F22A1 (MIT), F22A2 engines 18: F20A4 (MIT), F22A7 (MIT), F22A2 engines "8 H22A1, H22A2 engines "7: HZQAT, H2GA2 engines 78: F20A4, F22A1, F2ZA2 engines +8: Excopt KY model 219: KY model +: Bxeapt KO, KY, KT modole #2: Except KY, KT models 3: KY, KT modots 2 KO, KY models 3-17Design Specifications European Models WEIGHT vem erate ecusn | _nores Garb Woghe 2oemm 122049 2.99010 | Ke, Ko", KS, KE vee te Zloae ws __| Kee 7 zo1ar 1.245 kp 2.745 be] KF, RGF RS, RE uz20ig | Zant | Kee ZOU MT wih ABS 1235 ba 2.723 Ibe] KF, KOT KS, RE 1310tg 2068 iee__| weet ROU AT with ABS 7.260 ky 2.778 Ios | KF, KO" KS, RE K2sig | 2iyzeme | Ree 23.00 wih ABS 1-250 ko 2.756 ine | KF, KG* KS, RE 122008 Zrotis__| kes" RCAF with RES 1275 kp 2.811 he] KF, KEY KS, RE 128089 area | kes 230 Wi wl RBS, AWS 1.270 ke 21800 bs | KF, KG KS, RE tas 2a8ibe | Kees BRT ATT wih ABS, AWS 1295 ba 2.955 bs | KF KOT KS RE 270 Zoos | Kee" zacvicwT 1/208 kp 2.977 bs] KF KG*, RS, RE 1300 68 Zezate | Kes Weight Disbatons onoan Born 7e01860ks | 1.678/1,01416 | KF.KOM, KS, KE ‘s roe Zotar TOsIR60 tg | TAT,OT4 | KE KG RS, RE 2 y ee (2.00 MIT with ABS: 773/462 kg 1,704/1,018 Ibs | KF, KG*?, KS, KE a Be ZOUAT with ABS 7981862 eg | T7897, 078 | KF KORE RE iS Ey hau STMT wih ABS Fasiesig | 1 7807,028 te | Ke. KG KS, RE *° kes 230 ATT with ABS 810/465 kg 1,786/1.025 Ibs | KF, KG*1, KS, KE “ Z fee ZT with ABS, AS 7OBIa85 kg | 1.78971 008 ts | KF, KOT, KS, RE - zy Ge 2.3 0 AIT with ABS, 4WS_ 810/485 kg 1,786/1,069 Ibs KF, KG*', KS, KE = ke a20vieeweT 5081497 ke | —V 7BNIV OB Woe | KF, KO, KS, KE u [ko Max, Pornisabla Weight TAF 17201 | —a782 KG*1: KG type except Netherlands, KG*2: KG type for Netherlands (half tank of gesoline!. 3-18Except European Models | re metric ENGUISH ores want | cut weight 2aemir 1.220 kg zes0e | Ko 1260 Kg 2770 | KY aan 1245 ko 2.7456 | KO 12208 69 Zeastte | kv Pr 1.268 ko 2.70916 | KO 23tan 1280 te Zeesiee | KO 2.3 CMIT wih AOS, SAS 1.300 ke 2.8061 | KO 253 LAT with ABS, SRS 11338 tg Zerit | KO “Z2evtec Mit 1325.9 2.82116 | KO Weight Distibutions(FontReat 2eMr 7s01470%—0 | 1.959/1.038me | Ko ireaes te | 1300/1;060 ee _| KV _| 220A 775/470 %9 | —1.709/1.038 ms | KO sores tg | 1760/1068 te_| Kv 2acMr 77074983 | 1.698/1.081 ms | Ka 23uan roses x | 1350001 | KO 2.3 (MIT with AOS, SAS 305/498 x9 | —1-775!1.091m= | KO 2.3 CAT with ABS, SRS asoass ig | 1ea0rt.001 te | Ko _| 22evrec wir 215/510%3 | 1.797/1.124bs | KO Max. Lnaded Vette Weight (ADR) 1,655 kg 3684s | KO Max. Vehicle Weight (MV 17209 3702s | KY 3-197ST ase Unit: men in)Maintenance Lubrication Points ... Maintenance ScheduleLubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section, No. LUBRICATION POINTS. LUBRICANT 7 | Engine ‘Always use a fuel-efficient oll is that says “API Service SF, SG or SH. SAE Viscosity: See chart below. 2 | Transmission Manual ‘API Service Grade: SF or SG SAE Viscosity: 10 W-30 or 10 W-40 ‘Automatic Honda Premium Formula Automatic Transmission | Fluid or an equivalent DEXRON® II Automatic transmission fluid | Brake Line Clutch Line Brake fluid DOTS or DOTA Brake fluid DOTS or DOTS ‘Steering grease PIN 08733 BO70E Shift lever pivots (Manual transmission) Grease with molybdenum disulfide 3 4 5 | Power steering gearbox 6 7 | Release fork (Manual transmission) 3 Steering boots 9 | Stoering ball joints Urea Grease UM264 PIN 41211—PY5—305 10 | Select lever (Automatic transmission) 11 | Pedal linkage 12 | Intermediate shaft 13 | Brake master cylinder