Engine Electrical

Specifications02-1
Standards and Service Limits02-2

Standards and Service Limits02-2

Engine Electrical

Item

Measurement

Qualification

Standard or New

Service Limit

Ignition coil Rated voltage 12 V

Firing order 1 - 3 - 4 - 2

Spark plug Type NGK: ZFR6K-11 DENSO: KJ20DR-M11

Gap 1.0 - 1.1 mm (0.039 - 0.043 in.)
------

Ignition timing At idle (check the red mark) M/T (in neutral): 8 ± 2° BTDC at 650 ± 50 rpm (min-1)

A/T (in [N] or [P]): 8 ± 2° BTDC at 650 ± 50 rpm (min-1)

Alternator Output At 13.5 V and normal engine temperature 90 A

Coil (rotor) resistance at 20 C° (68 F°) 1.84 - 2.10

Slip ring O.D. 22.7 mm (0.89 in.) 21.7 mm (0.85 in.)

Brush length 19.0 mm (0.75 in.) 5.0 mm (0.20 in.)

Brush spring tension 3.3 - 4.1 N (0.34 - 0.42 kgf, 0.7 - 0.9 lbs)

Starter (MITSUBA) Output 1.2 kW, 1.6 kW

Commutator mica depth 0.4 - 0.5 mm (0.016 - 0.020 in.) 0.15 mm (0.006 in.)

Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Commutator O.D. 28.0 - 28.1 mm (1.102 - 1.106 in.) 27.5 mm (1.083 in.)

Brush length 11.1 - 11.5 mm (0.44 - 0.45 in.) 4.3 mm (0.17 in.)

Starter (DENSO) Output 1.0 kW, 1.1 kW

Commutator mica depth 0.50 - 0.80 mm (0.020 - 0.031 in.) 0.2 mm (0.008 in.)

Commutator runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Commutator O.D. 28.0 mm (1.10 in.) 27.0 mm (1.06 in.)

Brush length 14.0 - 14.5 mm (0.55 - 0.57 in.) 9.0 mm (0.35 in.)

Brush spring tension 13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 - 3.98 lbs)

Engine Assembly

Item

Measurement

Qualification

Standard or New

Service Limit

Compression Pressure check at 250 (min-1) rpm with wide open throttle. (See Design Specs for ratio) Minimum 930 kPa (9.5 kgf/cm2, 135 psi) ------

Maximum variation 200 kPa (2.0 kgf/cm2, 28 psi) ------

Cylinder Head02-3

Item

Measurement

Qualification

Standard or New

Service Limit

Head Warpage ------ 0.05 mm (0.002 in.)

Height 103.95 - 104.05 mm (4.093 - 4.096 in.) ------

Camshaft End play 0.05 - 0.20 mm (0.002 - 0.008 in.) 0.4 mm (0.02 in.)

Camshaft-to-holder oil clearance No.1 journal 0.030 - 0.069 mm (0.001 - 0.003 in.) 0.15 mm (0.006 in.)

No.2, 3, 4, 5 journals 0.060 - 0.099 mm (0.002 - 0.004 in.) 0.15 mm (0.006 in.)

Total runout 0.03 mm (0.001 in.) max. 0.04 mm (0.002 in.)

Cam lobe height Intake, primary 33.925 mm (1.3356 in.) ------

Intake, secondary 29.638 mm (1.1668 in.) ------

Exhaust 34.092 mm (1.3422 in.) ------

Valves Clearance (cold) Intake 0.21 - 0.25 mm (0.008 - 0.010 in.) ------

Exhaust 0.28 - 0.32 mm (0.011 - 0.013 in.) ------

Stem O.D. Intake 5.475 - 5.485 mm (0.2156 - 0.2159 in.) 5.445 mm (0.214 in.)

Exhaust 5.450 - 5.460 mm (0.2146 - 0.2150 in.) 5.42 mm (0.213 in.)

Stem-to-guide clearance Intake 0.030 - 0.055 mm (0.0012 - 0.0022 in.) 0.08 mm (0.003 in.)

Exhaust 0.055 - 0.080 mm (0.0022 - 0.0031 in.) 0.11 mm (0.004 in.)

Valve seats Width Intake 1.25 - 1.55 mm (0.049 - 0.061 in.) 2.00 mm (0.079 in.)

Exhaust 1.25 - 1.55 mm (0.049 - 0.061 in.) 2.00 mm (0.079 in.)

Stem installed height Intake 40.8 - 41.0 mm (1.606 - 1.614 in.) ------

Exhaust 54.6 - 54.8 mm (2.150 - 2.157 in.) ------

Valve springs Free length Intake 47.61 mm (1.874 in.) ------

Exhaust 49.64 mm (1.954 in.) 49.63 mm (1.954 in.) ------

Valve guides I.D. Intake 5.515 - 5.530 mm (0.2171 - 0.2177 in.) 5.55 mm (0.219 in.)

Exhaust 5.515 - 5.530 mm (0.2171 - 0.2177 in.) 5.55 mm (0.219 in.)

Installed height Intake 15.2 - 16.2 mm (0.598 - 0.638 in.) ------

Exhaust 15.5 - 16.5 mm (0.610 - 0.650 in.) ------

Rocker arms Arm-to-shaft clearance Intake 0.025 - 0.052 mm (0.0010 - 0.0020 in.) 0.08 mm (0.003 in.)

Exhaust 0.018 - 0.056 mm (0.0007 - 0.0022 in.) 0.08 mm (0.003 in.)

Engine Block02-4

Item

Measurement

Qualification

Standard or New

Service Limit

Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.)

Bore diameter (K20A4, K20A5 engines) A or l 86.010 - 86.020 mm (3.3862 - 3.3866 in.) 86.070 mm (3.3886 in.)

B or ll 86.000 - 86.010 mm (3.3858 - 3.3862 in.) 86.070 mm (3.3886 in.)

Bore diameter (K24A1 engines) A or l 87.010 - 87.020 mm (3.4256 - 3.4260 in.) 87.070 mm (3.4279 in.)

B or lI 87.000 - 87.010 mm (3.4252 - 3.4256 in.) 87.070 mm (3.4279 in.)

Bore taper ------ 0.05 mm (0.002 in.)

Reboring limit ------ 0.25 mm (0.01 in.)

Piston Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt (K20A4, K20A5 engines) No letter or A 85.980 - 85.990 mm (3.3850 - 3.3854 in.) 85.930 mm (3.3831 in.)

Letter B 85.970 - 85.980 mm (3.3846 - 3.3850 in.) 85.920 mm (3.3827 in.)

Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt (K24A1 engine) No letter or A 86.980 - 86.990 mm (3.4244 - v3.4248 in.) 86.930 mm (3.4224 in.)

Letter B 86.970 - 86.980 mm (3.4240 - 3.4244 in.) 86.920 mm (3.4220 in.)

Clearance in cylinder 0.020 - 0.040 mm (0.0008 - 0.0016 in.) 0.05 mm (0.002 in.)

Ring groove width Top (K20A4, K20A5 engines) 1.220 - 1.230 mm (0.0481 - 0.0484 in.) 1.25 mm (0.049 in.)

Top (K24A1 engine) 1.230 - 1.240 mm (0.0484 - 0.0488 in.) 1.26 mm (0.0450 in.)

Second (K20A4, K20A5 engines) 1.220 - 1.230 mm (0.0481 - 0.0484 in.) 1.25 mm (0.049 in.)

Second (K24A1 engine) 1.240 - 1.250 mm (0.0488 - 0.0492 in.) 1.270 mm (0.050 in.)

Oil (K20A4, K24A1 engines) 2.005 - 2.025 mm (0.0789 - 0.0797 in.) 2.05 mm (0.081 in.)

Oil (K20A5 engine) 2.805 - 2.825 mm (0.1104 - 0.1112 in.) 2.85 mm (0.112 in.)

Piston ring Ring-to-groove clearance Top (K20A4 engine) 0.035 - 0.060 mm (0.0014 - 0.0024 in.) 0.13 mm (0.005 in.)

Top (K20A5 engine) 0.030 - 0.055 mm (0.0012 - 0.0022 in.) 0.13 mm (0.005 in.)

Top (K24A1 engine) 0.045 - 0.070 mm (0.0018 - 0.0028 in.) 0.13 mm (0.005 in.)

Second (K20A4, K20A5 engines) 0.030 - 0.055 mm (0.0012 - 0.0022 in.) 0.13 mm (0.005 in.)

Second (K24A1 engine) 0.050 - 0.075 mm (0.0020 - 0.0030 in.) 0.13 mm (0.005 in.)

Ring end gap Top 0.20 - 0.35 mm (0.008 - 0.014 in.) 0.60 mm (0.024 in.)

Second 0.40 - 0.55 mm (0.016 - 0.022 in.) 0.70 mm (0.028 in.)

Oil (K20A4 (Except KY models) engine) 0.25 - 0.65 mm (0.010 - 0.026 in.) 0.75 mm (0.030 in.)

Oil (K20A4 (KY model), K20A5, K24A1 engines) 0.20 - 0.70 mm (0.008 - 0.028 in.) 0.80 mm (0.031 in.)

Piston pin O.D. 21.961 - 21.965 mm (0.8646 - 0.8648 in.) 21.953 mm (0.8643 in.)

Pin-to-piston clearance -0.005- +0.002 mm (-0.00020- + 0.00008 in.) 0.005 mm (0.0002 in.)

Connecting rod Pin-to-rod clearance 0.005 - 0.015 mm (0.0002 - 0.0006 in.) 0.02 mm (0.0008 in.)

Small-end bore diameter 21.970 - 21.976 mm (0.8650 - 0.8652 in.) ------

Large-end bore diameter (Normal) K20A4, K20A5 engines 48.0 mm (1.89 in.) ------

K24A1 engine 51.0 mm (2.01 in.) ------

End play installed on crankshaft 0.15 - 0.30 mm (0.006 - 0.012 in.) 0.40 mm (0.016 in.)

02-5

Item

Measurement

Qualification

Standard or New

Service Limit

Crankshaft Main journal diameter No. 1 journal No. 2 journal No. 4 journal No. 5 journal 54.984 - 55.008 mm (2.1648 - 2.1657 in.) ------

No. 3 journal 54.976 - 55.000 mm (2.1644 - 2.1654 in.) ------

Rod journal diameter K20A4, K20A5 engines 44.976 - 45.000 mm (1.7707 - 1.7717 in.) ------

K24A1 engine 47.976 - 48.000 mm (1.8888 - 1.8898 in.) ------

Rod/main journal taper 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.)

Rod/main journal out-of- round 0.005 mm (0.0002 in.) max. 0.010 mm (0.0004 in.)

End play 0.10 - 0.35 mm (0.004 - 0.014 in.) 0.45 mm (0.018 in.)

Runout 0.03 mm (0.0012 in.) max. 0.04 mm (0.0016 in.)

Crankshaft bearings Main bearing-to-journal oil clearance No. 1 journal No. 2 journal No. 4 journal No. 5 journal 0.017 - 0.041 mm (0.0007 - 0.0016 in.) 0.050 mm (0.0020 in.)

No. 3 journal 0.025 - 0.049 mm (0.0010 - 0.0019 in.) 0.055 mm (0.0022 in.)

Rod bearing clearance 0.021 - 0.049 mm (0.0008 - 0.0019 in.) 0.060 mm (0.0024 in.)

Engine Lubrication

Item

Measurement

Qualification

Standard or New

Service Limit

Engine oil Capacity 5.3 l (5.6 US qt, 4.7 lmp qt) for engine overhaul 4.2 l (4.4 US qt, 3.7 lmp qt) for oil change, including filter 4.0 l (4.2 US qt, 3.5 lmp qt) for oil change, without filter

Oil pump Inner-to-outer rotor clearance 0.02 - 0.16 mm (0.001 - 0.006 in.) 0.20 mm (0.008 in.)

Pump housing-to-outer rotor clearance 0.15 - 0.21 mm (0.006 - 0.008 in.) 0.23 mm (0.009 in.)

Pump housing-to-rotor axial clearance 0.02 - 0.07 mm (0.001 - 0.003 in.) 0.12 mm (0.005 in.)

Balancer shafts, journal diameter No. 1 journal, front shaft 19.938 - 19.950 mm (0.7850 - 0.7854 in.) 19.92 mm (0.784 in.)

No. 1 journal, rear shaft 23.938 - 23.950 mm (0.9424 - 0.9429 in.) 23.92 mm (0.942 in.)

No. 2 journal, front and rear shaft 32.949 - 32.961 mm (1.2972 - 1.2977 in.) 32.93 mm (1.296 in.)

Balancer shafts, journal taper 0.005 mm (0.0002 in.) max. ------

Balancer shafts, end play Front 0.070 - 0.135 mm (0.0028 - 0.0053 in.) 0.15 mm (0.006 in.)

Rear 0.070 - 0.135 mm (0.0028 - 0.0053 in.) 0.15 mm (0.006 in.)

Balancer shafts, shaft-to- bearing clearance No. 1 journal, front shaft 0.050 - 0.082 mm (0.0020 - 0.0032 in.) 0.10 mm (0.004 in.)

No. 1 journal, rear shaft 0.050 - 0.082 mm (0.0020 - 0.0032 in.) 0.10 mm (0.004 in.)

No. 2 journal, front and rear shaft 0.060 - 0.120 mm (0.0024 - 0.0047 in.) 0.15 mm (0.006 in.)

Balancer shaft bearings, I.D. No. 1 journal, front shaft 20.000 - 20.020 mm (0.7874 - 0.7882 in.) 20.03 mm (0.789 in.)

No. 1 journal, rear shaft 24.000 - 24.020 mm (0.9449 - 0.9457 in.) 24.03 mm (0.946 in.)

No. 2 journal, front and rear shaft 33.021 - 33.069 mm (1.3000 - 1.3019 in.) 33.09 mm (1.303 in.)

Relief valve, oil pressure with oil temperature at 80 °C (176 z°F) At idle 70 kPa (0.7 kgf/cm2, 10 psi) min.

at 3,000 rpm (min-1) 300 kPa (3.1 kgf/cm2, 44 psi) min.

Cooling02-6

Item

Measurement

Qualification

Standard or New

Service Limit

Radiator Coolant capacity for K20A4 and K20A5 engines
(including engine, heater, hoses, and reservoir) M/T: engine overhaul 7.1 L (7.5 US qt, 6.2 Imp qt)

M/T: coolant change 5.4 L (5.7 US qt, 4.8 Imp qt)

A/T: engine overhaul 7.0 l (7.4 US qt, 6.2 lmp qt)

A/T: coolant change 5.3 l (5.6 US qt, 4.7 lmp qt)

Coolant capacity for K24A1 engine (includes engine, heater, hoses, and reservoir) M/T at engine overhaul 7.2 L (7.6 US qt, 6.3 Imp qt)

M/T at coolant change 5.5 L (5.8 US qt, 4.8 Imp qt)

A/T at engine overhaul 7.1 L (7.5 US qt, 6.2 Imp qt)

A/T at coolant change 5.4 L (5.7 US qt, 4.8 Imp qt)

Reservoir Coolant capacity 0.55 L (0.58 US qt, 0.48 Imp qt)

Radiator cap Opening pressure 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi)

Thermostat Opening temperature Begins to open 76 - 80°C (169 - 176°F)

Fully open 90°C (194°F)

Valve lift at fully open 8.0 mm (0.31 in.) min.

Radiator fan switch Switching temperature Turns ON 91 - 95°C (196 - 203°F)

Turns OFF Subtract 3 - 8 °C (5 - 15 °F) from actual ON temperature

Fuel and Emissions

Item

Measurement

Qualification

Standard or New

Service Limit

Fuel pressure regulator Pressure with fuel pressure gauge connected 338 - 348 kPa (3.45 - 3.55 kgf/cm2, 49 - 50 psi)

Fuel tank Capacity 58 L (15 US gal, 13 Imp gal)

Engine idle Idle speed without a load M/T in neutral 650 ± 50 rpm (min-1)

A/T in [N] or [P] position 650 ± 50 rpm (min-1)

Fast idle M/T in neutral 1,600 ± 200 rpm (min-1)

A/T in [N] or [P] position 1,600 ± 200 rpm (min-1)

Idle CO % 0.1 max.

Clutch

Item

Measurement

Qualification

Standard or New

Service Limit

Clutch pedal Height from floor 200 mm (7.87 in.) ------

Stroke 125 - 135 mm (4.92 - 5.31 in.) ------

Play 6 - 17 mm (0.24 - 0.67 in.) ------

Disengagement height from floor 112 mm (4.41 in.) min. ------

Flywheel Runout on clutch mating surface 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.)

Clutch disc Rivet head depth 1.65 - 2.25 mm (0.065 - 0.089 in.) 0.7 mm (0.03 in.)

Thickness 8.7 - 9.3 mm (0.34 - 0.37 in.) 6.0 mm (0.24 in.)

Pressure plate Warpage 0.03 mm (0.001 in.) max. 0.15 mm (0.006 in.)

Height of diaphragm spring fingers measured with special tool and feeler gauge 0.6 mm (0.02 in.) max. 0.8 mm (0.03 in.)

Manual Transmission and M/T Differential02-7

Item

Measurement

Qualification

Standard or New

Service Limit

Transmission fluid Capacity 4WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt)

4WD at overhaul 2.3 L (2.4 US qt, 2.0 Imp qt)

2WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt)

2WD at overhaul 2.1 L (2.2 US qt, 1.8 Imp qt)

Mainshaft End play 0.11 - 0.17 mm (0.004 - 0.007 in.) Adjust

Diameter of bushing surface 20.80 - 20.85 mm (0.8189 - 0.8209 in.) 20.75 mm (0.817 in.)

Diameter of distance collar 31.984 - 32.000 mm (1.2594 - 1.2598 in.) 31.93 mm (1.257 in.)

Diameter of ball bearing contact area
(clutch housing side) 27.977 - 27.990 mm (1.1015 - 1.1020 in.) 27.94 mm (1.100 in.)

Diameter of needle bearing contact area 38.984 - 39.000 mm (1.5348 - 1.5354 in.) 38.93 mm (1.533 in.)

Diameter of ball bearing contact area (transmission housing side) 27.987 - 28.000 mm (1.1019 - 1.1024 in.) 27.94 mm (1.100 in.)

Runout 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

Mainshaft 3rd, 4th and 5th gears I.D. 44.009 - 44.025 mm (1.7326 - 1.7333 in.) 44.08 mm (1.735 in.)

End play 0.06 - 0.16 mm (0.002 - 0.006 in.) 0.25 mm (0.010 in.)

Thickness 23.92 - 23.97 mm (0.981 - 0.944 in.) 23.80 mm (0.937 in.)

Countershaft Diameter of needle bearing contact area (clutch housing side) Diameter of distance collar contact area 35.000 - 35.015 mm (1.3780 - 1.3785 in.) 34.95 mm (1.376 in.)

39.937 - 39.950 mm (1.5723 - 1.5728 in.) 39.88 mm (1.570 in.)

Diameter of ball bearing contact area (transmission housing side) 30.020 - 30.033 mm (1.1819 - 1.1824 in.) 29.97 mm (1.180 in.)

Run out 0.02 mm (0.001 in.) max. 0.05 mm (0.002 in.)

35 mm shim-to-bearing inner race clearance 0.04 - 0.10 mm (0.0016 - 0.0039 in.) Adjust

Countershaft 1st gear I.D. 52.010 - 52.029 mm (2.0476 - 2.0484 in.) 52.08 mm (2.050 in.)

End play 0.06 - 0.16 mm (0.002 - 0.006 in.) 0.25 mm (0.010 in.)

Thickness 22.92 - 22.97 mm (0.902 - 0.904 in.) 22.87 mm (0.900 in.)

Countershaft 2nd gear I.D. 52.010 - 52.029 mm (2.0476 - 2.0484 in.) 52.08 mm (2.050 in.)

End play 0.06 - 0.16 mm (0.002 - 0.006 in.) 0.25 mm (0.010 in.)

Thickness 27.92 - 27.97 mm (1.099 - 1.101 in.) 27.87 mm (1.097 in.)

Countershaft 1st gear distance collar I.D. 39.95 - 39.96 mm (1.5728 - 1.5732 in.) 39.97 mm (1.574 in.)

O.D. 46.989 - 47.000 mm (1.8499 - 1.8504 in.) 46.94 mm (1.848 in.)

Length 23.03 - 23.08 mm (0.907 - 0.909 in.) ------

Countershaft 2nd gear distance collar I.D. 39.95 - 39.96 mm (1.5728 - 1.5732 in.) 39.97 mm (1.574 in.)

O.D. 46.989 - 47.000 mm (1.8499 - 1.8504 in.) 46.94 mm (1.848 in.)

Length 28.03 - 28.08 mm (1.104 - 1.106 in.) ------

Mainshaft 4th and 5th gears distance collar I.D. 32.00 - 32.01 mm (1.2598 - 1.2602 in.) 32.02 mm (1.261 in.)

O.D. 38.989 - 39.000 mm (1.5350 - 1.5354 in.) 38.94 mm (1.533 in.)

Length

A 51.95 - 52.05 mm (2.045 - 2.049 in.) ------

B 24.03 - 24.08 mm (0.946 - 0.947 in.) ------

MBS distance collar I.D. 28.00 - 28.01 mm (1.102 - 1.103 in.) 28.02 mm (1.103 in.)

Length 23.95 - 24.05 mm (0.943 - 0.947 in.) ------

Manual Transmission and M/T Differential (cont'd)02-8

Item

Measurement

Qualification

Standard or New

Service Limit

Reverse idler gear I.D. 20.016 - 20.043 mm (0.7880 - 0.7891 in.) 20.90 mm (0.832 in.)

Gear-to-reverse gear shaft clearance 0.036 - 0.084 mm (0.0014 - 0.0033 in.) 0.16 mm (0.006 in.)

Synchro ring Ring-to-gear clearance Ring pushed against gear 0.70 - 1.49 mm (0.028 - 0.059 in.) 0.4 mm (0.016 in.)

Double cone synchro Outer synchro ring-to- synchro cone clearance Ring pushed against gear 0.70 - 1.19 mm (0.028 - 0.047 in.) 0.3 mm (0.012 in.)

Synchro cone-to-gear clearance Ring pushed against gear 0.50 - 1.04 mm (0.020 - 0.041 in.) 0.3 mm (0.012 in.)

Outer synchro ring-to- gear cone clearance Ring pushed against gear 0.95 - 1.68 mm (0.037 - 0.066 in.) 0.6 mm (0.024 in.)

Triple cone synchro Outer synchro ring-to- synchro cone clearance Ring pushed against gear 0.70 - 1.19 mm (0.028 - 0.047 in.) 0.3 mm (0.012 in.)

Synchro cone-to-gear clearance Ring pushed against gear 0.50 - 1.04 mm (0.020 - 0.041 in.) 0.3 mm (0.012 in.)

Outer synchro ring-to- gear cone clearance Ring pushed against gear 0.95 - 1.68 mm (0.037 - 0.066 in.) 0.6 mm (0.024 in.)

Shift fork Finger thickness 7.4 - 7.6 mm (0.29 - 0.30 in.) ------

Fork-to-synchro sleeve clearance 0.35 - 0.65 mm (0.014 - 0.026 in.) 1.0 mm (0.039 in.)

Reverse shift fork Finger thinkness 13.4 - 13.7 mm (0.527 - 0.539 in.) ------

Fork-to-reverse idler gear clearance 0.20 - 0.59 mm (0.007 - 0.024 in.) 1.2 mm (0.047 in.)

Shift arm I.D. 13.973 - 14.000 mm (0.5501 - 0.5512 in.) ------

Shift fork diameter at contact area 16.9 - 17.0 mm (0.665 - 0.669 in.) ------

Shift arm-to-shift lever clearance 0.2 - 0.5 mm (0.008 - 0.020 in.) 0.60 mm (0.023 in.)

Select lever Finger width 14.85 - 14.95 mm (0.585 - 0.589 in.) ------

Shift lever Shaft-to-select lever clearance 0.05 - 0.25 mm (0.002 - 0.010 in.) 0.50 mm (0.020 in.)

Groove (to select lever) 15.00 - 15.10 mm (0.591 - 0.594 in.) ------

Shaft-to-shift arm clearance 0.013 - 0.07 mm (0.0005 - 0.003 in.) 0.1 mm (0.004 in.)

M/T differential carrier Pinion shaft contact area I.D. 18.010 - 18.028 mm (0.7091 - 0.7098 in.) ------

Carrier-to-pinion shaft clearance 0.027 - 0.057 mm (0.0011 - 0.0022 in.) 0.1 mm (0.004 in.)

Driveshaft contact area I.D. 28.025 - 28.045 mm (1.1033 - 1.1041 in.) ------

M/T differential pinion gear Backlash 0.05 - 0.15 mm (0.002 - 0.006 in.) ------

I.D. 18.042 - 18.066 mm (0.7103 - 0.7113 in.) ------

Pinion gear-to-pinion shaft clearance 0.059 - 0.095 mm (0.0023 - 0.0037 in.) 0.15 mm (0.006 in.)

80 mm shim 80 mm shim-to-bearing outer race clearance in transmission housing 0 - 0.10 mm (0 - 0.0039 in.) Adjust

Transfer Diameter of tapered roller bearing contact area (transfer shaft) 24.975 - 24.990 mm (0.9833 - 0.9838 in.) 24.92 mm (0.9811 in.)

Diameter of tapered roller bearing contact area (transfer drive gear) 40.002 - 40.018 mm (1.5749 - 1.5755 in.) 38.95 mm (1.5335 in.)

Diameter of tapered roller bearing contact area (driven gear side) 35.002 - 35.018 mm (1.3780 - 1.3786 in.) 34.95 mm (1.3760 in.)

Diameter of tapered roller bearing contact area (splined side) 26.975 - 26.988 mm (1.0620 - 1.0625 in.) 26.92 mm (1.0598 in.)

Transfer gear backlash 0.06 - 0.16 mm (0.0024 - 0.0063 in.) Adjust

Total starting torque 2.24 - 3.71 N·m (22.0 - 36.4 kgf·cm, 19.1 - 31.6 lbf·in) Adjust

Automatic Transmission and A/T Differential02-9

Item

Measurement

Qualification

Standard or New

Service Limit

ATF (Automatic Transmission Fluid) Capacity Use Genuine Honda ATF- Z1 4WD at fluid change 3.1 L (3.3 US qt, 2.7 Imp qt)

2WD at fluid change 2.9 L (3.1 US qt, 2.6 Imp qt)

4WD at overhaul 7.2 L (7.6 US qt, 6.3 Imp qt)

2WD at overhaul 6.5 L (6.9 US qt, 5.7 Imp qt)

ATF pressure Line pressure at 2,000 rpm (min-1) in [P] or [N] position 900 - 960 kPa
(9.2 - 9.8 kgf/cm2, 130 - 140 psi) 850 kPa
(8.7 kgf/cm2, 120 psi)

1st clutch pressure at 2,000 rpm (min-1) in 1st gear in [1] position 890 - 970 kPa
(9.1 - 9.9 kgf/cm2, 130 - 140 psi) 840 kPa
(8.6 kgf/cm2, 120 psi)

2nd clutch pressure at 2,000 rpm (min-1) in 2nd gear in [2] position 890 - 970 kPa
(9.1 - 9.9 kgf/cm2, 130 - 140 psi) 840 kPa
(8.6 kgf/cm2, 120 psi)

3rd clutch pressure at 2,000 rpm (min-1) in 3rd gear in [D] position 890 - 970 kPa
(9.1 - 9.9 kgf/cm2, 130 - 140 psi) 840 kPa
(8.6 kgf/cm2, 120 psi)

4th clutch pressure at 2,000 rpm (min-1) in 4th gear in [D] position 890 - 970 kPa
(9.1 - 9.9 kgf/cm2, 130 - 140 psi) 840 kPa
(8.6 kgf/cm2, 120 psi)

Torque converter Stall speed
Check with vehicle on level ground 2,320 rpm (min-1) 2,170 - 2,470 rpm
(min-1)

Clutch
K20A4 and K20A5 engine models Clutch end plate-to-top disc clearance 1st ------ 1.23 - 1.43 mm
(0.048 - 0.056 in.)