pushrod naa aaesntareceat 14 | Trunk hinges and latches eee 15 | Door hinges upper/lower and latches 16 | Door opening detents 17 | Fue! filer id 18 | Hood hinges and hood laten 19 | Clutch master cylinder pushrod 20 | Throttle cable end 21 | Caliper Piston seal, Dust seal, { Caliper pin, Piston Silicone grease 22 | Shift and select cable ends 7 23 | Power steering system Honda power steering fluid-V 24 | Air conditioner compressor Compressor oil: SP-10 P/N 38899-—P13—003 (For Rofrigerant: HFC-134a (R-134a)) Select the oil for the car according to this chart: CAUTION: Used engine oll may cause skin cancer if repeatedly lettin contact with the skin for prolonged pe ‘ods. Although this is unlikely unless you handle used oll ‘on a dally basis, itis stil advisable to thoroughly wash your hands with soap and water as soon as possible ter handling used oil 71: Except cars with H22A1, H22A2 engines. #2: Cars with H22A1, H22A2 engines. 4-2Maintenance Schedule aunbes smoejquew Aq pepuowutor9: ‘apow! Sy 404 ‘Ze 000'09) 4 000°001 40 s1B04 g Arana s0e\doy :1, 2N9| 1UEIOOD PUB Ly ‘JO BuiBUE) A129 Aep Or ACG, ia ‘S0UWOD JaAQYOIYM "(Sy jeonse1d euop 24 pinoys seworsno oy) Aq jenuew 5 12umo yp 01 BuIpsoo0e T (00 8161 Pue pIBGS BIpy $189 104 JeUBAUOD OBAjeHD WIM 1D 105 [| ae «| Ela|—)e Jeuienuos onAjere9 IM S80 104 a "seuiBua Zv2zH “LWZZH 404 sBnjd eds ~ a wejo09 auibu3 Suop9eUUOD pue sas0y WaIsAs Buy00D | 7 ~ dnd see yaq Je9Uue|eq BuIA pue yeq Guan, jnossaiduos oiy Tomod “Pieurmy)BuoRpUOD PUB DOUBT 9g [A [sepa ueedoins veus oino 203 | i Sjepow ueadoing 103 aoueresto anien a ‘sj@pow ueedoang ueW eyo 203 | ~ ~ = ‘sjepow ueedoing 104 NO UoIssywsUELL « 300071 Mano aoe\doy | sepou veadoing ve .R0 03] Savou 2130 Fa 000'9) WH 000° have BEDE siopow uvadoina 10a | - J pue yo ou «| 96 | v8 | zz [oo | ev [98 [ez [zi] amow - — 96 | v6 | ez [00 [a [se | ve Sein o09r ¥ secu 091 [ort ozt oor] 08 | 08 [or oz | whoo ey (0 ae ae ‘Asess000u j! 900d! 10 sed “Ah ‘snipe ‘ue9jo ‘uonsadeul seyy Aoedsu—| eoeidoy—y 4-4Beque s,soBuessed yim sie 10) 1409%3 :£, warsig auensay yeruawa\ddng “948 SeipUBY 200P “ j09 10 68 (Suon@edo piBoqUseP “AIgeS “SSION) BAUP 189, 3uom Apoq pue seBewep Wwleg ‘ieeq 1yBypeay pue uoNeredo si ‘sqauow 2, ‘squow & th squow 2 Tee Peo iy aves ea 1 Aone veda {aieds Buypneuy) essed pue seem 7 ina woqupues Aiieg 7 Avene 130654 | 9701 9 1 uonseuueD pue Fesoy “UO;IDuN) BulBals TMOG i iepow Sint zl ((apow gant 10) soven9e Je94 BuIprjou)) 1 Tapour guy 10) 1400%q | __st009 pue xoq Je96 “spu9 pov-oN “uonduny BuLDONS 1 —— ‘siuauodwoa uorsuedsng 1 C i 1 ‘iauiani aaAeIE9 Gv 689 76g) PAI YOU J9UOANOD SAAD ~ UOTIPUOD PUR WaTBhS TEM=IR 103) 8504 @unssaid yBuy wersAs oyeIa yO ANY Geo 10g) woperedo Walshe axe BOE Tau pur ser0y 88g Be ugieedo 07819 6uPied sped put Bd99 oRIp Byeia 0 ‘sy8die9 pue S05Ip Oye14 1U01g sped 6ye1q 1u01 ‘zi {aor 96 | va | zc | 09 | ar | ve | vz ‘zt [sor | 96 | v8 | zz | 09 | av | 9¢ | ve 002 [081 | 091 fort |ozt [oor | os [09 | ov ‘sqquow 00071 WF 000" sequnu eo1nies ‘A1@S8090U 4! 80 E yy apedsuj—| 299iday—y 45Maintenance Schedule (cont'd) sxiuou 9 70 [52H 000'9) WH O00'OL ORT | 1 weisks Buuseis moa |» a+ Des Suiuou 21 20 (8eiw 000721) wr O00"OZ Kiang || Sped pu® siadyeo soap yea eeu | da 0+ BY W 000°9) 4 OOO"OL Wena | 1 Suadhe0 pov So5pp ea wos | a aqe BY w 000'OZ AuaA3 y T 1 000°8) 4 00070! Alena] | _seuonuoo onAreieo inoyuan sie9 104 000'bZ) 4 000'Or A1eng a [_ wy 000'02 Kena |_| _setienuos andrea yum sieo soy | ywawiejo 10U8=F ay wt 000'0% A18A3 u WO uorssiwsuel| 5000's Kong | Sjepow ueodomy wen iauio 70g ven r ‘SyIUOW g 10 (0006) wH 00's Aiea | oy ‘sjopou ueedoing 1oa pue yo oubuy | yee egy vearoiu voneiedo | sousueiuieW uontpueg ‘faesso00u 1! 