2nd ------ 0.75 - 0.95 mm
(0.030 - 0.037 in.)

3rd and 4th ------ 0.73 - 0.93 mm
(0.029 - 0.037 in.)

Clutch return spring free length 1st and 2nd 50.8 mm (2.00 in.) 48.8 mm (1.92 in.)

3rd and 4th 33.5 mm (1.32 in.) 31.5 mm (1.24 in.)

Clutch disc thickness 1.94 mm (0.076 in.) ------

Clutch plate thickness 2.00 mm (0.079 in.) When discolored

Clutch waved-plate phase difference 0.07 - 0.20 mm (0.003 - 0.008 in.) 0.05 mm (0.002 in)

1st Clutch end plate thickness Mark 1 2.3 mm (0.091 in.) When discolored

Mark 2 2.4 mm (0.094 in.) When discolored

Mark 3 2.5 mm (0.098 in.) When discolored

Mark 4 2.6 mm (0.102 in.) When discolored

Mark 5 2.7 mm (0.106 in.) When discolored

Mark 6 2.8 mm (0.110 in.) When discolored

Mark 7 2.9 mm (0.114 in.) When discolored

Mark 8 3.0 mm (0.118 in.) When discolored

Mark 9 3.1 mm (0.122 in.) When discolored

Mark 10 3.2 mm (0.126 in.) When discolored

Mark 11 3.3 mm (0.130 in.) When discolored

Mark 12 3.4 mm (0.134 in.) When discolored

2nd clutch end plate thickness Mark 1 2.6 mm (0.102 in.) When discolored

Mark 2 2.7 mm (0.106 in.) When discolored

Mark 3 2.8 mm (0.110 in.) When discolored

Mark 4 2.9 mm (0.114 in.) When discolored

Mark 5 3.0 mm (0.118 in.) When discolored

Mark 6 3.1 mm (0.122 in.) When discolored

Mark 7 3.2 mm (0.126 in.) When discolored

Mark 8 3.3 mm (0.130 in.) When discolored

Mark 9 3.4 mm (0.134 in.) When discolored

Automatic Transmission and A/T Differential (cont'd)02-10

Item

Measurement

Qualification

Standard or New

Service Limit

Clutch K20A4 and K20A5 engine models (cont'd) 3rd and 4th clutch end plate thickness Mark 11 3.1 mm (0.122 in.) When discolored

Mark 12 3.2 mm (0.126 in.) When discolored

Mark 13 3.3 mm (0.130 in.) When discolored

Mark 14 3.4 mm (0.134 in.) When discolored

Mark 15 3.5 mm (0.138 in.) When discolored

Mark 16 3.6 mm (0.142 in.) When discolored

Mark 17 3.7 mm (0.146 in.) When discolored

Mark 18 3.8 mm (0.150 in.) When discolored

Mark 19 3.9 mm (0.154 in.) When discolored

Clutch
K24A1 engine model Clutch end plate-to-top disc clearance 1st ------ 1.28 - 1.48 mm (0.050 - 0.058 in.)

2nd ------ 0.85 - 1.05 mm (0.033 - 0.041 in.)

3rd and 4th ------ 0.73 - 0.93 mm (0.029 - 0.037 in.)

Clutch return spring free length 1st and 2nd 50.8 mm (2.00 in.) 48.8 mm (1.92 in.)

3rd and 4th 33.5 mm (1.32 in.) 31.5 mm (1.24 in.)

Clutch disc thickness 1.94 mm (0.076 in.) ------

Clutch plate thickness 1st 1.6 mm (0.063 in.) When discolored

2nd 2.0 mm (0.079 in.) When discolored

3rd and 4th 2.3 mm (0.091 in.) When discolored

Clutch waved-plate phase difference 0.07 - 0.20 mm (0.003 - 0.008 in.) 0.05 mm (0.002 in)

1st Clutch end plate thickness Mark 1 2.6 mm (0.102 in.) When discolored

Mark 2 2.7 mm (0.106 in.) When discolored

Mark 3 2.8 mm (0.110 in.) When discolored

Mark 4 2.9 mm (0.114 in.) When discolored

Mark 5 3.0 mm (0.118 in.) When discolored

Mark 6 3.1 mm (0.122 in.) When discolored

Mark 7 3.2 mm (0.126 in.) When discolored

Mark 8 3.3 mm (0.130 in.) When discolored

Mark 9 3.4 mm (0.134 in.) When discolored

2nd clutch end plate thickness Mark 1 2.6 mm (0.102 in.) When discolored

Mark 2 2.7 mm (0.106 in.) When discolored

Mark 3 2.8 mm (0.110 in.) When discolored

Mark 4 2.9 mm (0.114 in.) When discolored

Mark 5 3.0 mm (0.118 in.) When discolored

Mark 6 3.1 mm (0.122 in.) When discolored

Mark 7 3.2 mm (0.126 in.) When discolored

Mark 8 3.3 mm (0.130 in.) When discolored

Mark 9 3.4 mm (0.134 in.) When discolored

3rd and 4th clutch end plate thickness Mark 1 2.1 mm (0.083 in.) When discolored

Mark 2 2.2 mm (0.087 in.) When discolored

Mark 3 2.3 mm (0.091 in.) When discolored

Mark 4 2.4 mm (0.094 in.) When discolored

Mark 5 2.5 mm (0.098 in.) When discolored

Mark 6 2.6 mm (0.102 in.) When discolored

Mark 7 2.7 mm (0.106 in.) When discolored

Mark 8 2.8 mm (0.110 in.) When discolored

Mark 9 2.9 mm (0.114 in.) When discolored

02-11

Item

Measurement

Qualification

Standard or New

Service Limit

Mainshaft Diameter of needle bearing contact area at stator shaft 22.984 - 23.000 mm (0.905 - 0.906 in.) When worn or damaged

at 3rd gear 51.975 - 51.991 mm (2.046 - 2.047 in.) When worn or damaged

at 4th gear collar 33.975 - 33.991 mm (1.3376 - 1.3382 in.) When worn or damaged

I.D. of gears 3rd gear 57.000 - 57.019 mm
(2.2441 - 2.2448 in.) When worn or damaged

4th gear 40.000 - 40.016 mm
(1.5748 - 1.5754 in.) When worn or damaged

End play of gears 3rd gear 0.03 - 0.31 mm (0.001 - 0.012 in.) ------

4th gear 0.1 - 0.212 mm (0.004-0.008 in.) ------

41 x 68 mm thrust washer thickness No. 1 6.35 mm (0.250 in.) When worn or damaged

No. 2 6.40 mm (0.252 in.) When worn or damaged

No. 3 6.45 mm (0.254 in.) When worn or damaged

No. 4 6.50 mm (0.256 in.) When worn or damaged

No. 5 6.55 mm (0.258 in.) When worn or damaged

No. 6 6.60 mm (0.260 in.) When worn or damaged

4th gear collar length 66.3 - 66.4 mm (2.610 - 2.614 in.) ------

Length of 4th gear collar flange from end 19.15 - 19.30 mm (0.754 - 0.760 in.) When worn or damaged

Sealing ring thickness 1.91 - 1.97 mm (0.0752 - 0.0776 in.) 1.86 (0.0732 in.)

Width of sealing ring
groove 2.025 - 2.060 mm
(0.0797 - 0.0811 in.) 2.080 mm (0.0819 in.)

Clutch feed pipe O.D. 7.97 - 7.98 mm (0.3138 - 0.3142 in.) 7.95 mm (0.313 in.)

Clutch feed pipe bushing I.D. 8.000 - 8.015 mm
(0.3150 - 0.3156 in.) 8.030 mm (0.3161 in.)

Countershaft Diameter of needle bearing contact area at torque converter housing 36.005-36.015 mm
(1.4175 - 1.4179 in.) When worn or damaged

at 4th gear collar 37.982 - 37.996 mm
(1.4954 - 1.4959 in.) When worn or damaged

at reverse gear collar 39.979 - 40.000 mm (1.5740 - 1.5748 in.) When worn or damaged

I.D. of gears 4th gear 43.000 - 43.016 mm
(1.6929 - 1.6935 in.) When worn or damaged

Reverse gear 46.000 - 46.016 mm (1.8110 - 1.8116 in.) When worn or damaged

End play of gears 1st gear 0.10 - 0.42 mm (0.004 - 0.017 in.) ------

2nd gear 0.10 - 0.42 mm (0.004 - 0.017 in.) ------

3rd gear 0.10 - 0.42 mm (0.004 - 0.017 in.) ------

4th gear 0.1 - 0.2 mm (0.004 - 0.008 in.) ------

Reverse gear 0.10 - 0.25 mm (0.004 - 0.010 in.) ------

4th gear collar length 24.00 - 24.05 mm (0.945 - 0.947 in.) ------

Distance collar length 74.25 - 74.30 mm (2.923 - 2.925 in.) ------

Reverse selector hub width 25.45 - 25.65 mm (1.002 - 1.010 in.) ------

Reverse selector hub O.D. 55.87 - 55.90 mm (2.200 - 2.201 in.) When worn or damaged

Automatic Transmission and A/T Differential (cont'd)02-12

Item

Measurement

Qualification

Standard or New

Service Limit

Secondary shaft Diameter of needle bearing contact area at 1st gear 39.986 - 39.999 mm
(1.5742 - 1.5748 in.) When worn or damaged

at 2nd gear 39.986 - 39.999 mm (1.5742 - 1.5748 in.) When worn or damaged

I.D. of gears 1st gear 47.000 - 47.016 mm
(1.8504 - 1.8510 in.) When worn or damaged

2nd gear 46.000 - 46.016 mm
(1.8110 - 1.8116 in.) When worn or damaged

End play of gears 1st gear 0.07 - 0.15 mm (0.003 - 0.006 in.) ------

2nd gear 0.04 - 0.12 mm (0.002 - 0.005 in.) ------

37 x 58 mm thrust washer thickness No. 1 3.900 mm (0.154 in.) When worn or damaged

No. 2 3.925 mm (0.155 in.) When worn or damaged

No. 3 3.950 mm (0.156 in.) When worn or damaged

No. 4 3.975 mm (0.156 in.) When worn or damaged

No. 5 4.000 mm (0.157 in.) When worn or damaged

No. 6 4.025 mm (0.158 in.) When worn or damaged

No. 7 4.050 mm (0.159 in.) When worn or damaged

No. 8 4.075 mm (0.160 in.) When worn or damaged

No. 9 4.100 mm (0.161 in.) When worn or damaged

No. 10 4.125 mm (0.162 in.) When worn or damaged

No. 11 4.150 mm (0.163 in.) When worn or damaged

No. 12 4.175 mm (0.164 in.) When worn or damaged

No. 13 4.200 mm (0.165 in.) When worn or damaged

No. 14 4.225 mm (0.166 in.) When worn or damaged

No. 15 4.250 mm (0.167 in.) When worn or damaged

No. 16 4.275 mm (0.168 in.) When worn or damaged

No. 17 4.300 mm (0.169 in.) When worn or damaged

No. 18 4.325 mm (0.170 in.) When worn or damaged

No. 19 4.350 mm (0.171 in.) When worn or damaged

No. 20 4.375 mm (0.172 in.) When worn or damaged

40 x 51.5 mm thrust washer thickness No. 1 4.80 mm (0.189 in.) When worn or damaged

No. 2 4.85 mm (0.191 in.) When worn or damaged

No. 3 4.90 mm (0.193 in.) When worn or damaged

No. 4 4.95 mm (0.195 in.) When worn or damaged

No. 5 5.00 mm (0.197 in.) When worn or damaged

No. 6 5.05 mm (0.199 in.) When worn or damaged

27 x 45 x 44 mm collar length 43.9 - 44.0 mm (1.728 - 1.732 in.) ------

Sealing ring thickness 1.91 - 1.97 mm (0.0752 - 0.0776 in.) 1.86 (0.0732 in.)

Width of sealing ring groove 2.025 - 2.060 mm (0.0797 - 0.0811 in.) 2.080 mm (0.0819 in.)

Clutch feed pipe O.D. 7.97 - 7.98 mm
(0.3138 - 0.3142 in.) 7.95 mm
(0.3130 in.)

Clutch feed pipe bushing O.D. 8.000 - 8.015 mm
(0.3150 - 0.3156 in.) 8.030 mm
(0.3161 in.)

ATF guide of sealing ring contact I.D. 29.000 - 29.021 mm
(1.1417 - 1.1426 in.) 29.05 mm (1.144 in.)

02-13

Item

Measurement

Qualification

Standard or New

Service Limit

Idler gear shaft Diameter of needle bearing contact area End cover side 32.003 - 32.013 mm (1.2600 - 1.2604 in.) When worn or damaged

Thickness of cotters 1.39 - 1.42 mm (0.0547 - 0.0559 in.) ------

Reverse idler gear Reverse idler gear shaft diameter at needle bearing contact area 14.99 - 15.00 mm (0.5902 - 0.5906 in.) When worn or damaged

I.D. 20.007 - 20.020 mm
(0.7877 - 0.7882 in.) When worn or damaged

I.D. of reverse idler gear shaft contact area on transmission housing 14.800 - 14.818 mm (0.5827 - 0.5834 in.) ------

I.D. of reverse idler gear shaft holder 14.800 - 14.824 mm (0.5827 - 0.5836 in.) When worn or damaged

ATF pump ATF pump thrust clearance 0.03 - 0.05 mm (0.001 - 0.002 in.) 0.07 mm (0.003 in.)

ATF pump gear-to-body clearance Drive gear 0.210 - 0.265 mm
(0.08 - 0.010 in.) ------

Driven gear 0.070 - 0.125 mm (0.003 - 0.005 in.) ------

ATF pump driven gear I.D. 14.016 - 14.034 mm (0.5518 - 0.5525 in.) When worn or damaged

ATF pump driven gear shaft O.D. 13.980 - 13.990 mm (0.5504 - 0.5508 in.) When worn or damaged

Stator shaft Needle bearing contact I.D. Torque converter side 27.000 - 27.021 mm (1.063 - 1.064 in.) When worn or damaged

ATF pump side 29.000 - 29.021 mm
(1.1417 - 1.1426 in.) ------

Sealing ring contact area I.D. 29.000 - 29.021 mm
(1.1417 - 1.1426 in.) 29.05 mm (1.144 in.)

Reverse shift fork Fork finger thickness 5.90 - 6.00 mm (0.232 - 0.236 in.) 5.40 mm (0.213 in.)

Park gear and pawl ------ When worn or damaged

Servo body Shift fork shaft bore I.D. 14.000 - 14.010 mm
(0.5512 - 0.5516 in.) ------

Shift fork shaft valve bore I.D. 37.000 - 37.039 mm (1.4567 - 1.4582 in.) 37.045 mm (1.4585 in.)

Regulator valve body Sealing ring contact I.D. 29.000 - 29.021 mm (1.1417 - 1.1426 in.) 29.05 mm (1.144 in.)

Item

Measurement

Qualification

Standard or New

Wire Diameter

O.D.

Free Length

No. of Coil

Main valve body springs (see page 14- 209) Shift valve A spring 0.8 mm
(0.031 in.) 5.6 mm
(0.220 in.) 28.1 mm
(1.106 in.) 15.9

Shift valve B spring 0.8 mm
(0.031 in.) 5.6 mm
(0.220 in.) 28.1 mm
(1.106 in.) 15.9

Shift valve C spring 0.8 mm
(0.031 in.) 5.6 mm
(0.220 in.) 28.1 mm
(1.106 in.) 15.9

Relief valve spring 1.0 mm
(0.039 in.) 9.6 mm
(0.378 in.) 34.1 mm
(1.343 in.) 10.2

Lock-up control valve spring 0.65 mm
(0.026 in.) 7.1 mm
(0.280 in.) 23.1 mm
(0.909 in.) 12.7

Cooler check valve spring 0.9 mm
(0.035 in.) 6.6 mm
(0.260 in.) 26.5 mm
(1.043 in.) 12.6

Servo control valve spring 0.7 mm
(0.028 in.) 6.6 mm
(0.260 in.) 35.7 mm (1.406 in.) 17.2

Shift valve E spring 0.8 mm
(0.031 in.) 5.6 mm
(0.220 in.) 28.1 mm
(1.106 in.) 15.9

Automatic Transmission and A/T Differential (cont'd)02-14

Item

Measurement

Qualification

Standard or New

Wire Diameter

O.D.

Free Length

No. of Coil

Regulator valve body springs (see page 14- 211) Stator reaction spring 4.5 mm
(0.177 in.) 35.4 mm
(1.394 in.) 30.3 mm
(1.193 in.) 1.92

Regulator valve spring A 1.9 mm
(0.075 in.) 14.7 mm
(0.579 in.) 80.6 mm
(3.173 in.) 16.1

Regulator valve spring B 1.6 mm
(0.063 in.) 9.2 mm
(0.362 in.) 44.0 mm
(1.732 in.) 12.5

Torque converter check valve spring 1.2 mm
(0.047 in.) 8.6 mm
(0.339 in.) 33.8 mm
(1.331 in.) 12.2

Lock-up shift valve spring 1.0 mm
(0.039 in.) 6.6 mm
(0.260 in.) 35.5 mm
(1.398 in.) 18.2

3rd accumulator spring 2.5 mm
(0.098 in.) 14.6 mm
(0.575 in.) 29.9 mm
(1.177 in.) 4.9

1st accumulator spring A 2.4 mm
(0.094 in.) 18.6 mm
(0.732 in.) 49.0 mm
(1.929 in.) 7.1

1st accumulator spring B 2.3 mm
(0.091 in.) 12.2 mm
(0.480 in.) 31.5 mm
(1.240 in.) 6.6

Servo body springs (see page 14-212) CPB valve spring 0.7 mm
(0.028 in.) 9.1 mm
(0.358 in.) 32.3 mm
(1.272 in.) 8.6

4th accumulator spring B 2.3 mm
(0.091 in.) 12.2 mm
(0.480 in.) 31.5 mm
(1.240 in.) 6.6

4th accumulator spring A 2.4 mm
(0.094 in.) 18.6 mm
(0.732 in.) 49.0 mm
(1.929 in.) 7.1

2nd accumulator spring B 2.0 mm
(0.079 in.) 10.6 mm
(0.417 in.) 34.0 mm
(1.339 in.) 8.0

2nd accumulator spring A 2.2 mm
(0.087 in.) 16.6 mm
(0.654 in.) 48.2 mm
(1.898 in.) 8.5

3th accumulator spring 2.5 mm
(0.098 in.) 14.6 mm
(0.575 in.) 29.9 mm
(1.177 in.) 4.9

Item

Measurement

Qualification

Standard or New

Service Limit

A/T differential carrier Pinion shaft contact area I.D. 18.000 - 18.025 mm
(0.709 - 0.710 in.) ------

Carrier-to-pinion shaft clearance 0.013 - 0.054 mm
(0.001 - 0.002 in.) 0.1 mm (0.004 in.)

Driveshaft contact area I.D. 28.015 - 28.045 mm
(1.103 - 1.104 in.) ------

Carrier-to-driveshaft clearance 0.035 - 0.086 mm (0.001 - 0.003 in.) 0.12 mm (0.005 in.)

Intermediate shaft contact I.D. 28.015 - 28.045 mm (1.103 - 1.104 in.) ------

Carrier-to-intermediate shaft clearance 0.065 - 0.111 mm (0.003 - 0.004 in.) 0.12 mm (0.005 in.)

Carrier bearing starting torque (preload) For new bearing 2.7 - 3.9 N·m
(28 - 40 kgf·cm, 24 - 35 lbf·in) Adjust

For bearing reused 2.5 - 3.6 N·m
(25 - 37 kgf·cm, 22 - 32 lbf·in) Adjust

Final driven gear backlash (references) 0.087 - 0.146 mm (0.003 - 0.006 in.) 0.2 mm (0.008 in.)

A/T differential pinion gear Backlash 0.05 - 0.15 mm (0.002 - 0.006 in.) ------

I.D. 18.042 - 18.066 mm
(0.7103 - 0.7113 in.) ------

Pinion gear-to-pinion shaft clearance 0.055 - 0.095 mm
(0.0022 - 0.0037 in.) 0.12 mm (0.005 in.)

Automatic Transmission and A/T Differential (cont'd)02-15

Item

Measurement

Qualification

Standard or New

Service Limit

Transfer (4WD) Diameter of transfer shaft on bearing contact area at roller bearing 38.485 - 38.500 mm
(1.5152 - 1.5157 in.) 38.43 mm (1.513 in.)

at tapered roller bearing 24.975 - 24.990 mm (0.9833 - 0.9839 in.) 24.92 mm (0.9811 in.)

Transfer drive gear diameter at tapered roller bearing 40.002 - 40.018 mm (1.5749 - 1.5755 in.) 38.95 mm (1.533 in.)

Diameter of transfer driven gear on tapered roller bearing contact area at driven gear side 35.002 - 35.018 mm (1.3780 - 1.3787 in.) 34.95 mm (1.376 in.)

at shaft splines side 26.975 - 26.988 mm (1.0620 - 1.0625 in.) 26.92 mm (1.060 in.)

Transfer gear backlash 0.06 - 0.16 mm (0.002 - 0.006 in.) Adjust

Total starting torque (Preload) 2.16 - 3.57 N·m (22.0 - 36.4 kgf·cm, 19.2 - 31.6 lbf·in) Adjust

Rear Differential

Item

Measurement

Qualification

Standard or New

Service Limit

Differential fluid Capacity Use genuine Honda DPSF at fluid change 1.0 L (1.1 US qt, 0.9 Imp qt)

at overhaul 1.2 L (1.3 US qt, 1.1 Imp qt)

Steering

Item

Measurement

Qualification

Standard or New

Service Limit

Steering wheel Rotational play measured at outside edge with engine running 0 - 10 mm (0 - 0.39 in.)

Starting load measured at outside edge with engine running 29 N (3.0 kgf, 6.6 lbs)

Gearbox Angle of rack guide screw loosened from locked position 20° Max.

Pump Output pressure with shut- off valve closed 6,900 - 7,500 kPa (70 - 77 kgf/cm2, 1,000 - 1,100 psi)

Power steering fluid Capacity Use genuine Honda power steering fluid Fluid change 0.2 L (0.21 US qt, 0.18 lmp qt)

System overhaul 0.72 L (0.74 US qt, 0.63 Imp qt)

Drive belt Auto adjust

Suspension

Item

Measurement

Qualification

Standard or New

Service Limit

Wheel alignment Camber Front 0°00' ± 45'

Rear - 1°00' ± 45'

Caster Front 1°45' ± 1°

Total Toe Front 0±2 mm (0 ± 0.08 in.)

Rear IN 2+2-1 mm (0.08+0.08-0.04 in.)

Front wheel turning angle Inside wheel 39°45' ± 2°

Outside wheel 32°30' ± 1° (Reference)

Wheel Aluminum wheel runout Axial 0 - 0.7 mm (0 - 0.03 in.) 2.0 mm (0.08 in.)

Radial 0 - 0.7 mm (0 - 0.03 in.) 1.5 mm (0.06 in.)

Steel wheel runout Axial 0 - 1.0 mm (0 - 0.04 in.) 2.0 mm (0.08 in.)

Radial 0 - 1.0 mm (0 - 0.04 in.) 1.5 mm (0.06 in.)

Wheel bearing End play Front 0 - 0.05 mm (0 - 0.002 in.)

Rear 0 - 0.05 mm (0 - 0.002 in.)

Brakes02-16

Item

Measurement

Qualification

Standard or New

Service Limit

Parking brake lever Distance travelled when lever pulled with 196 N (20 kgf, 44 lbs) of force 5 - 9 clicks

Brake pedal Pedal height (carpet removed) 173 mm (6 13/16 in.)

Free play 1 - 5 mm (0.04 - 0.2 in.)

Master cylinder Piston-to-pushrod clearance 0 - 0.4 mm (0 - 0.02 in.)

Brake disc Disc thickness Front 23.0 mm (0.91 in.) 21.0 mm (0.83 in.)

Rear 9.0 mm (0.35 in.) 7.0 mm (0.28 in.)

Disc runout Front and rear ------ 0.10 mm (0.004 in.)

Disc parallelism Front and rear ------ 0.015 mm (0.0006 in.)

Pad thickness Front 11.0 mm (0.43 in.) 1.6 mm (0.06 in.)

Rear 9.0 mm (0.35 in.) 1.0 mm (0.04 in.)

Rear parking brake Brake drum I.D. Brake shoe lining thickness 170 mm (6.69 in.) 171 mm (6.73 in.)

3.2 mm (0.13 in.) 1.0 mm (0.04 in.)

Brake booster Master cylinder fluid pressure with pressing brake pedal with 98 N (10 kgf, 22 lbs) at 0 kPa (0 mmHg, 0 in.Hg) of vacuum 1,040 kPa (10.8 kgf/cm2, 151 psi)

at 40.0 kPa (300 mmHg, 11.8 in.Hg) of vacuum 7,129 kPa (72.7 kgf/cm2, 1,030 psi)

at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum 11,248 kPa (114.7 kgf/cm2, 1,631 psi)

Air Conditioning

Item

Measurement

Qualification

Standard or New

Service Limit

Refrigerant Type HFC-134 a (R-134 a)

Capacity of system 650 - 700 g (22.9 - 24.7 oz)

Refrigerant oil Type ND-OIL8

Capacity of components Condenser 50 mL (1 2/3 fl oz, 1.3 Imp oz)

Evaporator 40 mL (1 1/3 fl oz, 1.4 Imp oz)

Each line and hose 10 mL (1/3 fl oz, 0.4 lmp oz)

Compressor 160 - 175 mL (5 2/5 - 6 fl oz, 5.6 - 6.2 Imp oz)

Compressor Starter coil resistance at 60°C (20°F) 3.9 - 4.3

Pulley-to-pressure plate clearance 0.35 - 0.6 mm (0.014 - 0.024 in.)