909idos 10 edad ‘dn iy “isnipe “veala ‘UoNoedsu oy asedsuI=| wedID=9 BomNlay uy 9211 & Bula peo) Appr 4o/pue yBnos uo S[euoiew anisouoo sayio ‘suompuod AYsnp ul Bulag :g UEISIp LOYS pareaday :y :pnjoul suonipuos Bunup sveneg sel ‘SuORPUOD BuIAUP e1enas 49pun pasn AjewoU soueuayuiew syeudordde ays x 129 Uo Ajuanbayy s10W pany mojeq u8yo a spy swey} BuIMO}O} BULL, suompucg Bung s10n0g 4-6Engine Lubrication Engine Oil Replacement . NOTE: The H22A1 engine has been adopted. For the service proce- dures, refer to the procedures for H22A2 engine Refer to Shop Manual 6255000 and 6255020 for the items not shown inthis section, Outline of Model Changes [reer tn bansEngine Oi r- Replacement 1. Warm up the engine. 2. Drain the engine ol pran/sour Boot arom, Wasien 3. Reinstall the drain bott with a new washer, and refill with the recommended oil. Requirement | Always use a fuel-efficient oils that says "API Service SF, SG or SH”, SAE Viscosity: See chart right column, Capacity | F20A4, F22A1, F22A2 engines: 3.8 (4.0 US qt, 33 Imp qt) at change, including filter. 4.9 € (5.2 US at, 4.3 Imp gt after engine overhaul. H23A1, H23A2 engines: 4.3. (4.5 US at, 3.8 Imp qt) at change, including filter 5.40 (6.7 US qt, 4.8 Imp atl after engine overhaul. H22A1, H22A2 engines: 4.8 (6.1 US at, 4.2 Imp at) at change, including fiter 5.9 (6.2 US qt, 52 Imp qt) after engine overhaul. Change Every 10,000 km (6,000 miles) or 6 L (12 months: *3: European models Engine Oil SAE Viscosity for Outside Temperature Ranges. “200008 Ambient temperature ranges +1: Except H22A1, H22A2 engines *2:H22A1, H22A2 engines 4. Fill the engine with oil up to the specified level, run the engine for more than 3 minutes, then check for oll leakage. 8-2Fuel and Emissions Component Locations Index .. System Description Vacuum Connections Electrical Connections Troubleshooting Self-diagnostic Procedures .... PGM-FI Control System Ignition Output Signal . Fuel Supply System Fuel Injectors ... PGM-FI Main Relay Idle Control System Idle Speed Setting . . 11-2 - 11-3 . 11-4 . 11-7 . 11-10 . 11-12 . 11-14 Outline of Model Changes + H22A1 engine has been added for KO mode. +The main wire harness (Ignition Output Signal, PGMFI Main Relay circuit) has been changed.Component Locations Index (H22A1 engine) THROTTLE ANGLE SENSOR FAST IDLE VALVE [MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR, ELD (Electrical Load Detector) INJECTOR RESISTOR = EGR VALVE PURGE CONTROL ‘SOLENOID VALVE ere COTE) ‘AIR BOOST VALVE ‘SOLENOID VALVE INTAKE AIR Gurren unit ‘TEMPERATURE (TA) Troubleshooting. SENSOR page 118 BYPASS CONTROL TDC/CRANK/- DIAPHRAGM YL SENSOR constant vacuum CONTROL (CVC) VALVE ore os EGR CONTHOL SOLENOID VALVE (TW) SENSOR Ps OL Fuet nectors PRESSURE SWITCH kwock SENSOR Troubleshooting page 11-10 HEATED OXYGEN (0s) SENSOR BYPASS CONTROL SOLENOID VALVE 11-2System Description Vacuum Connections (H22A1 engine) PURGE CONTROL SOLENOID VALVE ‘CHARCOAL CANISTER To Two.way VALVE. PURGE CONTROL DIAPHRAGM VALVE EGR VALVE MAP SENSOR wrare oa poe aoe, comsTan VACUUM coer pressure REGULATOR To CRUISE CONTROL ACTUATOR BYPASS CONTROL DIAPHRAGM intake CONTROL DIAPHRAGM EGR CONTROL SOLENOID VALVE 11-3System Description Electrical Connections