***Engine Electrical***
Item	Measurement	Qualification	Standard or New	Service Limit
Ignition coil	Rated voltage		12 V
Firing order		1 - 3 - 4 - 2
Spark plug	Type		NGK: ZFR6K-11 DENSO: KJ20DR-M11
Gap		1.0 - 1.1 mm (0.039 - 0.043 in.)	------
Ignition timing		At idle (check the red mark)	M/T (in neutral): 8 ± 2° BTDC at 650 ± 50 rpm (min-1)
A/T (in [N] or [P]): 8 ± 2° BTDC at 650 ± 50 rpm (min-1)
Alternator	Output	At 13.5 V and normal engine temperature	90 A
Coil (rotor) resistance	at 20 C° (68 F°)	1.84 - 2.10
Slip ring O.D.		22.7 mm (0.89 in.)	21.7 mm (0.85 in.)
Brush length		19.0 mm (0.75 in.)	5.0 mm (0.20 in.)
Brush spring tension		3.3 - 4.1 N (0.34 - 0.42 kgf, 0.7 - 0.9 lbs)
Starter (MITSUBA)	Output		1.2 kW, 1.6 kW
Commutator mica depth		0.4 - 0.5 mm (0.016 - 0.020 in.)	0.15 mm (0.006 in.)
Commutator runout		0.02 mm (0.001 in.) max.	0.05 mm (0.002 in.)
Commutator O.D.		28.0 - 28.1 mm (1.102 - 1.106 in.)	27.5 mm (1.083 in.)
Brush length		11.1 - 11.5 mm (0.44 - 0.45 in.)	4.3 mm (0.17 in.)
Starter (DENSO)	Output		1.0 kW, 1.1 kW
Commutator mica depth		0.50 - 0.80 mm (0.020 - 0.031 in.)	0.2 mm (0.008 in.)
Commutator runout		0.02 mm (0.001 in.) max.	0.05 mm (0.002 in.)
Commutator O.D.		28.0 mm (1.10 in.)	27.0 mm (1.06 in.)
Brush length		14.0 - 14.5 mm (0.55 - 0.57 in.)	9.0 mm (0.35 in.)
Brush spring tension		13.7 - 17.7 N (1.40 - 1.80 kgf, 3.09 - 3.98 lbs)

***Engine Assembly***
Item	Measurement	Qualification	Standard or New	Service Limit
Compression	Pressure check at 250 (min-1) rpm with wide open throttle. (See Design Specs for ratio)	Minimum	930 kPa (9.5 kgf/cm2, 135 psi)	------
Maximum variation	200 kPa (2.0 kgf/cm2, 28 psi)	------

***Cylinder Head02-3***
Item	Measurement	Qualification	Standard or New	Service Limit
Head	Warpage		------	0.05 mm (0.002 in.)
Height		103.95 - 104.05 mm (4.093 - 4.096 in.)	------
Camshaft	End play		0.05 - 0.20 mm (0.002 - 0.008 in.)	0.4 mm (0.02 in.)
Camshaft-to-holder oil clearance	No.1 journal	0.030 - 0.069 mm (0.001 - 0.003 in.)	0.15 mm (0.006 in.)
No.2, 3, 4, 5 journals	0.060 - 0.099 mm (0.002 - 0.004 in.)	0.15 mm (0.006 in.)
Total runout		0.03 mm (0.001 in.) max.	0.04 mm (0.002 in.)
Cam lobe height	Intake, primary	33.925 mm (1.3356 in.)	------
Intake, secondary	29.638 mm (1.1668 in.)	------
Exhaust	34.092 mm (1.3422 in.)	------
Valves	Clearance (cold)	Intake	0.21 - 0.25 mm (0.008 - 0.010 in.)	------
Exhaust	0.28 - 0.32 mm (0.011 - 0.013 in.)	------
Stem O.D.	Intake	5.475 - 5.485 mm (0.2156 - 0.2159 in.)	5.445 mm (0.214 in.)
Exhaust	5.450 - 5.460 mm (0.2146 - 0.2150 in.)	5.42 mm (0.213 in.)
Stem-to-guide clearance	Intake	0.030 - 0.055 mm (0.0012 - 0.0022 in.)	0.08 mm (0.003 in.)
Exhaust	0.055 - 0.080 mm (0.0022 - 0.0031 in.)	0.11 mm (0.004 in.)
Valve seats	Width	Intake	1.25 - 1.55 mm (0.049 - 0.061 in.)	2.00 mm (0.079 in.)
Exhaust	1.25 - 1.55 mm (0.049 - 0.061 in.)	2.00 mm (0.079 in.)
Stem installed height	Intake	40.8 - 41.0 mm (1.606 - 1.614 in.)	------
Exhaust	54.6 - 54.8 mm (2.150 - 2.157 in.)	------
Valve springs	Free length	Intake	47.61 mm (1.874 in.)	------
Exhaust	49.64 mm (1.954 in.) 49.63 mm (1.954 in.)	------
Valve guides	I.D.	Intake	5.515 - 5.530 mm (0.2171 - 0.2177 in.)	5.55 mm (0.219 in.)
Exhaust	5.515 - 5.530 mm (0.2171 - 0.2177 in.)	5.55 mm (0.219 in.)
Installed height	Intake	15.2 - 16.2 mm (0.598 - 0.638 in.)	------
Exhaust	15.5 - 16.5 mm (0.610 - 0.650 in.)	------
Rocker arms	Arm-to-shaft clearance	Intake	0.025 - 0.052 mm (0.0010 - 0.0020 in.)	0.08 mm (0.003 in.)
Exhaust	0.018 - 0.056 mm (0.0007 - 0.0022 in.)	0.08 mm (0.003 in.)

***Engine Block02-4***
Item	Measurement	Qualification	Standard or New	Service Limit
Block	Warpage of deck		0.07 mm (0.003 in.) max.	0.10 mm (0.004 in.)
Bore diameter (K20A4, K20A5 engines)	A or l	86.010 - 86.020 mm (3.3862 - 3.3866 in.)	86.070 mm (3.3886 in.)
B or ll	86.000 - 86.010 mm (3.3858 - 3.3862 in.)	86.070 mm (3.3886 in.)
Bore diameter (K24A1 engines)	A or l	87.010 - 87.020 mm (3.4256 - 3.4260 in.)	87.070 mm (3.4279 in.)
B or lI	87.000 - 87.010 mm (3.4252 - 3.4256 in.)	87.070 mm (3.4279 in.)
Bore taper		------	0.05 mm (0.002 in.)
Reboring limit		------	0.25 mm (0.01 in.)
Piston	Skirt O.D. at 11 mm (0.4 in.) from bottom of skirt (K20A4, K20A5 engines)	No letter or A	85.980 - 85.990 mm (3.3850 - 3.3854 in.)	85.930 mm (3.3831 in.)
Letter B	85.970 - 85.980 mm (3.3846 - 3.3850 in.)	85.920 mm (3.3827 in.)
Skirt O.D. at 13 mm (0.5 in.) from bottom of skirt (K24A1 engine)	No letter or A	86.980 - 86.990 mm (3.4244 - v3.4248 in.)	86.930 mm (3.4224 in.)
Letter B	86.970 - 86.980 mm (3.4240 - 3.4244 in.)	86.920 mm (3.4220 in.)
Clearance in cylinder		0.020 - 0.040 mm (0.0008 - 0.0016 in.)	0.05 mm (0.002 in.)
Ring groove width	Top (K20A4, K20A5 engines)	1.220 - 1.230 mm (0.0481 - 0.0484 in.)	1.25 mm (0.049 in.)
Top (K24A1 engine)	1.230 - 1.240 mm (0.0484 - 0.0488 in.)	1.26 mm (0.0450 in.)
Second (K20A4, K20A5 engines)	1.220 - 1.230 mm (0.0481 - 0.0484 in.)	1.25 mm (0.049 in.)
Second (K24A1 engine)	1.240 - 1.250 mm (0.0488 - 0.0492 in.)	1.270 mm (0.050 in.)
Oil (K20A4, K24A1 engines)	2.005 - 2.025 mm (0.0789 - 0.0797 in.)	2.05 mm (0.081 in.)
Oil (K20A5 engine)	2.805 - 2.825 mm (0.1104 - 0.1112 in.)	2.85 mm (0.112 in.)
Piston ring	Ring-to-groove clearance	Top (K20A4 engine)	0.035 - 0.060 mm (0.0014 - 0.0024 in.)	0.13 mm (0.005 in.)
Top (K20A5 engine)	0.030 - 0.055 mm (0.0012 - 0.0022 in.)	0.13 mm (0.005 in.)
Top (K24A1 engine)	0.045 - 0.070 mm (0.0018 - 0.0028 in.)	0.13 mm (0.005 in.)
Second (K20A4, K20A5 engines)	0.030 - 0.055 mm (0.0012 - 0.0022 in.)	0.13 mm (0.005 in.)
Second (K24A1 engine)	0.050 - 0.075 mm (0.0020 - 0.0030 in.)	0.13 mm (0.005 in.)
Ring end gap	Top	0.20 - 0.35 mm (0.008 - 0.014 in.)	0.60 mm (0.024 in.)
Second	0.40 - 0.55 mm (0.016 - 0.022 in.)	0.70 mm (0.028 in.)
Oil (K20A4 (Except KY models) engine)	0.25 - 0.65 mm (0.010 - 0.026 in.)	0.75 mm (0.030 in.)
Oil (K20A4 (KY model), K20A5, K24A1 engines)	0.20 - 0.70 mm (0.008 - 0.028 in.)	0.80 mm (0.031 in.)
Piston pin	O.D.		21.961 - 21.965 mm (0.8646 - 0.8648 in.)	21.953 mm (0.8643 in.)
Pin-to-piston clearance		-0.005- +0.002 mm (-0.00020- + 0.00008 in.)	0.005 mm (0.0002 in.)
Connecting rod	Pin-to-rod clearance		0.005 - 0.015 mm (0.0002 - 0.0006 in.)	0.02 mm (0.0008 in.)
Small-end bore diameter		21.970 - 21.976 mm (0.8650 - 0.8652 in.)	------
Large-end bore diameter (Normal)	K20A4, K20A5 engines	48.0 mm (1.89 in.)	------
K24A1 engine	51.0 mm (2.01 in.)	------
End play installed on crankshaft		0.15 - 0.30 mm (0.006 - 0.012 in.)	0.40 mm (0.016 in.)

Item	Measurement	Qualification	Standard or New	Service Limit
Crankshaft	Main journal diameter	No. 1 journal No. 2 journal No. 4 journal No. 5 journal	54.984 - 55.008 mm (2.1648 - 2.1657 in.)	------
No. 3 journal	54.976 - 55.000 mm (2.1644 - 2.1654 in.)	------
Rod journal diameter	K20A4, K20A5 engines	44.976 - 45.000 mm (1.7707 - 1.7717 in.)	------
K24A1 engine	47.976 - 48.000 mm (1.8888 - 1.8898 in.)	------
Rod/main journal taper		0.005 mm (0.0002 in.) max.	0.010 mm (0.0004 in.)
Rod/main journal out-of- round		0.005 mm (0.0002 in.) max.	0.010 mm (0.0004 in.)
End play		0.10 - 0.35 mm (0.004 - 0.014 in.)	0.45 mm (0.018 in.)
Runout		0.03 mm (0.0012 in.) max.	0.04 mm (0.0016 in.)
Crankshaft bearings	Main bearing-to-journal oil clearance	No. 1 journal No. 2 journal No. 4 journal No. 5 journal	0.017 - 0.041 mm (0.0007 - 0.0016 in.)	0.050 mm (0.0020 in.)
No. 3 journal	0.025 - 0.049 mm (0.0010 - 0.0019 in.)	0.055 mm (0.0022 in.)
Rod bearing clearance		0.021 - 0.049 mm (0.0008 - 0.0019 in.)	0.060 mm (0.0024 in.)

***Engine Lubrication***
Item	Measurement	Qualification	Standard or New	Service Limit
Engine oil	Capacity		5.3 l (5.6 US qt, 4.7 lmp qt) for engine overhaul 4.2 l (4.4 US qt, 3.7 lmp qt) for oil change, including filter 4.0 l (4.2 US qt, 3.5 lmp qt) for oil change, without filter
Oil pump	Inner-to-outer rotor clearance		0.02 - 0.16 mm (0.001 - 0.006 in.)	0.20 mm (0.008 in.)
Pump housing-to-outer rotor clearance		0.15 - 0.21 mm (0.006 - 0.008 in.)	0.23 mm (0.009 in.)
Pump housing-to-rotor axial clearance		0.02 - 0.07 mm (0.001 - 0.003 in.)	0.12 mm (0.005 in.)
Balancer shafts, journal diameter	No. 1 journal, front shaft	19.938 - 19.950 mm (0.7850 - 0.7854 in.)	19.92 mm (0.784 in.)
No. 1 journal, rear shaft	23.938 - 23.950 mm (0.9424 - 0.9429 in.)	23.92 mm (0.942 in.)
No. 2 journal, front and rear shaft	32.949 - 32.961 mm (1.2972 - 1.2977 in.)	32.93 mm (1.296 in.)
Balancer shafts, journal taper		0.005 mm (0.0002 in.) max.	------
Balancer shafts, end play	Front	0.070 - 0.135 mm (0.0028 - 0.0053 in.)	0.15 mm (0.006 in.)
Rear	0.070 - 0.135 mm (0.0028 - 0.0053 in.)	0.15 mm (0.006 in.)
Balancer shafts, shaft-to- bearing clearance	No. 1 journal, front shaft	0.050 - 0.082 mm (0.0020 - 0.0032 in.)	0.10 mm (0.004 in.)
No. 1 journal, rear shaft	0.050 - 0.082 mm (0.0020 - 0.0032 in.)	0.10 mm (0.004 in.)
No. 2 journal, front and rear shaft	0.060 - 0.120 mm (0.0024 - 0.0047 in.)	0.15 mm (0.006 in.)
Balancer shaft bearings, I.D.	No. 1 journal, front shaft	20.000 - 20.020 mm (0.7874 - 0.7882 in.)	20.03 mm (0.789 in.)
No. 1 journal, rear shaft	24.000 - 24.020 mm (0.9449 - 0.9457 in.)	24.03 mm (0.946 in.)
No. 2 journal, front and rear shaft	33.021 - 33.069 mm (1.3000 - 1.3019 in.)	33.09 mm (1.303 in.)
Relief valve, oil pressure with oil temperature at 80 °C (176 z°F)	At idle	70 kPa (0.7 kgf/cm2, 10 psi) min.
at 3,000 rpm (min-1)	300 kPa (3.1 kgf/cm2, 44 psi) min.

***Cooling02-6***
Item	Measurement	Qualification	Standard or New	Service Limit
Radiator	Coolant capacity for K20A4 and K20A5 engines (including engine, heater, hoses, and reservoir)	M/T: engine overhaul	7.1 L (7.5 US qt, 6.2 Imp qt)
M/T: coolant change	5.4 L (5.7 US qt, 4.8 Imp qt)
A/T: engine overhaul	7.0 l (7.4 US qt, 6.2 lmp qt)
A/T: coolant change	5.3 l (5.6 US qt, 4.7 lmp qt)
Coolant capacity for K24A1 engine (includes engine, heater, hoses, and reservoir)	M/T at engine overhaul	7.2 L (7.6 US qt, 6.3 Imp qt)
M/T at coolant change	5.5 L (5.8 US qt, 4.8 Imp qt)
A/T at engine overhaul	7.1 L (7.5 US qt, 6.2 Imp qt)
A/T at coolant change	5.4 L (5.7 US qt, 4.8 Imp qt)
Reservoir	Coolant capacity		0.55 L (0.58 US qt, 0.48 Imp qt)
Radiator cap	Opening pressure		93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi)
Thermostat	Opening temperature	Begins to open	76 - 80°C (169 - 176°F)
Fully open	90°C (194°F)
Valve lift at fully open		8.0 mm (0.31 in.) min.
Radiator fan switch	Switching temperature	Turns ON	91 - 95°C (196 - 203°F)
Turns OFF	Subtract 3 - 8 °C (5 - 15 °F) from actual ON temperature

***Fuel and Emissions***
Item	Measurement	Qualification	Standard or New	Service Limit
Fuel pressure regulator	Pressure with fuel pressure gauge connected		338 - 348 kPa (3.45 - 3.55 kgf/cm2, 49 - 50 psi)
Fuel tank	Capacity		58 L (15 US gal, 13 Imp gal)
Engine idle	Idle speed without a load	M/T in neutral	650 ± 50 rpm (min-1)
A/T in [N] or [P] position	650 ± 50 rpm (min-1)
Fast idle	M/T in neutral	1,600 ± 200 rpm (min-1)
A/T in [N] or [P] position	1,600 ± 200 rpm (min-1)
Idle CO %		0.1 max.

***Clutch***
Item	Measurement	Qualification	Standard or New	Service Limit
Clutch pedal	Height from floor		200 mm (7.87 in.)	------
Stroke		125 - 135 mm (4.92 - 5.31 in.)	------
Play		6 - 17 mm (0.24 - 0.67 in.)	------
Disengagement height from floor		112 mm (4.41 in.) min.	------
Flywheel	Runout on clutch mating surface		0.05 mm (0.002 in.) max.	0.15 mm (0.006 in.)
Clutch disc	Rivet head depth		1.65 - 2.25 mm (0.065 - 0.089 in.)	0.7 mm (0.03 in.)
Thickness		8.7 - 9.3 mm (0.34 - 0.37 in.)	6.0 mm (0.24 in.)
Pressure plate	Warpage		0.03 mm (0.001 in.) max.	0.15 mm (0.006 in.)
Height of diaphragm spring fingers measured with special tool and feeler gauge		0.6 mm (0.02 in.) max.	0.8 mm (0.03 in.)

***Manual Transmission and M/T Differential02-7***
Item	Measurement	Qualification	Standard or New	Service Limit
Transmission fluid	Capacity	4WD at fluid change	1.9 L (2.0 US qt, 1.7 Imp qt)
4WD at overhaul	2.3 L (2.4 US qt, 2.0 Imp qt)
2WD at fluid change	1.9 L (2.0 US qt, 1.7 Imp qt)
2WD at overhaul	2.1 L (2.2 US qt, 1.8 Imp qt)
Mainshaft	End play		0.11 - 0.17 mm (0.004 - 0.007 in.)	Adjust
Diameter of bushing surface		20.80 - 20.85 mm (0.8189 - 0.8209 in.)	20.75 mm (0.817 in.)
Diameter of distance collar		31.984 - 32.000 mm (1.2594 - 1.2598 in.)	31.93 mm (1.257 in.)
Diameter of ball bearing contact area (clutch housing side)		27.977 - 27.990 mm (1.1015 - 1.1020 in.)	27.94 mm (1.100 in.)
Diameter of needle bearing contact area		38.984 - 39.000 mm (1.5348 - 1.5354 in.)	38.93 mm (1.533 in.)
Diameter of ball bearing contact area (transmission housing side)		27.987 - 28.000 mm (1.1019 - 1.1024 in.)	27.94 mm (1.100 in.)
Runout		0.02 mm (0.001 in.) max.	0.05 mm (0.002 in.)
Mainshaft 3rd, 4th and 5th gears	I.D.		44.009 - 44.025 mm (1.7326 - 1.7333 in.)	44.08 mm (1.735 in.)
End play		0.06 - 0.16 mm (0.002 - 0.006 in.)	0.25 mm (0.010 in.)
Thickness		23.92 - 23.97 mm (0.981 - 0.944 in.)	23.80 mm (0.937 in.)
Countershaft	Diameter of needle bearing contact area (clutch housing side) Diameter of distance collar contact area		35.000 - 35.015 mm (1.3780 - 1.3785 in.)	34.95 mm (1.376 in.)
	39.937 - 39.950 mm (1.5723 - 1.5728 in.)	39.88 mm (1.570 in.)
Diameter of ball bearing contact area (transmission housing side)		30.020 - 30.033 mm (1.1819 - 1.1824 in.)	29.97 mm (1.180 in.)
Run out		0.02 mm (0.001 in.) max.	0.05 mm (0.002 in.)
35 mm shim-to-bearing inner race clearance		0.04 - 0.10 mm (0.0016 - 0.0039 in.)	Adjust
Countershaft 1st gear	I.D.		52.010 - 52.029 mm (2.0476 - 2.0484 in.)	52.08 mm (2.050 in.)
End play		0.06 - 0.16 mm (0.002 - 0.006 in.)	0.25 mm (0.010 in.)
Thickness		22.92 - 22.97 mm (0.902 - 0.904 in.)	22.87 mm (0.900 in.)
Countershaft 2nd gear	I.D.		52.010 - 52.029 mm (2.0476 - 2.0484 in.)	52.08 mm (2.050 in.)
End play		0.06 - 0.16 mm (0.002 - 0.006 in.)	0.25 mm (0.010 in.)
Thickness		27.92 - 27.97 mm (1.099 - 1.101 in.)	27.87 mm (1.097 in.)
Countershaft 1st gear distance collar	I.D.		39.95 - 39.96 mm (1.5728 - 1.5732 in.)	39.97 mm (1.574 in.)
O.D.		46.989 - 47.000 mm (1.8499 - 1.8504 in.)	46.94 mm (1.848 in.)
Length		23.03 - 23.08 mm (0.907 - 0.909 in.)	------
Countershaft 2nd gear distance collar	I.D.		39.95 - 39.96 mm (1.5728 - 1.5732 in.)	39.97 mm (1.574 in.)
O.D.		46.989 - 47.000 mm (1.8499 - 1.8504 in.)	46.94 mm (1.848 in.)
Length		28.03 - 28.08 mm (1.104 - 1.106 in.)	------
Mainshaft 4th and 5th gears distance collar	I.D.		32.00 - 32.01 mm (1.2598 - 1.2602 in.)	32.02 mm (1.261 in.)
O.D.		38.989 - 39.000 mm (1.5350 - 1.5354 in.)	38.94 mm (1.533 in.)
Length	A	51.95 - 52.05 mm (2.045 - 2.049 in.)	------
B	24.03 - 24.08 mm (0.946 - 0.947 in.)	------
MBS distance collar	I.D.		28.00 - 28.01 mm (1.102 - 1.103 in.)	28.02 mm (1.103 in.)
Length		23.95 - 24.05 mm (0.943 - 0.947 in.)	------

***Manual Transmission and M/T Differential (cont'd)02-8***
Item	Measurement	Qualification	Standard or New	Service Limit
Reverse idler gear	I.D.		20.016 - 20.043 mm (0.7880 - 0.7891 in.)	20.90 mm (0.832 in.)
Gear-to-reverse gear shaft clearance		0.036 - 0.084 mm (0.0014 - 0.0033 in.)	0.16 mm (0.006 in.)
Synchro ring	Ring-to-gear clearance	Ring pushed against gear	0.70 - 1.49 mm (0.028 - 0.059 in.)	0.4 mm (0.016 in.)
Double cone synchro	Outer synchro ring-to- synchro cone clearance	Ring pushed against gear	0.70 - 1.19 mm (0.028 - 0.047 in.)	0.3 mm (0.012 in.)
Synchro cone-to-gear clearance	Ring pushed against gear	0.50 - 1.04 mm (0.020 - 0.041 in.)	0.3 mm (0.012 in.)
Outer synchro ring-to- gear cone clearance	Ring pushed against gear	0.95 - 1.68 mm (0.037 - 0.066 in.)	0.6 mm (0.024 in.)
Triple cone synchro	Outer synchro ring-to- synchro cone clearance	Ring pushed against gear	0.70 - 1.19 mm (0.028 - 0.047 in.)	0.3 mm (0.012 in.)
Synchro cone-to-gear clearance	Ring pushed against gear	0.50 - 1.04 mm (0.020 - 0.041 in.)	0.3 mm (0.012 in.)
Outer synchro ring-to- gear cone clearance	Ring pushed against gear	0.95 - 1.68 mm (0.037 - 0.066 in.)	0.6 mm (0.024 in.)
Shift fork	Finger thickness		7.4 - 7.6 mm (0.29 - 0.30 in.)	------
Fork-to-synchro sleeve clearance		0.35 - 0.65 mm (0.014 - 0.026 in.)	1.0 mm (0.039 in.)
Reverse shift fork	Finger thinkness		13.4 - 13.7 mm (0.527 - 0.539 in.)	------
Fork-to-reverse idler gear clearance		0.20 - 0.59 mm (0.007 - 0.024 in.)	1.2 mm (0.047 in.)
Shift arm	I.D.		13.973 - 14.000 mm (0.5501 - 0.5512 in.)	------
Shift fork diameter at contact area		16.9 - 17.0 mm (0.665 - 0.669 in.)	------
Shift arm-to-shift lever clearance		0.2 - 0.5 mm (0.008 - 0.020 in.)	0.60 mm (0.023 in.)
Select lever	Finger width		14.85 - 14.95 mm (0.585 - 0.589 in.)	------
Shift lever	Shaft-to-select lever clearance		0.05 - 0.25 mm (0.002 - 0.010 in.)	0.50 mm (0.020 in.)
Groove (to select lever)		15.00 - 15.10 mm (0.591 - 0.594 in.)	------
Shaft-to-shift arm clearance		0.013 - 0.07 mm (0.0005 - 0.003 in.)	0.1 mm (0.004 in.)
M/T differential carrier	Pinion shaft contact area I.D.		18.010 - 18.028 mm (0.7091 - 0.7098 in.)	------
Carrier-to-pinion shaft clearance		0.027 - 0.057 mm (0.0011 - 0.0022 in.)	0.1 mm (0.004 in.)
Driveshaft contact area I.D.		28.025 - 28.045 mm (1.1033 - 1.1041 in.)	------
M/T differential pinion gear	Backlash		0.05 - 0.15 mm (0.002 - 0.006 in.)	------
I.D.		18.042 - 18.066 mm (0.7103 - 0.7113 in.)	------
Pinion gear-to-pinion shaft clearance		0.059 - 0.095 mm (0.0023 - 0.0037 in.)	0.15 mm (0.006 in.)
80 mm shim	80 mm shim-to-bearing outer race clearance in transmission housing		0 - 0.10 mm (0 - 0.0039 in.)	Adjust
Transfer	Diameter of tapered roller bearing contact area (transfer shaft)		24.975 - 24.990 mm (0.9833 - 0.9838 in.)	24.92 mm (0.9811 in.)
Diameter of tapered roller bearing contact area (transfer drive gear)		40.002 - 40.018 mm (1.5749 - 1.5755 in.)	38.95 mm (1.5335 in.)
Diameter of tapered roller bearing contact area (driven gear side)		35.002 - 35.018 mm (1.3780 - 1.3786 in.)	34.95 mm (1.3760 in.)
Diameter of tapered roller bearing contact area (splined side)		26.975 - 26.988 mm (1.0620 - 1.0625 in.)	26.92 mm (1.0598 in.)
Transfer gear backlash		0.06 - 0.16 mm (0.0024 - 0.0063 in.)	Adjust
Total starting torque		2.24 - 3.71 N·m (22.0 - 36.4 kgf·cm, 19.1 - 31.6 lbf·in)	Adjust