oe ‘Sthison crank. Sensor ‘SPEED senson q ty ss = > ae re see SET ss, fearon | cooLANT i "ATURE SWITCH io. 13 METER (10 A) nN @ No. 9 R/C MIRROR (15 A) w ‘Harr POSTON {8 No, 11 REAR DEFROSTER a INpiearoR RELAY (10.8) on No.2 STARTER SIGNAL (75 A) GB INTERIOR LIGHTS (15 Ai" ----! De 19 ECU (15.8) “Ii the UNDER-HOOD FUSE/RELAY BOXTan | ___ ves | —_beavvece ninorne| | oaaaee _| meee on ome ar naib —F ren $ EES + fon om [sr ag {a | SEtson us oe wot ris08 TE s001 VALVE pressure Gg Euan | secon ‘Tw seNsor & near ot —| | ae sournow vaves _] [@ EGR CONTROL SOLENOID VALVE |@ PURGE CUT-OFF SOLENOID VALVE | BYPASS CONTROL SOLENOID VALVE @ INTAKE CONTROL SOLENOID VALVE +: KO model only “SH: KY, KT model only (F2282 engine) ‘>: Except KY, KT model H22A1, H22A2 engine H22At, HazAz, H23A1, H22A2 engine * Excopt F22A1 engine PE HZ2AT, H23At os NOT USED on » [eeeeesscesees lessees ee TERMINAL LOCATIONS 11-5System Description H22A1 engine: @ HEATED OXYGEN (02) SENSOR @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ COOLANT TEMPERATURE SENSOR @ INTAKE AIR TEMPERATURE SENSOR ® KNOCK SENSOR @ ELECTRONIC AIR CONTROL VALVE (EACV) © IDLE ADJUSTING SCREW @ FAST IDLE VALVE © AIR BOOST VALVE ® FUEL INJECTOR PRESSURE REGULATOR @ FUEL FILTER @ FUEL PUMP 9 FUEL TANK GB AIR CLEANER ® RESONATOR 11-6 @ BYPASS CONTROL DIAPHRAGM ® BYPASS CONTROL SOLENOID VALVE @ VACUUM TANK @® CHECK VALVE @) INTAKE CONTROL DIAPHRAGM @ INTAKE CONTROL SOLENOID VALVE @ VACUUM TANK @ CHECK VALVE @ EGR VALVE @ EGR CONTROL SOLENOID VALVE @® CONSTANT VACUUM CONTROL (CVC) VALVE @® CATALYTIC CONVERTER @ PCV VALVE @ CHARCOAL CANISTER ) PURGE CONTROL DIAPHRAGM VALVE ® PURGE CONTROL SOLENOID VALVE @ TWO-WAY VALVETroubleshooting a [- Self-diagnostic Procedures f T ai Fone 0 ECU o o oT o | 6 an! | OXYGEN SENSOR, oo o o x o 3 Twararoio ansowwre messune warsenson|| 0 | © | 0 ° | 0 [cn ANGLE CaN SERSOW Sd Cle |iarOEal 6 COOLANT TEMPERATURE (TW SENSOR) o o o o _ 7 THROTTLE ANGLE o o |] oO o se “TDC POSITION (TDC SENSOR) To a o oO 3 ‘No. 1 CYLINDER POSITION (CYL SENSOR) o o oS o 70 | INTAKE AIR TEMPERATURE (TA SENSOR) ~ o “o o o “ ELECTRONIC AIR CONTROL (EACV) o ° oO o ° oO ir ‘VENICUE SPEED SENSOR [Le 3 o 20 ELECTRICAL LOAD DETECTOR (ELD) f oO x x o x a 23 KNOCK SENSOR _o * x x x o 30 ‘AIT FISIGNAL A ~ aT o o o_o ©: Refor to 6255000 9: Refer to 6288010, x: Not indicated ‘codes other than those listed above are indicate, verity the code. the code indicated is not isted above, replace the ECU ‘The Chock Engine Light may come on, indicating a system problem when, infact, there is 8 poor oF intermittent electr- cal connection. First, check the electrical connections, clean or repair connections if necessary # The Check Engine Light and (5 ight may light simultaneously when the self-diagnosis indieator blinks 6, 7 and 17 Check the PEM-FI system according to the PGM-Fi control system troubleshooting, then racheck the [) light ‘© The Check Engine Light does not come on when there is @ malfunction in the AVT Fl signal or Electrical Load Detector circuits. However, it wll indicate the codes when the Service Check Connector is jumped. 