***Automatic Transmission and A/T Differential02-9***
Item	Measurement	Qualification	Standard or New	Service Limit
ATF (Automatic Transmission Fluid)	Capacity Use Genuine Honda ATF- Z1	4WD at fluid change	3.1 L (3.3 US qt, 2.7 Imp qt)
2WD at fluid change	2.9 L (3.1 US qt, 2.6 Imp qt)
4WD at overhaul	7.2 L (7.6 US qt, 6.3 Imp qt)
2WD at overhaul	6.5 L (6.9 US qt, 5.7 Imp qt)
ATF pressure	Line pressure	at 2,000 rpm (min-1) in [P] or [N] position	900 - 960 kPa (9.2 - 9.8 kgf/cm2, 130 - 140 psi)	850 kPa (8.7 kgf/cm2, 120 psi)
1st clutch pressure	at 2,000 rpm (min-1) in 1st gear in [1] position	890 - 970 kPa (9.1 - 9.9 kgf/cm2, 130 - 140 psi)	840 kPa (8.6 kgf/cm2, 120 psi)
2nd clutch pressure	at 2,000 rpm (min-1) in 2nd gear in [2] position	890 - 970 kPa (9.1 - 9.9 kgf/cm2, 130 - 140 psi)	840 kPa (8.6 kgf/cm2, 120 psi)
3rd clutch pressure	at 2,000 rpm (min-1) in 3rd gear in [D] position	890 - 970 kPa (9.1 - 9.9 kgf/cm2, 130 - 140 psi)	840 kPa (8.6 kgf/cm2, 120 psi)
4th clutch pressure	at 2,000 rpm (min-1) in 4th gear in [D] position	890 - 970 kPa (9.1 - 9.9 kgf/cm2, 130 - 140 psi)	840 kPa (8.6 kgf/cm2, 120 psi)
Torque converter	Stall speed Check with vehicle on level ground		2,320 rpm (min-1)	2,170 - 2,470 rpm (min-1)
Clutch K20A4 and K20A5 engine models	Clutch end plate-to-top disc clearance	1st	------	1.23 - 1.43 mm (0.048 - 0.056 in.)
2nd	------	0.75 - 0.95 mm (0.030 - 0.037 in.)
3rd and 4th	------	0.73 - 0.93 mm (0.029 - 0.037 in.)
Clutch return spring free length	1st and 2nd	50.8 mm (2.00 in.)	48.8 mm (1.92 in.)
3rd and 4th	33.5 mm (1.32 in.)	31.5 mm (1.24 in.)
Clutch disc thickness		1.94 mm (0.076 in.)	------
Clutch plate thickness		2.00 mm (0.079 in.)	When discolored
Clutch waved-plate phase difference		0.07 - 0.20 mm (0.003 - 0.008 in.)	0.05 mm (0.002 in)
1st Clutch end plate thickness	Mark 1	2.3 mm (0.091 in.)	When discolored
Mark 2	2.4 mm (0.094 in.)	When discolored
Mark 3	2.5 mm (0.098 in.)	When discolored
Mark 4	2.6 mm (0.102 in.)	When discolored
Mark 5	2.7 mm (0.106 in.)	When discolored
Mark 6	2.8 mm (0.110 in.)	When discolored
Mark 7	2.9 mm (0.114 in.)	When discolored
Mark 8	3.0 mm (0.118 in.)	When discolored
Mark 9	3.1 mm (0.122 in.)	When discolored
Mark 10	3.2 mm (0.126 in.)	When discolored
Mark 11	3.3 mm (0.130 in.)	When discolored
Mark 12	3.4 mm (0.134 in.)	When discolored
2nd clutch end plate thickness	Mark 1	2.6 mm (0.102 in.)	When discolored
Mark 2	2.7 mm (0.106 in.)	When discolored
Mark 3	2.8 mm (0.110 in.)	When discolored
Mark 4	2.9 mm (0.114 in.)	When discolored
Mark 5	3.0 mm (0.118 in.)	When discolored
Mark 6	3.1 mm (0.122 in.)	When discolored
Mark 7	3.2 mm (0.126 in.)	When discolored
Mark 8	3.3 mm (0.130 in.)	When discolored
Mark 9	3.4 mm (0.134 in.)	When discolored

***Automatic Transmission and A/T Differential (cont'd)02-10***
Item	Measurement	Qualification	Standard or New	Service Limit
Clutch K20A4 and K20A5 engine models (cont'd)	3rd and 4th clutch end plate thickness	Mark 11	3.1 mm (0.122 in.)	When discolored
Mark 12	3.2 mm (0.126 in.)	When discolored
Mark 13	3.3 mm (0.130 in.)	When discolored
Mark 14	3.4 mm (0.134 in.)	When discolored
Mark 15	3.5 mm (0.138 in.)	When discolored
Mark 16	3.6 mm (0.142 in.)	When discolored
Mark 17	3.7 mm (0.146 in.)	When discolored
Mark 18	3.8 mm (0.150 in.)	When discolored
Mark 19	3.9 mm (0.154 in.)	When discolored
Clutch K24A1 engine model	Clutch end plate-to-top disc clearance	1st	------	1.28 - 1.48 mm (0.050 - 0.058 in.)
2nd	------	0.85 - 1.05 mm (0.033 - 0.041 in.)
3rd and 4th	------	0.73 - 0.93 mm (0.029 - 0.037 in.)
Clutch return spring free length	1st and 2nd	50.8 mm (2.00 in.)	48.8 mm (1.92 in.)
3rd and 4th	33.5 mm (1.32 in.)	31.5 mm (1.24 in.)
Clutch disc thickness		1.94 mm (0.076 in.)	------
Clutch plate thickness	1st	1.6 mm (0.063 in.)	When discolored
2nd	2.0 mm (0.079 in.)	When discolored
3rd and 4th	2.3 mm (0.091 in.)	When discolored
Clutch waved-plate phase difference		0.07 - 0.20 mm (0.003 - 0.008 in.)	0.05 mm (0.002 in)
1st Clutch end plate thickness	Mark 1	2.6 mm (0.102 in.)	When discolored
Mark 2	2.7 mm (0.106 in.)	When discolored
Mark 3	2.8 mm (0.110 in.)	When discolored
Mark 4	2.9 mm (0.114 in.)	When discolored
Mark 5	3.0 mm (0.118 in.)	When discolored
Mark 6	3.1 mm (0.122 in.)	When discolored
Mark 7	3.2 mm (0.126 in.)	When discolored
Mark 8	3.3 mm (0.130 in.)	When discolored
Mark 9	3.4 mm (0.134 in.)	When discolored
2nd clutch end plate thickness	Mark 1	2.6 mm (0.102 in.)	When discolored
Mark 2	2.7 mm (0.106 in.)	When discolored
Mark 3	2.8 mm (0.110 in.)	When discolored
Mark 4	2.9 mm (0.114 in.)	When discolored
Mark 5	3.0 mm (0.118 in.)	When discolored
Mark 6	3.1 mm (0.122 in.)	When discolored
Mark 7	3.2 mm (0.126 in.)	When discolored
Mark 8	3.3 mm (0.130 in.)	When discolored
Mark 9	3.4 mm (0.134 in.)	When discolored
3rd and 4th clutch end plate thickness	Mark 1	2.1 mm (0.083 in.)	When discolored
Mark 2	2.2 mm (0.087 in.)	When discolored
Mark 3	2.3 mm (0.091 in.)	When discolored
Mark 4	2.4 mm (0.094 in.)	When discolored
Mark 5	2.5 mm (0.098 in.)	When discolored
Mark 6	2.6 mm (0.102 in.)	When discolored
Mark 7	2.7 mm (0.106 in.)	When discolored
Mark 8	2.8 mm (0.110 in.)	When discolored
Mark 9	2.9 mm (0.114 in.)	When discolored

***02-11***
Item	Measurement	Qualification	Standard or New	Service Limit
Mainshaft	Diameter of needle bearing contact area	at stator shaft	22.984 - 23.000 mm (0.905 - 0.906 in.)	When worn or damaged
at 3rd gear	51.975 - 51.991 mm (2.046 - 2.047 in.)	When worn or damaged
at 4th gear collar	33.975 - 33.991 mm (1.3376 - 1.3382 in.)	When worn or damaged
I.D. of gears	3rd gear	57.000 - 57.019 mm (2.2441 - 2.2448 in.)	When worn or damaged
4th gear	40.000 - 40.016 mm (1.5748 - 1.5754 in.)	When worn or damaged
End play of gears	3rd gear	0.03 - 0.31 mm (0.001 - 0.012 in.)	------
4th gear	0.1 - 0.212 mm (0.004-0.008 in.)	------
41 x 68 mm thrust washer thickness	No. 1	6.35 mm (0.250 in.)	When worn or damaged
No. 2	6.40 mm (0.252 in.)	When worn or damaged
No. 3	6.45 mm (0.254 in.)	When worn or damaged
No. 4	6.50 mm (0.256 in.)	When worn or damaged
No. 5	6.55 mm (0.258 in.)	When worn or damaged
No. 6	6.60 mm (0.260 in.)	When worn or damaged
4th gear collar length		66.3 - 66.4 mm (2.610 - 2.614 in.)	------
Length of 4th gear collar flange from end		19.15 - 19.30 mm (0.754 - 0.760 in.)	When worn or damaged
Sealing ring thickness		1.91 - 1.97 mm (0.0752 - 0.0776 in.)	1.86 (0.0732 in.)
Width of sealing ring groove		2.025 - 2.060 mm (0.0797 - 0.0811 in.)	2.080 mm (0.0819 in.)
Clutch feed pipe O.D.		7.97 - 7.98 mm (0.3138 - 0.3142 in.)	7.95 mm (0.313 in.)
Clutch feed pipe bushing I.D.		8.000 - 8.015 mm (0.3150 - 0.3156 in.)	8.030 mm (0.3161 in.)
Countershaft	Diameter of needle bearing contact area	at torque converter housing	36.005-36.015 mm (1.4175 - 1.4179 in.)	When worn or damaged
at 4th gear collar	37.982 - 37.996 mm (1.4954 - 1.4959 in.)	When worn or damaged
at reverse gear collar	39.979 - 40.000 mm (1.5740 - 1.5748 in.)	When worn or damaged
I.D. of gears	4th gear	43.000 - 43.016 mm (1.6929 - 1.6935 in.)	When worn or damaged
Reverse gear	46.000 - 46.016 mm (1.8110 - 1.8116 in.)	When worn or damaged
End play of gears	1st gear	0.10 - 0.42 mm (0.004 - 0.017 in.)	------
2nd gear	0.10 - 0.42 mm (0.004 - 0.017 in.)	------
3rd gear	0.10 - 0.42 mm (0.004 - 0.017 in.)	------
4th gear	0.1 - 0.2 mm (0.004 - 0.008 in.)	------
Reverse gear	0.10 - 0.25 mm (0.004 - 0.010 in.)	------
4th gear collar length		24.00 - 24.05 mm (0.945 - 0.947 in.)	------
Distance collar length		74.25 - 74.30 mm (2.923 - 2.925 in.)	------
Reverse selector hub width		25.45 - 25.65 mm (1.002 - 1.010 in.)	------
Reverse selector hub O.D.		55.87 - 55.90 mm (2.200 - 2.201 in.)	When worn or damaged

***Automatic Transmission and A/T Differential (cont'd)02-12***
Item	Measurement	Qualification	Standard or New	Service Limit
Secondary shaft	Diameter of needle bearing contact area	at 1st gear	39.986 - 39.999 mm (1.5742 - 1.5748 in.)	When worn or damaged
at 2nd gear	39.986 - 39.999 mm (1.5742 - 1.5748 in.)	When worn or damaged
I.D. of gears	1st gear	47.000 - 47.016 mm (1.8504 - 1.8510 in.)	When worn or damaged
2nd gear	46.000 - 46.016 mm (1.8110 - 1.8116 in.)	When worn or damaged
End play of gears	1st gear	0.07 - 0.15 mm (0.003 - 0.006 in.)	------
2nd gear	0.04 - 0.12 mm (0.002 - 0.005 in.)	------
37 x 58 mm thrust washer thickness	No. 1	3.900 mm (0.154 in.)	When worn or damaged
No. 2	3.925 mm (0.155 in.)	When worn or damaged
No. 3	3.950 mm (0.156 in.)	When worn or damaged
No. 4	3.975 mm (0.156 in.)	When worn or damaged
No. 5	4.000 mm (0.157 in.)	When worn or damaged
No. 6	4.025 mm (0.158 in.)	When worn or damaged
No. 7	4.050 mm (0.159 in.)	When worn or damaged
No. 8	4.075 mm (0.160 in.)	When worn or damaged
No. 9	4.100 mm (0.161 in.)	When worn or damaged
No. 10	4.125 mm (0.162 in.)	When worn or damaged
No. 11	4.150 mm (0.163 in.)	When worn or damaged
No. 12	4.175 mm (0.164 in.)	When worn or damaged
No. 13	4.200 mm (0.165 in.)	When worn or damaged
No. 14	4.225 mm (0.166 in.)	When worn or damaged
No. 15	4.250 mm (0.167 in.)	When worn or damaged
No. 16	4.275 mm (0.168 in.)	When worn or damaged
No. 17	4.300 mm (0.169 in.)	When worn or damaged
No. 18	4.325 mm (0.170 in.)	When worn or damaged
No. 19	4.350 mm (0.171 in.)	When worn or damaged
No. 20	4.375 mm (0.172 in.)	When worn or damaged
40 x 51.5 mm thrust washer thickness	No. 1	4.80 mm (0.189 in.)	When worn or damaged
No. 2	4.85 mm (0.191 in.)	When worn or damaged
No. 3	4.90 mm (0.193 in.)	When worn or damaged
No. 4	4.95 mm (0.195 in.)	When worn or damaged
No. 5	5.00 mm (0.197 in.)	When worn or damaged
No. 6	5.05 mm (0.199 in.)	When worn or damaged
27 x 45 x 44 mm collar length		43.9 - 44.0 mm (1.728 - 1.732 in.)	------
Sealing ring thickness		1.91 - 1.97 mm (0.0752 - 0.0776 in.)	1.86 (0.0732 in.)
Width of sealing ring groove		2.025 - 2.060 mm (0.0797 - 0.0811 in.)	2.080 mm (0.0819 in.)
Clutch feed pipe O.D.		7.97 - 7.98 mm (0.3138 - 0.3142 in.)	7.95 mm (0.3130 in.)
Clutch feed pipe bushing O.D.		8.000 - 8.015 mm (0.3150 - 0.3156 in.)	8.030 mm (0.3161 in.)
ATF guide of sealing ring contact I.D.		29.000 - 29.021 mm (1.1417 - 1.1426 in.)	29.05 mm (1.144 in.)