11-7PGM-FI Control System [- Troubleshooting Flowchart — Ignition Output Signal SHETT= LISTE seitciagnosis Check Engine Light indicates code 15: A prablem inthe ignition Output Signal ctcut Haat YEL (H22A1, Hz2az H25A1 engine) — Haat BLKIYEL. Check Engine Light has been He2az )~ (H22A2, H23A2 engine) reported on be ta202, 2 With service check connector jumped CODE 15 is indica iumpet ted, peads is ina Stem the engine. take 20 seconde of cranking to set the code. Intermittent failure, system is OK at this time [test drive may be necessary) ‘Turn th ignition switch OFF. | [ Disconnect the 2° connector at the distributor. “Turn the fanition switch ON. vey (F221 engine) BLK/YEL BLK/VEL* (s) terminal and body around. Ee voltage between YEL or = no! “ CL Test the ignition co ves J oe yes (To page 11-9) *:F20A4, F22A2, H22A2, ‘open in YEL wire P connector (M22At, F221, ‘open in BLK/YEL wire between the ignition coil and ignition switch Except #2241, F241, H2BAN engine) 11-8(From page 11-8) ‘Turn the ignition switch OFF. Perm Connect the test harness be- ‘toon the ECU and connectors. — “Turn the ignition switch ON. ‘Measure voltage between AZ {eh terminal and A26 (-) terminal | ves Substitute known-good ECU and recheck. If symptom/indica ton goes away, replace the origi nal ECU. 0 ovr — = Replace the igniter unit = Repair open of short YEL/ GRN wire between igniter unit and ECU (A211, NOTE: Ifthe YELIGRN wire was shorted, the igniver mey be damaged, Aalto} 305000000800] 60000000 SBBSSS] 55055000000 0.000000000009 | 000000001 699600| 00000000000 A283) 11-9Fuel Supply System [ Troubleshooting Flowchart — Fuel Injectors.) 2 —____ oo Self-diagnosis Check Engine Light indicates code 16: A problem in the Fuel Injector circuit, The Fue! Injectors are a solenoid-actuated constant-stroke pintle type consisting of a solenoid, plunger needle valve and housing. When current is epplied to the solenoid coil, the valve lifts up and pressurized fuel is injected. Because the neo- dle valve lift and the fuel pressure are constant, the injection quantity is determined by the length of time that the valve ig open (Le. the duration the current is supplied to the solenoid coil). The Fuel Injector is sealed by an O-ring and seal ring at the top and bottom. These seals also reduce operating noise. FUEL PIPE PLUNGER HOUSING FUEL PIPE INSULATOR INTAKE MANIFOLD RING FUEL INJECTOR INSULATOR — Check Engine Light has been reported on. — With service check connector jumped CODE 16 is indicated. Do the ECU Rasst Procedure NOTE: Hf ongine will not start it may take Start the engine and allow it to | 19 seconds af eranking to aet the code Intermittent failure, system is OK ——__1 at this time (test drive may be is Check Engine Light on and NO_| necessary) does it indieate CODE 167, Check for poor connections or ——— oose wires between fuel injec [ves tors and ECU. ‘Start engine and listen at each {uel injector fo a clicking sound. -——_______ Turn the ignition switeh OFF. Disconnect the 2P connector from the fuel injector that dove not ciek, (To page 1-10) 11-10(From page 11-10) Measure resistance between the 2terminals of fuel injector <__tethere 15-2507 yes ‘Turn the ignition switch on. | [Measure vottag BLK (+1 torming Je between RED/ in the 2P con: rector and body ground, No is there baer vetage? >| NO_| Repta tors that are not 15~25 0, the fuel injector/injec- ‘Turn the fontion switch OFF. Connect the t harness be- ‘hwoen the ECU and connectors, — Wieeron _ ves: r ——— ~ I r I the fol nestor. L_Tamthefontionewiet ont _| Ms aure voltage between No.1 fuel injector AN (eI terminal 83 (=) terminal + No.3 fuel injector AS) terninal + No.4 fuel injoctor A2 ie) terminal ‘Turn the fanition snitch ON, Ai terminal and following termina Saooseccato Does the injector reistor tat ox? ves. oer No_| Repair open in the YEL/BLK wir between the injector resistor and the PEM.FI man relay. No Foplace the injector resistor. Joctor resistor. VoUrAce? Repair open RED/BLK wire be- | ‘tween the 2P connector and in- SESE SESE SSE SETSTS known-good ECU and recheck. H symptomindica tion goes away, replace the inal ECU. NO_[ Repair open in the wire between 11-11Fuel Supply System PGM-FI Main Relay Troubleshooting Flowchart Disconnect the PGM-FI main re lay connector. | heat or sonny berwoon BUX torminal @ and body ground, a) = ves [om sure the voltage between YELIBLU terminal @) and body around: ee se [= Replace No, 4 BACK UP (10 A) fuse [ves eryvokage? >. 4 — l “Turn the ignition switeh ON. Measure tha voltage betwe: BLKIVEL terminal @) and body ground. : NO] — Repair open in the BLK/YEL << tethore battery voltage a pee oOee ee ce main relay and the No. 19 ECU (15 Al fuse. ‘Turn the ignition ewiteh to the START postion, | ts BISRES mie cna sy Is there batt vel) aki -YEL® BUD BKD vEL® (To page 11-13) 11-12(rom page 11-12) “Turn the ignition switch of pon sation st aeer| Connect the test harness be: tween the ECU and connectors, Disconnect "A" connector from the ECU only, not the main wire harness. Check for continuity between GAN/BLK terminal @) and AT tor minal yes. Reconnect “A” connector to the ecu. | ‘Connect the PGW-FI main relay connector ‘Turn the ignition switch ON, Measure the voltage between AZ (-) terminal and the follow= Ing terminate: 25 (o} 61 () 1 BSSHSSSIOIIG OG0O0S 9000000000000] 00000000. [Es3S8el oocccccc0c0 ——_! No_ | Repair open in GAN/BLK wire be- | << Dows continuity ext? >—"°)twoen ECU TAT) and PGM-FI imately pent 3OG5500000088 | 50000000 9000000000000] 00000000 Pea acess Isthe ves = Repair open in the YEL/BLK NO. ® wire between the ECU Teneywtase? Yaa SuPSCE REM msn relay. |__— Replace PGW-F1 main relay. ‘Turn the ignition switeh OFF, ‘Meature the voltage between A7 (61 terminal and A23 (-) terminal ‘uring the frst two seconds after the ignition switch is turned ON. 0 > 24% 1.25 mm, Mainshaft Locknut 470 Nem (17.0 kom, 123 ttt) Left-hand threads 1 230 Nm (23.0 kom, 166 ft) > 0 > 28x 1.25 mm Secondsry Shaft 470 Nem (17.0 kg-m | 123 lb-ft) Locknut a 230 Nem (23.0 kom, 166 bt} > 0 > 24x 1.25 mm Countershaft 470 Nem (17.0 kam. 123 Ib-ft) Locknut kK 8 Nm (0.8 kgm, 58 bsft) 8x0.8mm 14-7Mlustrated Index Transmission Housing 14-8 89908 6 68THRUST WASHER THRUST NEEDLE BEARING QSECONDARY SHAFT 2ND GEAR ‘QNEEDLE BEARINGS THRUST NEEDLE BEARING @SPLINED WASHER Slective part @1ST/2ND CLUTCH ASSEMBLY @O-RINGS Replace. @SECONDARY SHAFT (OTHRUST NEEDLE BEARING (DNEEDLE BEARING SECONDARY SHAFT 1ST GEAR (DISTANCE COLLAR, 5.0 mm G9COTTERS, 29 mm «SCOTTER RETAINER GBSNAP RING @SEALING RINGS, 32 mm LOCK BOLT G3LOCK WASHER Replace, @OSHIFT FORK @COUNTERSHAFT 2ND GEAR @COUNTERSHAFT REVERSE GEAR @NEEDLE BEARING ‘REVERSE SELECTOR HUB Q$REVERSE SELECTOR @SCOUNTERSHAFT 4TH GEAR @NEEDLE BEARING @SNAP RING COLLAR, 32mm GOCOTTERS, 29 mm DISTANCE COLLAR @COUNTERSHAFT 3RD GEAR (THRUST NEEDLE BEARING (ONE-WAY CLUTCH. (SCOUNTERSHAFT 1ST GEAR NEEDLE BEARING @PTHRUST WASHER QBCOUNTERSHAFT 1ST GEAR COLLAR, @1ST-HOLD CLUTCH ASSEMBLY @O-RINGS Replace. @COUNTERSHAFT ‘TORQUE SPECIFICATIONS. (@SNAP RING @coLLaR ‘S@THAUST NEEDLE BEARING SGMAINSHAFT 4THIREVERSE GEAR NEEDLE BEARINGS THRUST NEEDLE BEARING @aTH Gear COLLAR @3RD/4TH CLUTCH ASSEMBLY 93RD GEAR COLLAR S)THRUST NEEDLE BEARING ‘S2NEEDLE BEARING MAINSHAFT 3RD