***02-13***
Item	Measurement	Qualification	Standard or New	Service Limit
Idler gear shaft	Diameter of needle bearing contact area	End cover side	32.003 - 32.013 mm (1.2600 - 1.2604 in.)	When worn or damaged
Thickness of cotters		1.39 - 1.42 mm (0.0547 - 0.0559 in.)	------
Reverse idler gear	Reverse idler gear shaft diameter at needle bearing contact area		14.99 - 15.00 mm (0.5902 - 0.5906 in.)	When worn or damaged
I.D.		20.007 - 20.020 mm (0.7877 - 0.7882 in.)	When worn or damaged
I.D. of reverse idler gear shaft contact area on transmission housing		14.800 - 14.818 mm (0.5827 - 0.5834 in.)	------
I.D. of reverse idler gear shaft holder		14.800 - 14.824 mm (0.5827 - 0.5836 in.)	When worn or damaged
ATF pump	ATF pump thrust clearance		0.03 - 0.05 mm (0.001 - 0.002 in.)	0.07 mm (0.003 in.)
ATF pump gear-to-body clearance	Drive gear	0.210 - 0.265 mm (0.08 - 0.010 in.)	------
Driven gear	0.070 - 0.125 mm (0.003 - 0.005 in.)	------
ATF pump driven gear I.D.		14.016 - 14.034 mm (0.5518 - 0.5525 in.)	When worn or damaged
ATF pump driven gear shaft O.D.		13.980 - 13.990 mm (0.5504 - 0.5508 in.)	When worn or damaged
Stator shaft	Needle bearing contact I.D.	Torque converter side	27.000 - 27.021 mm (1.063 - 1.064 in.)	When worn or damaged
ATF pump side	29.000 - 29.021 mm (1.1417 - 1.1426 in.)	------
Sealing ring contact area I.D.		29.000 - 29.021 mm (1.1417 - 1.1426 in.)	29.05 mm (1.144 in.)
Reverse shift fork	Fork finger thickness		5.90 - 6.00 mm (0.232 - 0.236 in.)	5.40 mm (0.213 in.)
Park gear and pawl			------	When worn or damaged
Servo body	Shift fork shaft bore I.D.		14.000 - 14.010 mm (0.5512 - 0.5516 in.)	------
Shift fork shaft valve bore I.D.		37.000 - 37.039 mm (1.4567 - 1.4582 in.)	37.045 mm (1.4585 in.)
Regulator valve body	Sealing ring contact I.D.		29.000 - 29.021 mm (1.1417 - 1.1426 in.)	29.05 mm (1.144 in.)

Item	Measurement	Qualification	Standard or New
			Wire Diameter	O.D.	Free Length	No. of Coil
Main valve body springs (see page 14- 209)	Shift valve A spring		0.8 mm (0.031 in.)	5.6 mm (0.220 in.)	28.1 mm (1.106 in.)	15.9
Shift valve B spring		0.8 mm (0.031 in.)	5.6 mm (0.220 in.)	28.1 mm (1.106 in.)	15.9
Shift valve C spring		0.8 mm (0.031 in.)	5.6 mm (0.220 in.)	28.1 mm (1.106 in.)	15.9
Relief valve spring		1.0 mm (0.039 in.)	9.6 mm (0.378 in.)	34.1 mm (1.343 in.)	10.2
Lock-up control valve spring		0.65 mm (0.026 in.)	7.1 mm (0.280 in.)	23.1 mm (0.909 in.)	12.7
Cooler check valve spring		0.9 mm (0.035 in.)	6.6 mm (0.260 in.)	26.5 mm (1.043 in.)	12.6
Servo control valve spring		0.7 mm (0.028 in.)	6.6 mm (0.260 in.)	35.7 mm (1.406 in.)	17.2
Shift valve E spring		0.8 mm (0.031 in.)	5.6 mm (0.220 in.)	28.1 mm (1.106 in.)	15.9

***Automatic Transmission and A/T Differential (cont'd)02-14***
Item	Measurement	Qualification	Standard or New
			Wire Diameter	O.D.	Free Length	No. of Coil
Regulator valve body springs (see page 14- 211)	Stator reaction spring		4.5 mm (0.177 in.)	35.4 mm (1.394 in.)	30.3 mm (1.193 in.)	1.92
Regulator valve spring A		1.9 mm (0.075 in.)	14.7 mm (0.579 in.)	80.6 mm (3.173 in.)	16.1
Regulator valve spring B		1.6 mm (0.063 in.)	9.2 mm (0.362 in.)	44.0 mm (1.732 in.)	12.5
Torque converter check valve spring		1.2 mm (0.047 in.)	8.6 mm (0.339 in.)	33.8 mm (1.331 in.)	12.2
Lock-up shift valve spring		1.0 mm (0.039 in.)	6.6 mm (0.260 in.)	35.5 mm (1.398 in.)	18.2
3rd accumulator spring		2.5 mm (0.098 in.)	14.6 mm (0.575 in.)	29.9 mm (1.177 in.)	4.9
1st accumulator spring A		2.4 mm (0.094 in.)	18.6 mm (0.732 in.)	49.0 mm (1.929 in.)	7.1
1st accumulator spring B		2.3 mm (0.091 in.)	12.2 mm (0.480 in.)	31.5 mm (1.240 in.)	6.6
Servo body springs (see page 14-212)	CPB valve spring		0.7 mm (0.028 in.)	9.1 mm (0.358 in.)	32.3 mm (1.272 in.)	8.6
4th accumulator spring B		2.3 mm (0.091 in.)	12.2 mm (0.480 in.)	31.5 mm (1.240 in.)	6.6
4th accumulator spring A		2.4 mm (0.094 in.)	18.6 mm (0.732 in.)	49.0 mm (1.929 in.)	7.1
2nd accumulator spring B		2.0 mm (0.079 in.)	10.6 mm (0.417 in.)	34.0 mm (1.339 in.)	8.0
2nd accumulator spring A		2.2 mm (0.087 in.)	16.6 mm (0.654 in.)	48.2 mm (1.898 in.)	8.5
3th accumulator spring		2.5 mm (0.098 in.)	14.6 mm (0.575 in.)	29.9 mm (1.177 in.)	4.9

Item	Measurement	Qualification	Standard or New	Service Limit
A/T differential carrier	Pinion shaft contact area I.D.		18.000 - 18.025 mm (0.709 - 0.710 in.)	------
Carrier-to-pinion shaft clearance		0.013 - 0.054 mm (0.001 - 0.002 in.)	0.1 mm (0.004 in.)
Driveshaft contact area I.D.		28.015 - 28.045 mm (1.103 - 1.104 in.)	------
Carrier-to-driveshaft clearance		0.035 - 0.086 mm (0.001 - 0.003 in.)	0.12 mm (0.005 in.)
Intermediate shaft contact I.D.		28.015 - 28.045 mm (1.103 - 1.104 in.)	------
Carrier-to-intermediate shaft clearance		0.065 - 0.111 mm (0.003 - 0.004 in.)	0.12 mm (0.005 in.)
Carrier bearing starting torque (preload)	For new bearing	2.7 - 3.9 N·m (28 - 40 kgf·cm, 24 - 35 lbf·in)	Adjust
For bearing reused	2.5 - 3.6 N·m (25 - 37 kgf·cm, 22 - 32 lbf·in)	Adjust
Final driven gear backlash	(references)	0.087 - 0.146 mm (0.003 - 0.006 in.)	0.2 mm (0.008 in.)
A/T differential pinion gear	Backlash		0.05 - 0.15 mm (0.002 - 0.006 in.)	------
I.D.		18.042 - 18.066 mm (0.7103 - 0.7113 in.)	------
Pinion gear-to-pinion shaft clearance		0.055 - 0.095 mm (0.0022 - 0.0037 in.)	0.12 mm (0.005 in.)

***Automatic Transmission and A/T Differential (cont'd)02-15***
Item	Measurement	Qualification	Standard or New	Service Limit
Transfer (4WD)	Diameter of transfer shaft on bearing contact area	at roller bearing	38.485 - 38.500 mm (1.5152 - 1.5157 in.)	38.43 mm (1.513 in.)
at tapered roller bearing	24.975 - 24.990 mm (0.9833 - 0.9839 in.)	24.92 mm (0.9811 in.)
Transfer drive gear diameter	at tapered roller bearing	40.002 - 40.018 mm (1.5749 - 1.5755 in.)	38.95 mm (1.533 in.)
Diameter of transfer driven gear on tapered roller bearing contact area	at driven gear side	35.002 - 35.018 mm (1.3780 - 1.3787 in.)	34.95 mm (1.376 in.)
at shaft splines side	26.975 - 26.988 mm (1.0620 - 1.0625 in.)	26.92 mm (1.060 in.)
Transfer gear backlash		0.06 - 0.16 mm (0.002 - 0.006 in.)	Adjust
Total starting torque (Preload)		2.16 - 3.57 N·m (22.0 - 36.4 kgf·cm, 19.2 - 31.6 lbf·in)	Adjust

***Rear Differential***
Item	Measurement	Qualification	Standard or New	Service Limit
Differential fluid	Capacity Use genuine Honda DPSF	at fluid change	1.0 L (1.1 US qt, 0.9 Imp qt)
at overhaul	1.2 L (1.3 US qt, 1.1 Imp qt)

***Steering***
Item	Measurement	Qualification	Standard or New	Service Limit
Steering wheel	Rotational play measured at outside edge with engine running		0 - 10 mm (0 - 0.39 in.)
Starting load measured at outside edge with engine running		29 N (3.0 kgf, 6.6 lbs)
Gearbox	Angle of rack guide screw loosened from locked position		20° Max.
Pump	Output pressure with shut- off valve closed		6,900 - 7,500 kPa (70 - 77 kgf/cm2, 1,000 - 1,100 psi)
Power steering fluid	Capacity Use genuine Honda power steering fluid	Fluid change	0.2 L (0.21 US qt, 0.18 lmp qt)
System overhaul	0.72 L (0.74 US qt, 0.63 Imp qt)
Drive belt			Auto adjust

***Suspension***
Item	Measurement	Qualification	Standard or New	Service Limit
Wheel alignment	Camber	Front	0°00' ± 45'
Rear	- 1°00' ± 45'
Caster	Front	1°45' ± 1°
Total Toe	Front	0±2 mm (0 ± 0.08 in.)
Rear	IN 2+2-1 mm (0.08+0.08-0.04 in.)
Front wheel turning angle	Inside wheel	39°45' ± 2°
Outside wheel	32°30' ± 1° (Reference)
Wheel	Aluminum wheel runout	Axial	0 - 0.7 mm (0 - 0.03 in.)	2.0 mm (0.08 in.)
Radial	0 - 0.7 mm (0 - 0.03 in.)	1.5 mm (0.06 in.)
Steel wheel runout	Axial	0 - 1.0 mm (0 - 0.04 in.)	2.0 mm (0.08 in.)
Radial	0 - 1.0 mm (0 - 0.04 in.)	1.5 mm (0.06 in.)
Wheel bearing	End play	Front	0 - 0.05 mm (0 - 0.002 in.)
Rear	0 - 0.05 mm (0 - 0.002 in.)

***Brakes02-16***
Item	Measurement	Qualification	Standard or New	Service Limit
Parking brake lever	Distance travelled when lever pulled with 196 N (20 kgf, 44 lbs) of force		5 - 9 clicks
Brake pedal	Pedal height (carpet removed)		173 mm (6 13/16 in.)
Free play		1 - 5 mm (0.04 - 0.2 in.)
Master cylinder	Piston-to-pushrod clearance		0 - 0.4 mm (0 - 0.02 in.)
Brake disc	Disc thickness	Front	23.0 mm (0.91 in.)	21.0 mm (0.83 in.)
Rear	9.0 mm (0.35 in.)	7.0 mm (0.28 in.)
Disc runout	Front and rear	------	0.10 mm (0.004 in.)
Disc parallelism	Front and rear	------	0.015 mm (0.0006 in.)
Pad thickness	Front	11.0 mm (0.43 in.)	1.6 mm (0.06 in.)
Rear	9.0 mm (0.35 in.)	1.0 mm (0.04 in.)
Rear parking brake	Brake drum I.D. Brake shoe lining thickness		170 mm (6.69 in.)	171 mm (6.73 in.)
	3.2 mm (0.13 in.)	1.0 mm (0.04 in.)
Brake booster	Master cylinder fluid pressure with pressing brake pedal with 98 N (10 kgf, 22 lbs)	at 0 kPa (0 mmHg, 0 in.Hg) of vacuum	1,040 kPa (10.8 kgf/cm2, 151 psi)
at 40.0 kPa (300 mmHg, 11.8 in.Hg) of vacuum	7,129 kPa (72.7 kgf/cm2, 1,030 psi)
at 66.7 kPa (500 mmHg, 19.7 in.Hg) of vacuum	11,248 kPa (114.7 kgf/cm2, 1,631 psi)

***Air Conditioning***
Item	Measurement	Qualification	Standard or New	Service Limit
Refrigerant	Type		HFC-134 a (R-134 a)
Capacity of system		650 - 700 g (22.9 - 24.7 oz)
Refrigerant oil	Type		ND-OIL8
Capacity of components	Condenser	50 mL (1 2/3 fl oz, 1.3 Imp oz)
Evaporator	40 mL (1 1/3 fl oz, 1.4 Imp oz)
Each line and hose	10 mL (1/3 fl oz, 0.4 lmp oz)
Compressor	160 - 175 mL (5 2/5 - 6 fl oz, 5.6 - 6.2 Imp oz)
Compressor	Starter coil resistance	at 60°C (20°F)	3.9 - 4.3
Pulley-to-pressure plate clearance		0.35 - 0.6 mm (0.014 - 0.024 in.)

Specifications02-1
Standards and Service Limits02-2