GEAR ‘@THRUST NEEDLE BEARING SORINGS Replace. SMAINSHAFT SEALING RINGS, 35 me (@SEALING RING, 29 mm QNEEDLE BEARING @SET RING ‘QREVERSE IDLER GEAR SHAFT HOLDER, BORING Replace. SQREVERSE IDLER GEAR SHAFT NEEDLE BEARING O-RING Ropie GOI SEAL Heplce, {TRANSMISSION HOUSING OIL SEAL Replace. (@THRUST SHIM Selective part {BEARING OUTER RACE {0 TRANSMISSION HOUSING GASKET Replace. ‘ooweL PIN SNAP RING TRANSMISSION HOUSING MAINSHAFT BEARING GSTRANSMISSION HOUSING SECONDARY SHAFT BEARING (TRANSMISSION HOUSING COUNTERSHAFT BEARING {REVERSE IDLER GEAR DIFFERENTIAL ASSEMBLY @BEARING OUTER RACE @ TORQUE CONVERTER HOUSING OIL SEAL Replace. ‘@TORQUE CONVERTER HOUSING = Femme (aanee a Pe eeeansees sed ras $ | Beanziee ee, etiam 14-9Illustrated Index Torque Converter Housing 14-10ATF STRAINER @CHECK BALL @OIL FEED PIPE @FILTER Replace. (OIL FEED PIPE 9DOWEL PIN (aT ACCUMULATOR COVER (OIL FEED PIPE @O-RING Replace. MAIN VALVE BODY (SERVO DETENT BASE OIL PUMP DRIVEN GEAR SHAFT @SERVO BODY OIL PUMP DRIVE GEAR SERVO SEPARATOR PLATE BOIL PUMP DRIVEN GEAR GOCHECK BALL (SCONTROL SHAFT (QSECONDARY VALVE BODY GODETENT SPRING (DOWEL PIN @DDETENT ARM (BSECONDARY SEPARATOR PLATE @DETENT ARM SHAFT (SACCUMULATOR BODY COVER @DOWEL PIN 51ST ACCUMULATOR CHOKE G@MAIN SEPARATOR PLATE (SCHECK BALL G@COUNTERSHAFT NEEDLE BEARING 21ST/2ND ACCUMULATOR BODY @OI GUIDE PLATE GBTHROTTLE VALVE BODY @SECONDARY SHAFT BALL BEARING GSTHROTTLE SEPARATOR PLATE @OIL GUIDE PLATE ‘DOWEL PIN @OIL SEAL Replace. THROTTLE CONTROL SHAFT SHIFT CONTROL SOLENOID FILTER/GASKET Replace. @E-RING Replace. @)SHIFT CONTROL SOLENOID VALVE ASSEMBLY FILTER Replac LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY @REGULATOR VALVE BODY @SCONNECTOR HOLDER (50-RING Replace. LOCK-UP CONTROL SOLENOID FILTER/GASKET @STATOR SHAFT Replace. @STOPPER SHAFT {TORQUE CONVERTER HOUSING TORQUE CONVERTER CHECK VALVE GOMAINSHAFT BALL BEARING. @TORQUE CONVERTER CHECK VALVE SPRING @OIL SEAL Replace, @OIL FEED PIPE @CONTROL LEVER LOCK WASHER Replace. TORQUE SPECIFICATIONS Ref No, Torque Value Bok Size Remarks A 12 Nem (1.2 kam, 9 Ib-ft) 6x 1.0mm 8 14 Nem (14 kam, 10 ibe) 6x1.0mm c 18 Nem (1.8 kam, 13 Ib) 8x 1.25mm 14-11Right Side Cover r— Removal Nore: ‘* Clean all parts thoroughly in solvent or carburetor ier and dry with compressed air. * Blow out all passages. ‘+ When removing the transmission right side cover, replace the following: + Right side cover gasket + Lock washers + Transmission housing gasket + O-rings + Each shaft locknut and conical spring washer * Sealing washers CONICAL spRuNa. WASHER Fopkce. RIGHT SIDE COVER SECONDARY RIGHT SIDE COVER GASKET Repke. THROTTLE CONTROL. CABLE STAY) TRANSMISSION HANGER’ ATF LEVEL GAUGE ‘SEALING WASHERS Replce. Mawsarr ATE Cooter! Pipes. vowr sour: SEALING WASHERS Replece. 1. Remove the eleven bolts securing the right side cover, then remove the right side cover. 2. Slip the special tool onto the mainshatt. PARKING GEAR COUNTERSHAFT IDLER GEAR REVERSE LER GEAR y SHAFT HOLDER PARKING BRAKE PAWL ‘TRANSMISSION HOUSING MOUNTING BOLTS TRANSMISSION HOUSING REVERSE IDLER GEAR ae ‘TORQUE CONVERTER HOUSING 14-1210. "1 Engage the parking brake pawl with the parking gear. Cut the lock tabs of each shatt locknut using a chisel fas shown, Then remove the locknuts and conical ‘spring washers from each shaft. Nore: + Mainshaft locknut has leftchand threads. + Clean the old locknuts; they are used to install the press fit idler gears on the mainshaft and secondary shaft and the parking gear on the countershaft. + Always wear safety glasses. CAUTION: Keep all of the chis ‘trangmission. Remove the special tool from the mainsheft after removing the locknuts. Remove the parking gear using a puller from the coun- tershaft as shown. Then remove the idler gears from the mainshaft and secondary shaft using a puller, MainsHarT IDLER GEAR ‘SECONDARY SHAFT IDLER. GEAR’ PARKING GEAR Remove the countershaft idler goar, needle bearing, thrust needle bearing, end thrust washer from the countershatt Remove the parking brake pawl, spring, shaft, and stopper from the housing Remove the throttle control lever and spring from the ‘throttle control shaft. Remove the ATF cooler pipe mounting bolt from the Remove the transmission housing mounting bots. 12. Remove the reverse idler gear shaft and reverse idler gear shaft holder using a 5 x 0.8 mm bolt as shown. REVERSE IDLER GEAR SHAFT HOLDER REVERSE IDLER GEAR SHAFT 13. Move the reverse idler gear to disengage it from the ccountershaft and mainshaft reverse gears as shown, NOTE: The transmission housing will not separate from the torque converter housing if the reverse idler gear is not removed. ‘COUNTERSHAFT MAINSHAFT REVERSE IDLER GEAR Move in this direction 14-13Main Valve Body 7 Disassembly/Inspection/Reassembly Noe: 1 Guna parts thoroughly insolvent of carburetor cloner nd dry with compressed a. Blow out al passages, ‘ Replace valve body as an assembly if any parts are. * Check all valves for free movement. i any fall 0 side fresyoace Valve Body Repair ‘CAUTION: Do not use a magnet to remove the check ball t may magnetize the balls. cPc VALVE ‘32 KlcK-DOWN Waive moouLaTon VALVE \ Lk ee Bx erent seg ser <: ae pera SBS 1-2 SHIFT VALVE Inspect for scoring > 2-3 SHIFT VALVE ‘ mai vauve Boov e . MANUAL VALVE 14-14FILTER @ ® © o @ Renee CHECK BALLS © MAIN VALVE BODY (Sectional View! ® ‘ DETENT ARM SHAFT SPRING SPECIFICATIONS Unit: em fn) Standard (New) No. Spring Wire Dia. 0. Froe Length No. of Colts @ | Lock-up control valve spring 0.70 (0.028) 8.60 (0.260) 38.00 (1.498) 144 @ | Lock-up shift valve spring 0.90 (0.036) 7.60 (0.299) 73.70 (2902) 320 ® | Cooler relief vatve spring 1.10 (0.043) 840 (0.331) 46.80 (1.843) 170 @ | Modulator valve spring 1.40 (0.088) 9.40 (0.370), 33.00 (1.298) 105 ® | CPC valve spring 1/40 (0.055) 9.40 (0.370), 33.00 (1/298) 105 ® | 3~2kick-down vaive spring 1.201004” 7.10 (0.280) 46.90 (1.846) 208 ® | 1—2shift valve spring 1.00 (0.039) 8.60 (0.339) 41.30 (1.626) 16.9 ® | 2-S:hite valve spring 0.90 (0.038) 7.80 (0.299) 57.00 (2.248) 268 14-15Secondary Shaft - Disassembly/Inspection/Reassembly NOTE: ‘Lubricate all parts with ATF during reassembly. Install the thrust needle be: Inspect thrust needle and needie bearings for gall * Bofore installing the O-rings, wrap the shaft spin o-nINes Replace. ‘SECONDARY SHAFT Check spines for excessh wear or damoge. Check bearing surta scoring, seretche ‘THRUST NEEDLE BEARING NEEDLE BEARING 1ST GEAR DISTANCE COLLAR, 5 mm & SEALING RINGS, 32 mm 198 with unrolled edge of bearing retainer facing wash ‘and rough movement. ‘ith tape to prevent damage to the O-rings. LOCKNUT (FLANGE NUT) Ropiece. 230 Nm (230 kom, 168 1) Som 170 Nem (17.0 kgm, 123 bet) ‘COMICAL SPRING WASHER Replace, IDLER GEAR ‘TRANSMISSION HOUSING BEARING THRUST WASHER + THnust NEEDLE BEARING 2ND GEAR, NEEDLE BEARINGS. aa ‘THRUST NEEDLE BEARING SSPLINED WASHER Sa SF sT/2Nv cLuTcH ASSEMBLY 14-16